Precision & performance for innovative laboratory diagnostics products

Röchling Medical is an innovative development partner and contract manufacturer for leading global pharmaceutical, biotech and medical technology companies. At its German site in Waldachtal, Röchling has been producing specialized polystyrene contact trays for laboratory diagnostics that offer improved ergonomics and safety: thanks to a well-designed three-point snap-fit mechanism instead of conventional threads, the lid can be mounted quickly and easily and remains securely closed during transportation of the samples.

However, this delicate mechanism places increased demands on precision and process consistency during production. Even the slightest deviation in the geometry of the moving components could impair functionality. At the same time, the shortest possible cycle time is essential to ensure cost-effective production - a must with an annual production volume of around 12 million units. To meet these challenges, Röchling turned to ENGEL.

The specifications for this laboratory diagnostics application clearly identified ENGEL's all-electric high-performance e-motion series as the most suitable base machine. Its powerful servo-electric direct drives enable significantly faster machine movements compared to hydraulic or hybrid systems, while also ensuring exceptionally high repeatability - an advantage for the mass production of diagnostic products. In addition, the all-electric drive concept is particularly low in emissions - another key benefit for operation under cleanroom conditions.

To meet Röchling's requirements in the best possible way, ENGEL equipped the 1,600 kN injection molding machine with several optional packages: A cleanroom package enables ultra-clean production down to ISO Class 7 and allows for especially easy cleaning of all potential contamination sources. In addition, the PREMIUM version of the electric injection unit delivers the required performance to reliably fill the thin-walled cavities shot after shot: Its servo-electric direct drive is not only highly powerful, but also offers 100% synchronization of movements compared to a belt drive. In combination with ENGEL’s smart shut non-return valve, this ensures maximum precision on the injection side as well.

Daniel Tobien, Head of Production at Röchling Medical, summarizes: "The precision of all-electric machines is significantly better than that of hydraulic ones. The advantage becomes especially apparent during short cycle times: switching the electric motors is much easier and faster than with a hydraulic pump or valve."

Another essential factor in injection molding for laboratory diagnostics is temperature control. Röchling relies on the ENGEL temperature control system to ensure fast and uniform cooling of parts within the mold cavities. The combination of ENGEL e-temp temperature control units and the e-flomo automatic water manifold is precisely managed by the intelligent iQ flow control assistance system. iQ flow control continuously monitors the temperature difference (ΔT) between the supply and return flow. If deviations occur, it automatically adjusts the flow rate via the e-flomo units. This ensures consistently optimal and rapid cooling of the parts while minimizing both water and energy consumption. Defective components caused by temperature control errors are avoided by using iQ flow control. This process also reduces wear on the temperature control units and extends their service life.

It wasn’t just the machine itself that impressed Röchling Medical, but also the competent support provided by ENGEL throughout the entire process: ENGEL demonstrated a deep understanding of Röchling Medical's specific requirements even during the planning phase. In addition to customizing the machine to the customer’s needs, ENGEL also ensured a smooth and fast production start through efficient logistics, commissioning, and service.

Daniel Tobien emphasizes: "As of today, we are very satisfied with the machine. In combination with the mold and automation, we are achieving high output. So far, we haven't had a single machine-related downtime."