• Joint stand pools expertise: connected overall solution with specialised technology partners

• Systems using the natural refrigerant propane (R290) comply with the tightened F-Gas Regulation

• Live application: production of transparent polycarbonate components with direct optical stress testing using polarising filters

• New development: latest-generation vario GEKKO variothermal temperature control system developed jointly with Contura and CycleTemp

Energy efficiency, sustainability and uncompromising component quality: at this year’s Fakuma in Friedrichshafen, technotrans will present forward-looking thermal management solutions for plastics processing. At the heart of the trade fair presentation is a fully automated live production cell featuring an injection moulding machine from Sumitomo (SHI) Demag, which produces transparent playing card boxes made of polycarbonate. A technological highlight of the system is the newly developed vario GEKKO variothermal temperature control solution, created jointly with partners Contura and CycleTemp, which ensures short cycle times and high energy efficiency. An interactive station equipped with polarising filters visually reveals the internal stress distribution of the plastic components produced live on the stand. technotrans will also showcase climate-friendly cooling and temperature control technology that already complies with the stringent requirements of the F-Gas Regulation.

“Rising energy costs, stricter environmental requirements and increasingly complex applications: the demands placed on injection moulding are growing, making close cooperation between specialised technology partners increasingly important,” says Nicolai Küls, Managing Director of technotrans solutions GmbH. “At Fakuma, we are demonstrating this with a live application in which intelligent and resource-efficient thermal management significantly reduces energy consumption while at the same time ensuring the highest optical quality standards for complex components.”

An automated system on the stand produces highly transparent playing card boxes made of polycarbonate (PC). The application is based on an all-electric injection moulding machine from Sumitomo (SHI) Demag. It is precisely in this demanding process that intelligent variothermal temperature control demonstrates its strengths: it enables highly precise temperature management that reproducibly and economically meets even the most stringent optical requirement.

Intelligent thermal management throughout the entire process chain

Two technotrans temperature control units from the eco.line series make a key contribution to the energy efficiency of the live application. The systems feature speed-controlled centrifugal pumps and the innovative ecoAnalyser. The integrated Pump Efficiency Module (PEM) precisely adjusts the pumps’ energy consumption to the actual process requirements. This intelligent control sustainably reduces electricity consumption while ensuring stable flow conditions in all cooling circuits.

The temperature control units also process data from the orcinus multi-circuit water distribution system integrated into the injection moulding machine. All parameters are exchanged centrally between the systems, including the orcinus distribution system, and the machine via the OPC UA interface and are visualised accordingly.

To minimise internal stresses in the plastic components produced, technotrans combines conventional temperature control with the newly developed GEKKO variothermal system. Its technological advantage is that the compact unit requires no additional external valve stations. Instead, the heat transfer medium, water, is always routed back to the correct circuit via an integrated, separate return flow system.

Thanks to large water reservoirs, users benefit from extremely fast heating and cooling times, shorter cycle times and energy savings of up to 40 per cent. This precise temperature control effectively eliminates optical defects such as birefringence or clouding. technotrans makes the result immediately visible to trade visitors at the stand: a polarising filter reveals the internal stress distribution within the plastic in the form of colour spectra.

Sustainable refrigeration technology with natural refrigerant

At Fakuma, technotrans is also addressing one of the most pressing issues facing the plastics industry: the far-reaching restrictions resulting from the tightened F-Gas Regulation. Visitors can experience technotrans’ innovative strength in this area in two live applications at the joint stand.

A powerful teco cw series chilled water temperature control unit provides reliable process cooling for the playing card box application. A further application demonstrates the performance of sustainable refrigeration technology in conventional high-performance packaging production. On another injection moulding machine, Sumitomo (SHI) Demag uses a 48-cavity mould to produce high volumes of beverage closures. The complex mould and machine cooling is provided by a compact, air-cooled technotrans weco 85 chiller. Equipped with a reliable high-pressure pump, it ensures a stable production process even under maximum load.

Both technotrans refrigeration systems use the natural refrigerant propane (R290), enabling plastics processors to significantly reduce their carbon footprint. In this way, users invest in a technology that provides long-term regulatory certainty and already meets future regulatory requirements today. technotrans is thus demonstrating how the highest environmental standards and economical system operation can be successfully combined in practice.

Combined technology expertise at the joint stand

The trade fair presentation also demonstrates that modern injection moulding processes require the integrated interaction of multiple disciplines. To achieve this, technotrans is collaborating with specialised partners on the stand.

Contura and CycleTemp are responsible for the intelligent variothermal mould temperature control and thermally balanced inserts. The intelligent Orcinus distribution system, featuring maintenance-free dual-ultrasound technology, provides precise hydraulic balancing of the temperature control circuits. A material dryer from Matsui positioned directly at the machine ensures optimum material preparation.

Individually adapted quick-release couplings from TST connect all water and cooling circuits securely and with minimal leakage. Finally, Optogon enhances the finished playing card boxes using a precise ultrashort-pulse laser system and, on request, engraves the names of visitors to the stand.

“A highly productive manufacturing process today is the result of seamless coordination between all peripheral and machine components,” Küls concludes. “Our trade fair presentation underlines how strong technology partnerships enable us to create future-proof and sustainable integrated solutions for the market.”

technotrans will exhibit at Fakuma 2026 in Friedrichshafen from 12 to 16 October in Hall B1, Stand 1104.

Further information: www.technotrans.com