press | release

ENGEL is showcasing a comprehensive range of inject 4.0 products

Experience meets innovation

Schwertberg, Austria – June 2016

inject 4.0 is ENGEL's answer to the challenges of the Fourth Industrial Revolu-
tion. The injection moulding machine manufacturer and systems expert, with
headquarters in Schwertberg, Austria, is to present its inject 4.0 program at
K 2016 from October 19th to 26th in Dusseldorf. ENGEL is creating additional
added value for its customers with new solutions for intelligent control and
forward-looking maintenance – be the first – with ENGEL on stand C58, in hall
15 at K 2016.

The aim of Industrie 4.0 is a smart factory. With the help of the networking and integration of
production systems, the systematic exploitation of machines, process and production data
and the use of decentralised, intelligent assistance systems, the manufacturing processes in
a smart factory continuously optimise themselves, making it possible to react very flexibly to
the ever more quickly changing requirements. The result is greater efficiency, productivity,
machine availability and quality.

ENGEL is making it possible to actually experience the smart factory at K 2016. For all three
areas of the smart factory – smart machine, smart production and smart service – ENGEL
already has solutions within the range today to support processors to enable their processes
to tackle the new challenges. Industry 4.0 is nothing new for ENGEL – it has been current
practice in many areas for a long time, and ENGEL is continuously further-developing its
inject 4.0 programme. At ENGEL, experience meets innovation.

smart machine: compensating for any fluctuations before rejects are produced

The human-machine interface will play an increasingly important role in tomorrow's factory.
As the processes become increasingly complex because of greater integration and automa-
tion, its management and control must become all the more simple and intuitive. Self-

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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adapting, decentralised systems increase process capability and quality, without the machine
operator having to assimilate additional specialist knowledge.

For example, the iQ software products from ENGEL continually analyse critical process pa-
rameters in order to identify and immediately compensate for deviations even before rejects
are produced. While iQ weight control keeps the injected melt volume and the viscosity con-
stant throughout the entire injection moulding process, including the holding pressure phase,
the new iQ clamp control software determines the mould breathing to continually readjust the
clamping force. Even if the environmental conditions change, or the granulate quality fluctu-
ates, the software solutions keep the process constant and consistently ensure high product
quality.

As mould temperature control also affects efficiency and quality, ENGEL already introduced
an electronic temperature-control water manifold system at K 2010 and has continuously
developed this further since then. ENGEL e-flomo monitors and documents all cooling and
temperature control circuits of injection moulds and independently regulates either the flow
volumes or differences in temperature. ENGEL is now going one step further for K 2016.
ENGEL e-flomo and temperature control unit merge at controller level to form a single unit.
With the help of the new iQ flow control software, the pump speed is adapted automatically
to current requirements based on the measurement values determined by ENGEL e-flomo.
Whereas ENGEL e-flomo increases the process stability and therefore lowers the reject risk,
the automatic speed adjustment ensures that temperature control requires less energy.

ENGEL will demonstrate during K 2016 how the potential of smart machine can be optimally
exploited in practice with the manufacture of inject 4.0 logos on an all-electric, tie-bar-less
ENGEL e-motion 80 TL injection moulding machine. Fluctuating process conditions will be
simulated in the CC300 controller in order to monitor the automatic readjustment of the intel-
ligent assistance systems on the injection moulding machine display.

smart production: high vertical and horizontal data integration

ENGEL's exhibition stand at K 2016 is already a regular small business with seven highly
integrated and automated production cells plus the iQ demonstration injection moulding ma-
chine. All production cells are networked together using ENGEL e-factory to be able to view
and analyse the current condition of the individual injection moulding machines, their utilisa-
tion and output from a central computer.

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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With ENGEL e-factory, ENGEL has its own MES (Manufacturing Execution System) in its
product portfolio that is specifically tailored to the requirements of the plastics processing
industry and achieves an extremely high level of vertical data integration. It even takes ac-
count of the number of cavities in the mould.

ENGEL e-factory ensures greater transparency. Bottlenecks and downtime are localised at a
glance. Only in this way is it possible to optimally utilise the overall available capacity of ma-
chinery. The condition and process data transferred in real time is correlated both with quality
and key business operating figures and analysed in a variety of ways. It then becomes par-
ticularly exciting if not only the production cells of an individual site but of a global production
network are integrated using ENGEL e-factory. The processes can be optimised from the
company headquarters, and colleagues are better supported locally.

ENGEL e-factory has a modular design. The solution is therefore adapted exactly to the pro-
cessor's individual requirements and is able to grow with the system flexibly according to
demand. The energy module is new to the K 2016 that allows the detailed presentation,
analysis and optimisation of energy consumers. Energy enables ENGEL e-factory to control
the start-up of the injection moulding machines and production cells automatically and relia-
bly avoid any energy peaks. The electricity costs of the machinery are therefore reduced.

