Pipettes Tips Molding | Produce Faster

64
cavity
mold
5-6
sec
cycle time
330
mio
pc/year
25
sqm
footprint

These are the challenges in the production of pipette tips

Precise liquid due to perfect mold and hot runner technology: 

  • Hot runner balancing

  • Temperature management 

  • Centering the mold cores 

 

Superior hot-runner balancing for superior injection molded parts
The key to achieving superior part quality and minimal rejects is a smart design, precise construction of the injection mold, combined with a finely balanced hot runner system. A crucial aspect in hot runners is achieving an optimal design at bends and the injection point so that melt is processed gently and not damaged, all while ensuring temperature distribution is as homogeneous as possible. So what does our system do to achieve this?

Temperature management is the key to uniform filling 
In order to achieve as the most homogeneous temperature distribution possible, Männer systems heat the nozzle body of the hot runner system and the tip. The result is precise individual temperature control, which is clearly seen in start-up behavior and short-shot tests. The lower the temperature deviation from cavity to cavity the better balanced the hot runner is and the more precise the part geometry because overfilling and underfilling are avoided allowing the molder to achieve the narrow tolerance values and impressive quality. 

Long-wearing and rugged centering bushing
Because the long, narrow tip can be easily damaged due its narrow touching diameter, Männer developed a protective construction solution for the opposite bushing. The geometry of the robust bushing enables the slender core of the mold insert to be centered gently.

 

See for yourself how superior part quality is achieved by visiting our Pipette Tip Test Center. 

Show More

Molding performance driven by perfectly coordinated components: 

Mold geometries for optimized heating and cooling phases 
Heat balance in the mold has a decisive effect on product quality and manufacturing performance. High-precision molds used in pipette tips production feature optimized flow cross sections that enable high-speed production with cooling channels closely correspond part geometry. This mold precision paired with our uniquely designed hot runner systems, provides optimal temperature management of short cycle times so that a high degree of pipette tip dimensional accuracy is achieved! 

Precise temperature control in the mold 
With control accuracy of +/-0.1 Kelvin, HB-Therm temperature control units satisfy highly demanding process requirements for exact temperature control of all 64 cavities. The external flow meters individually monitor the flow volume of the 16 circuits using ultrasonic technology. The fully automated process monitoring ensures a high level of reproducibility because monitoring responds to even the smallest changes and process data can be collected.  

Highly responsive hot-runner temperature control
The real-time values for the temperature sensors of the 64 thermocouples are transferred to the Gammaflux hot-runner temperature control system. The G24 controllers capture measurement values 20 times a second and carry out adjustments even when the setpoint temperature deviates only by 0.014°C.

All-electric injection molding machine with high injection dynamics 
The production speed specified is ultimately also determined by the performance capability of the injection molding machine and automation system. The all-electric IntElect 130 S from Sumitomo (SHI) Demag is designed specifically for high-cavity applications in the high-speed cycle range. Sumitomo (SHI) Demag relies on its own drive technology, which achieves dry cycle speeds as fast as 1.0 sec in the speed variant deployed. 

High-speed demolding
As soon as the pipette tips have cooled down to the demold temperature and the mold rises, the innovative, scalable and modular demolding unit from MA micro automation and its high-speed handling unit spring into action. In this demo plant the robotic handling unit removes the 64 pipette tips and transfers them to a downstream handling unit and places them in a quality-assurance drawer. In a later real-time manufacturing scenario a camera station would be integrated as part of the production process directly after demolding to enable 100% side-view inspection of all pipette tips.
MA micro automation is the only European vendor that manufactures its own handling system using beltless technology for achievement of greater dynamics.


Find out how smoothly our turnkey plant works by visiting our Pipette Tip Test Center

Show More

A stable process enhances part quality: 

  • Process control based on real-time tool data
  • Automatically balancing deviations
  • Automated fill balancing


We rely on monitoring and control software from Priamus to improve and automate the injection molding process and systematically reduce cycle times. In addition to improved quality, automated process control requires far less effort by operators and contributes to safer and more stable production of good parts, regardless of who is operating your machine. The production cell at the Pipette Tip Test Center is equipped with different FILLCONTROL modules for you to experience. 

Balancing deviations to produce more good part
All FILLCONTROL modules work directly with process parameters that are generated in the mold or hot runner and not with calculated values. These are generally pressure and temperature readings which are collected and monitored in real time by highly sensitive Priamus sensors.

Even an injection molding process that has been set up well has to be constantly monitored and re-adjusted when necessary, such as when compensating for batch-specific changes, deviations in the melt or when adapting to changes in ambient conditions. For example, the FILLCONTROL system is able to detect the flow front and the melt position in the cavity and automatically adjust pressure.

It is also possible to automate fill balancing. The integrated OPC UA interface with the Gammaflux hot-ru
nner control system allows constant and fully automated balancing of the temperature setting for the hot runner nozzles regardless of the melt flow.

Meet our experts at our Pipette Tip Test Center to learn more about automated process control. 

