Breaking boundaries: Delivering gigantic injection molding machines across continents

8000 tons in weight, a good 30 meters long – how do you manage to ship such a gigantic injection moulding machine across the big pond? In an industry where logistics and size present special challenges, ENGEL has managed to master them with expertise and a cooperative approach.

In an interview with K-MAG, Anders Nybäck, an expert from ENGEL, sheds light on the successful delivery of two massive 8,000-ton injection molding machines from Austria to the United States. What is the significance of these machines, and how is the future outlook for injection molding machines with such high clamping forces?

Mr. Nybäck, ENGEL recently delivered two 8,000-ton injection moulding machines to the USA. How did that happen exactly? And how long did it take from order to handover?

Anders Nybäck: ENGEL received the order in November 2020 and the first machine could already be handed over in February 2022. Now, one year later, a second identical machine has been delivered.

What must be considered when supplying machines of this size?

Nybäck: Logistics is a special challenge. Before delivery, each machine is completely assembled and tested at the ENGEL plant. Such large machines then have to be disassembled again for transport. The weight of the individual components plays a major role in logistics planning. The mould fixing platens for these two 8000-ton machines, for example, were transported on barges on the Danube.

What challenges did you face and how did you overcome them?

Nybäck: From the initial idea to completion, the project was a close team effort across company boundaries. Our long collaboration with Infiltrator, mutual trust, and not least the fact that everyone knows what is important to the other were key success factors here. This is the only way to deal with the risks that naturally come with the size of the machines, the degree of innovation and the immense investment volume. We are thrilled to see what we have achieved here together. When we develop solutions together with our customers, we do everything we can to make them even more successful with innovative and forward-looking concepts.

What makes injection molding machines with such high clamping forces necessary?

Nybäck: Injection molding enables particularly resource-efficient processing of plastics and also a high degree of process integration and automation. As a result, more and more very large components are being produced by injection molding for which other processes were previously used or which were previously assembled from several individual components - for example, large containers and underground tanks, but also more and more large-area vehicle components such as structural components and lightweight body components or glazing. We see a lot of potential in the automotive sector in particular. Hyundai-Kia in Korea, for example, recently took delivery of a particularly large injection molding machine from us.

Why did Infiltrator approach ENGEL specifically with its request? What makes your machines special?

Nybäck: ENGEL has a great deal of experience and expertise in building large-scale machines and also a global production network, which simplifies logistics, shortens time-to-market and makes the overall project more cost-effective. ENGEL already has a long business relationship with Infiltrator. This was the deciding factor in this particular case. All previous projects for Infiltrator were completed by ENGEL on time, and costs were not exceeded either. Therefore, Infiltrator also placed the necessary trust in us for this particularly challenging project.

To what extent does ENGEL contribute to sustainability with these injection molding machines (e.g. in this specific case)?

Nybäck: The large machines make it possible to produce components that previously consisted of several individual parts and had to be assembled in a single process step and in one piece. This saves process steps and thus a lot of energy and raw material. Infiltrator also says that with the new machines they can manufacture the products even more cost-effectively and efficiently. Sustainability played a major role in the overall project. Infiltrator produces innovative water management products that have a high percentage of recycling. The company recycles more plastic than any other in North America.

How will the demand for injection molding machines with such high clamping forces develop in the future and how is ENGEL preparing for these developments?

Nybäck: We see an increasing need and an increasing demand. However, it is important to realize that injection moulding machines with clamping forces of over 5500 tons are a niche market and will remain that way. However, this niche is very interesting for ENGEL because we are one of the injection moulding machine manufacturers with the greatest experience and competence in the field of large machines. Not to forget: With our worldwide production network, we have the capacity to efficiently build and deliver such machines.