In many businesses, ENGEL already forms the basis for consistently tracking individual
products through its entire development process right down to the raw materials. Data track-
ing is now standard in many more sectors, not just in the automotive and medical technology
sectors. inject 4.0 will make traceability even simpler in the future. The inject 4.0 logos manu-
factured by ENGEL on the exhibition stand are marked singularly with an individually gener-
ated QR code. Visitors to the exhibition will also be able to get information about when and
under what process conditions the injection moulded part was manufactured for a long time
after K 2016 by using the QR code.

smart service: condition-based, predictive maintenance shows the way forward

To increase the machine availability of injection moulding machines and manufacturing cells,
smart service relies on short routes, remote maintenance and a view into the future. The new
ENGEL e-connect.monitor will make it possible to analyse the condition of process-critical
machine core components in the live operation and reliably predict the risk of default. The
condition-based, predictive maintenance makes it possible to exploit the service life of critical

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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machine parts to the full and avoid any unplanned equipment stoppages that occur in spite of
this. The regular condition monitoring supports process optimisation in the long term. Critical
process settings that accelerate the wear of certain components are identified by analysing
the wear parameters and are then subsequently avoided through process changes.

Whereas smart machine und smart production solutions fall largely within the processor's
responsibility, there are benefits for smart service in several instances if ENGEL, as the sup-
plier, is able to access certain data approved by the customer. Mutual trust is important for
this but is not enough by far. For data transfer, ENGEL consistently uses state-of-the-art
safety technologies and has its systems regularly checked by independent experts.

Furthermore, ENGEL jointly with its customers and partners is working to establish OPC UA
(Open Platform Communication Unified Architecture) as a shared information mode in the
plastics sector, even in the field of condition monitoring. The communication protocol offers
great flexibility with its service-based and scalable structure, independent of any platform. In
addition, safety features are already an integral part of the architecture.

To guarantee the stability of the CPU, the complex and the computation-intensive processing
of data does not take place in the machine control unit but in server systems that ENGEL has
designed especially for this. ENGEL develops the stored algorithms further and each is
adapted on the system. This ensures that ENGEL's customers have access to the latest
state-of-the-art technology at all times.

ENGEL at K 2016: hall 15, stand C58

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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ENGEL demonstrates how smart machine's potential can be exploited in practice on its exhibition
stand with the manufacture of the inject 4.0 logo on an all-electric, tie-bar-less ENGEL e-motion 80 TL
injection moulding machine.

smart factory means the systematic use of process and production data, the networking and
integration of production cells, machines and components and decentralised use of adaptive
assistance systems results in higher productivity, machine availability, quality and flexibility.

The intelligent assistance systems of the iQ product family, such as iQ weight control, balance out any
process fluctuations, even before any rejects are produced.

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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ENGEL e-flomo and temperature control unit merge at the level of the control unit to form a single unit.
The pump speed is adjusted automatically to current demand based on the measurement values cal-
culated by ENGEL e-flomo with the help of the new iQ flow control software.

ENGEL e-factory enables the processor to have a view of the entire production process from the cen-
tral computer. The transparency of injection moulding machines and process parameters simplifies
capacity planning and the production of statistics.

The new ENGEL e-connect.monitor makes it possible to analyse the condition of process-critical ma-
chine components, such as plasticizing screws, in the live operation and create a reliable default fore-
cast.
Pictures: ENGEL

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com

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ENGEL AUSTRIA GmbH

ENGEL is one of the global leaders in the manufacture of plastics processing machines. Today, the
ENGEL Group offers a full range of technology modules for plastics processing as a single source
supplier: injection moulding machines for thermoplastics and elastomers, and automation, with the
assurance that individual components are also competitive and successful in the world markets. With
nine production plants in Europe, North America and Asia (China and Korea), and subsidiaries and
representatives in more than 85 countries, ENGEL offers its customers the excellent global support
they need to compete and succeed with new technologies and leading-edge production systems.
Contact for journalists:
Martin Streicher, Group Marketing Director, ENGEL AUSTRIA GmbH,
Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria,
tel.: +43 (0)50 620 3800, fax: -3009, e-mail: martin.streicher@engel.at
Susanne Zinckgraf, Public Relations Manager, ENGEL AUSTRIA GmbH,
Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria
PR Office: Theodor-Heuss-Strasse 85, D-67435 Neustadt, Germany,
tel.: +49 (0)6327 97699-02, fax: -03, e-mail: susanne.zinckgraf@engel.at
Contact for readers:
ENGEL AUSTRIA GmbH, Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria,
tel.: +43 (0)50 620-0, fax: -3009, e-mail: sales@engel.at
www.engelglobal.com

ENGEL AUSTRIA GmbH | A-4311 Schwertberg | tel.: +43 (0)50 620 0 | fax: +43 (0)50 620 3009
sales@engel.at | www.engelglobal.com