Show More

Fast replacement and rugged components minimize production shutdowns

  • Quick-exchange cavity clusters
  • Low-maintenance components
  • Fast start-up after a production stop

Disposable medical products require the utmost in precision as well as extremely high rates of output. Any interruption for maintenance work is painful on a 24/7 production schedule.

An innovative cluster concept minimizes downtimes
The männer 64-cavity mold features 8 quick-change clusters of 8 cavities each. This means nearly all downtime can be avoided in 24/7 operations. Each cluster contains a nozzle head and its own power supply for the independently heated nozzle tips. This allows mold maintenance caused to be carried out directly on the machine. A cluster can be swapped out for production to resume.

An assembly kit is supplied with the injection mold to enable safe, precise and trouble-free installation. 

Rugged, low-maintenance components
All Männer injection molds are high-performance molds requiring little maintenance. Centering the long, narrow mold cores without damaging the tip is a unique challenge in this area. Männer has developed an own technical construction design for the centering bushing which enables the centering of the long, narrow core of the mold insert to be done gently.

Fast start-up after a production stop
After installation, the drooling-free concept allows rapid, trouble-free start-up of pipette tip production. The optimally balanced hot runner prevents nozzle drooling of melt into the cavity and eliminating most time-consuming controls.

 

Meet our experts at our Pipette Tip Test Center to learn more about the lifespan, durability and maintenance of pipette tip molds. 

 

Show More

Drooling-free thanks to homogeneous temperature distribution

  • Balanced hot runners
  • Optimized fill levels
  • Highly responsive temperature control
     

After a production stop, all cavities must be checked to ensure no drooling has occurred which may be damaged leading to downtime and high repair costs. As all processors know, manual inspection of all 64 cavities is necessary, but time-consuming.

No drooling thanks to optimal balancing
Quality assurance costs can be minimized by utilizing a finely balanced Männer hot runner system. Together with the Gammaflux high-precision temperature control and Priamus automated fill level balancing, the system is able to prevent nozzle drooling of melt into the cavities after a production shutdown.

The temperature is kept constant not only by heating the nozzle but also through individual temperature control of the nozzle tips. High-precision hot runner control is carried out by a highly responsive Gammaflux G24 temperature control system. The control operation takes place automatically using an integrated interface with the Priamus process control.

Fill levels are optimized even when material properties vary
The dynamic process control solution from PRIAMUS based on real-time process data from sensors that measure the internal mold pressure and mold wall temperature in the cavity. By accounting for variations in melt properties, FILLCONTROL modules prevent cavities from being left unfilled.

 

Meet our experts at our Pipette Tip Test Center to learn more about perfect hot runner balancing.

Show More

Precise liquid due to perfect mold and hot runner technology: 

  • Hot runner balancing

  • Temperature management 

  • Centering the mold cores 

 

Superior hot-runner balancing for superior injection molded parts
The key to achieving superior part quality and minimal rejects is a smart design, precise construction of the injection mold, combined with a finely balanced hot runner system. A crucial aspect in hot runners is achieving an optimal design at bends and the injection point so that melt is processed gently and not damaged, all while ensuring temperature distribution is as homogeneous as possible. So what does our system do to achieve this?

Temperature management is the key to uniform filling 
In order to achieve as the most homogeneous temperature distribution possible, Männer systems heat the nozzle body of the hot runner system and the tip. The result is precise individual temperature control, which is clearly seen in start-up behavior and short-shot tests. The lower the temperature deviation from cavity to cavity the better balanced the hot runner is and the more precise the part geometry because overfilling and underfilling are avoided allowing the molder to achieve the narrow tolerance values and impressive quality. 

Long-wearing and rugged centering bushing
Because the long, narrow tip can be easily damaged due its narrow touching diameter, Männer developed a protective construction solution for the opposite bushing. The geometry of the robust bushing enables the slender core of the mold insert to be centered gently.

 

See for yourself how superior part quality is achieved by visiting our Pipette Tip Test Center. 

Show More

Molding performance driven by perfectly coordinated components: 

Mold geometries for optimized heating and cooling phases 
Heat balance in the mold has a decisive effect on product quality and manufacturing performance. High-precision molds used in pipette tips production feature optimized flow cross sections that enable high-speed production with cooling channels closely correspond part geometry. This mold precision paired with our uniquely designed hot runner systems, provides optimal temperature management of short cycle times so that a high degree of pipette tip dimensional accuracy is achieved! 

Precise temperature control in the mold 
With control accuracy of +/-0.1 Kelvin, HB-Therm temperature control units satisfy highly demanding process requirements for exact temperature control of all 64 cavities. The external flow meters individually monitor the flow volume of the 16 circuits using ultrasonic technology. The fully automated process monitoring ensures a high level of reproducibility because monitoring responds to even the smallest changes and process data can be collected.  

Highly responsive hot-runner temperature control
The real-time values for the temperature sensors of the 64 thermocouples are transferred to the Gammaflux hot-runner temperature control system. The G24 controllers capture measurement values 20 times a second and carry out adjustments even when the setpoint temperature deviates only by 0.014°C.

