Mould production times slashed at Habitat Industries
MOULD production times have been slashed at Habitat Industries following its recent commissioning of a new vertical machining centre from Micro Dynamics.
The new system cuts metal far faster, more quietly and accurately than anything the company has used before, said Habitat MD Donovan Barnes.
Habitat Industries is one of South Africa’s leading manufacturers of moulds for injection-stretch and extrusion blow moulding and produces moulds for a number of SA top convertors, with the bulk of its moulds being for FMCG containers.
The Killarney Gardens company purchased the Micro Dynamics’ Tera 50V machining centre from WD Hearn, which is a supplier of a wide range of metal machining equipment and related systems, also based in Cape Town. WD Hearn is the agent for Micro Dynamics, an American machine tool manufacturer which builds many of its machines in Taiwan. The company manufactures heavy-duty precision metal cutting systems and visitors to the Machine Tools Africa show in Joburg in May commented about the exceptional performance of its machining centres.
Habitat opted for a 4-axis Tera 50V system from Micro Dynamics which performs required tasks admirably. The machine offers good Y axis travel. Its main initial function at Habitat is cavity cutting. This process, the excavation of aluminum or steel, is often time-consuming. Now the task is being performed far more quickly, which speeds up overall production times. But it’s not only the time-saving that is helping Habitat: the process is quieter and more accurate than what it was able to achieve before.
The unit’s spindle can turn at 15,000-20,000 rpm with a power supply of 34kW. The Tera unit is also heavier than most equivalent machines and this results in extremely minimal tool movement.
“The surface finishes achieved are of a very high standard and require minimal additional polishing,” said Barnes.
Another feature of the machine is its automated rapid tool change ability. Micro Dynamics markets this as a 1,9 second change, which is impressive (it certainly happens at lightning speed) and further allows for faster mould production. The Tera 50V has a tool change belt that fits 40 tools.
Build locally
Such technology has been available before, but invariably from European manufacturers at what was perceived as prohibitive cost, with SA toolmakers sometimes reluctant to make such big investments. That however has also backfired on the SA toolmakers as slow mould production times have resulted in many customers going offshore. Habitat’s investment (which is understood to be considerable) is thus a show of faith in its customers and confidence in its own systems. It should thus be able to build more moulds locally.
“And the service and back-up from WD Hearn has been top-class too,” said Barnes.
Initial reaction to speedier mould production has been positive. Habitat’s moulds are used mainly in fast-cycling blow moulding systems, including machines such as Sidel, Blowmax, Nissei ASB, SIPA, Aoki and Krones machines as well as extrusion blow moulding machines, so it is now elevating itself to operate on a par with these global leaders.