All-electric injection molding machine with high injection dynamics 
The production speed specified is ultimately also determined by the performance capability of the injection molding machine and automation system. The all-electric IntElect 130 S from Sumitomo (SHI) Demag is designed specifically for high-cavity applications in the high-speed cycle range. Sumitomo (SHI) Demag relies on its own drive technology, which achieves dry cycle speeds as fast as 1.0 sec in the speed variant deployed. 

High-speed demolding
As soon as the pipette tips have cooled down to the demold temperature and the mold rises, the innovative, scalable and modular demolding unit from MA micro automation and its high-speed handling unit spring into action. In this demo plant the robotic handling unit removes the 64 pipette tips and transfers them to a downstream handling unit and places them in a quality-assurance drawer. In a later real-time manufacturing scenario a camera station would be integrated as part of the production process directly after demolding to enable 100% side-view inspection of all pipette tips.
MA micro automation is the only European vendor that manufactures its own handling system using beltless technology for achievement of greater dynamics.


Find out how smoothly our turnkey plant works by visiting our Pipette Tip Test Center

Show More

A stable process enhances part quality: 

  • Process control based on real-time tool data
  • Automatically balancing deviations
  • Automated fill balancing


We rely on monitoring and control software from Priamus to improve and automate the injection molding process and systematically reduce cycle times. In addition to improved quality, automated process control requires far less effort by operators and contributes to safer and more stable production of good parts, regardless of who is operating your machine. The production cell at the Pipette Tip Test Center is equipped with different FILLCONTROL modules for you to experience. 

Balancing deviations to produce more good part
All FILLCONTROL modules work directly with process parameters that are generated in the mold or hot runner and not with calculated values. These are generally pressure and temperature readings which are collected and monitored in real time by highly sensitive Priamus sensors.

Even an injection molding process that has been set up well has to be constantly monitored and re-adjusted when necessary, such as when compensating for batch-specific changes, deviations in the melt or when adapting to changes in ambient conditions. For example, the FILLCONTROL system is able to detect the flow front and the melt position in the cavity and automatically adjust pressure.

It is also possible to automate fill balancing. The integrated OPC UA interface with the Gammaflux hot-ru
nner control system allows constant and fully automated balancing of the temperature setting for the hot runner nozzles regardless of the melt flow.

Meet our experts at our Pipette Tip Test Center to learn more about automated process control. 

Show More

Fast replacement and rugged components minimize production shutdowns

  • Quick-exchange cavity clusters
  • Low-maintenance components
  • Fast start-up after a production stop

Disposable medical products require the utmost in precision as well as extremely high rates of output. Any interruption for maintenance work is painful on a 24/7 production schedule.

An innovative cluster concept minimizes downtimes
The männer 64-cavity mold features 8 quick-change clusters of 8 cavities each. This means nearly all downtime can be avoided in 24/7 operations. Each cluster contains a nozzle head and its own power supply for the independently heated nozzle tips. This allows mold maintenance caused to be carried out directly on the machine. A cluster can be swapped out for production to resume.

An assembly kit is supplied with the injection mold to enable safe, precise and trouble-free installation. 

Rugged, low-maintenance components
All Männer injection molds are high-performance molds requiring little maintenance. Centering the long, narrow mold cores without damaging the tip is a unique challenge in this area. Männer has developed an own technical construction design for the centering bushing which enables the centering of the long, narrow core of the mold insert to be done gently.

Fast start-up after a production stop
After installation, the drooling-free concept allows rapid, trouble-free start-up of pipette tip production. The optimally balanced hot runner prevents nozzle drooling of melt into the cavity and eliminating most time-consuming controls.

 

Meet our experts at our Pipette Tip Test Center to learn more about the lifespan, durability and maintenance of pipette tip molds. 

 

Show More

Drooling-free thanks to homogeneous temperature distribution

  • Balanced hot runners
  • Optimized fill levels
  • Highly responsive temperature control
     

After a production stop, all cavities must be checked to ensure no drooling has occurred which may be damaged leading to downtime and high repair costs. As all processors know, manual inspection of all 64 cavities is necessary, but time-consuming.

No drooling thanks to optimal balancing
Quality assurance costs can be minimized by utilizing a finely balanced Männer hot runner system. Together with the Gammaflux high-precision temperature control and Priamus automated fill level balancing, the system is able to prevent nozzle drooling of melt into the cavities after a production shutdown.

The temperature is kept constant not only by heating the nozzle but also through individual temperature control of the nozzle tips. High-precision hot runner control is carried out by a highly responsive Gammaflux G24 temperature control system. The control operation takes place automatically using an integrated interface with the Priamus process control.

Fill levels are optimized even when material properties vary
The dynamic process control solution from PRIAMUS based on real-time process data from sensors that measure the internal mold pressure and mold wall temperature in the cavity. By accounting for variations in melt properties, FILLCONTROL modules prevent cavities from being left unfilled.

 

Meet our experts at our Pipette Tip Test Center to learn more about perfect hot runner balancing.

Show More
Pipette tips for safe results.

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Otto Männer GmbH
Unter Gereuth 9-11
79353 Bahlingen a.K.
Germany


  E. Beric +49 151 27604436
  info@maenner-group.com

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