Completely flexible, universal in application.

SynErgy: user-friendly high-performance injection mouldingfor one-component and multi-component applications.

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Perfectly packed:in-mould-labelling (IML)Joining the moulded product and the labelby the moulding process doesn't just bringfunctional advantages, it also holds aconsiderable potential to reduce costs. Thehigher demands imposed in the foodstuffssector as regards packaging, decorationand functionality lead to a growing use ofthe in-mould-labelling process.

Clinically pure:medical mouldingsWhether syringes, pipettes, petri dishes orsystem solutions such as inhalers or insulinpens are concerned: they are typicalapplications for a SynErgy. The whole rangeof these machines is laid out to cope withthe requirements of a clean-roomproduction.

Twice as good:multi-component mouldingCombining different materials or colours isby now a well-established technique inmany areas of injection moulding. With itsSynErgy 2C, Netstal is offering a powerfulsolution also for these applications.

ypically Netstal: demanding applications.

In the more recent past, injec-tion moulding of plastics hasattained an eminent signifi-cance. New application possibil-ities keep coming up in allimportant areas of technology.The consequence is that everhigher demands are imposedon the production processes.

Already for decades Netstal hasbeen devoting itself with muchsuccess to the particularly demand-ing applications. This is how theproverbial Swiss Quality and pre-cision workmanship have becomethe hallmark of Netstal-Maschinen AG.

All injection moulding machinesmade by Netstal stand out by thesame five basic attributes. Theseare: speed, precision, reliability,user-friendliness and economicefficiency.

Thanks to these performancecharacteristics Netstal's SynErgyrange with clamping forces fromcurrently 600 to 8000 kN is firmlyestablished in the world market.As a user-friendly high-outputmachine, the SynErgy reveals itscapabilities to the full extentespecially when it comes to com-plex mouldedarticles and mouldingprocesses.

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Packed in the appropriate medium:DVD and Jewel BoxesAn advancing branch of the industry.Packaging products for all types of datacarriers represent a growth market. Themouldings must be highly precise andweight-optimized, and they must beproduced at short cycle times. Anothertypical case in which the SynErgy excels.

Special in its performance,

All models of the SynErgyrange display the typicalproperties of a Netstal machine:speed, precision, reliability,user-friendliness and economicefficiency.

21 Rugged: mould closing unitThe sturdy execution of the 5-point togglelever guarantees fast movements andminimal wear, also in the mould. Twoimportant factors in the striving for a lowcost per piece.

Straightforward: controlThe new, integrated operating unit isequipped with a high-resolution TFT screen.All elements are clearly arranged, theoperator guidance easy to handle and veryconvenient.

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The particular performancecapability of this range is theresult of numerous individualfeatures. Three of these,however, stand out especially. 1Closing unit

Flexible: injection unitThe injection unit is trimmed forperformance entirely: laid out for a widespectrum of applications, it provides therequired plasticizing capacity and permitsto adapt the drive values individually.

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strong in its technology.

2Injection unit

3 Control

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Solid mould closing unit

Injection unit for highest plasticizingand injection capacities

New operating unit with integratedsequence display

The interaction of the forces.

The name SynErgy refers to theinteraction of the forces. Netstalselected it for the underlyingconcept: the SynErgy rangeoffers five substantial strengths

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from which every user benefits.The interaction of theseperformance characteristics ofthe SynErgy guarantees highreturns.

Precision

� All sequences are perfectly reproducible

� Intelligent, exact closed loop control ofthe process

� Exact closed loop temperature control

Reliability

� Robust execution

� Stable mechanical sequences

� Comprehensive inspection of all components and assemblies before delivery

Speed

� Fast movements

� Short mould movement times thanks tothe 5-point toggle lever

� High injection capacity

Value

Profit

Number of pieces

Costs

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Fast and precise movements thanks to the 5-point togglelever of solid design

Economic efficiency

� Lowest reject rates

� Low cost per piece

� High return on investment

User-friendliness

� Safe and simple operation

� Ergonomic layout of all elements

� Easy programming with clear overview

� Excellent access to the mould compartment

The SynErgy enables lowest costs per piece and therebymaximum returns

Good accessibility of the machine from all sides

High performance

Netstal successfully extendedthe top end of its SynErgyrange from 5000 to currently8000 kN clamping force andearned much praise for thismeasure. The “large SynErgymachines” are in the meantimefirmly established in themarket.

They are based on a modulardesign. The separation ofmould closing and injection unitenables a customizedspecification of the machine,so that every user gets the mosteffective combination coveringthe particular requirements.

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21 Hybrid driveAll injection units feature an electric motorfor the screw rotation, while the remainingconsumers on the machine are operatedhydraulically. In other words, the machineis based on a hybrid drive concept.

Short dry-cycle timesThe “large” Netstal machines achieve ahigh efficiency also because their dry-cycletimes are extremely short.

3Two-part executionMould closing and injection unit areseparate, enabling an individualcombination of the two elements to suitthe applications on hand. A modularprinciple in the interest of maximumeconomic efficiency.

on a big scale.

Typical applications

� Decorated packaging products (IML)

� Fast-cycling thin-walled parts

� Complex, highly precise technical moulding

� Medium packaging products(for DVD, Optical Discs)

� Bottle closures

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Bladder accumulators enable parallel processsequences under constant pressure

Separate mould closing and injection unit based onthe modular principle

Bottle closures – a typical application

More colours. More components

Today, modern injection mouldingmeans more than just providinganswers to technical issues. Inmany areas the design of themoulded article plays a decisiverole for the success of the productin the market.

Multi-component injectionmoulding takes this fact intoaccount. Moulded products madefrom one or even severalcomponents are now state-of-the-art technology.

Netstal has laid out its SynErgy 2Crange to cope with practically alltechniques and processes. A widespectrum of applications is coveredwith the clamping forces from 600to 8000 kN and the injection unitcombination possibilities.

Flexibility in the processBoth injection units can inject in parallelor independent of each other, i.e.simultaneously, in sequence or offset time-wise. The processor can also define whichinjection unit is to inject first.

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Flexibility in the arrangementof the injection unitsIn standard execution the two injectionunits are arranged in L-shape because thisis often the most efficient solution. However,other arrangements are readily available ifthe application on hand requires this.

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s. Overview of all processes.

O V E R M O U L D I N G

Index plate techniqueFor applications in which the geo-metry of the moulding needs tobe adapted by the second com-ponent on both sides. This tech-nique offers a good deal of free-dom in the design of the product.

Application examples:

Adjustment wheels(automotive)Ball pen handlesTooth brushesLetter openers

Rotary plate techniqueAfter injection of the first materialcomponent the rotation to thefinishing position takes placewhere the plastic moulding iscompleted.

Application examples:

Drinking cupsHandlesClosuresSeals

Transfer techniqueA handling device transfers theadvance moulding to the finishingposition and affords maximumfreedom in the design of the firstand second component.

Application examples:

Transport rollers for printersTechnical partsTooth brushes

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Bi-InjectionBoth materials are simultaneouslyinjected into one cavity. Thechoice of the gate location andthe cavity's geometry are decisivefor the distribution of the material.

Co-InjectionDemanding process control in caseof thin-walled moulded products.A process perfectly tailored to thecapabilities of the SynErgy 2C!Optimal for processing recycledplastic in combination with high-grade material for the surfaces.

Application examples:

Mainly products whosefunctionality is in the fore-ground; the flow of thematerial cannot be controlled

Application examples:

PET preformsHousingsAutomotive products

B I - I N J E C T I O N / C O - I N J E C T I O N

Slide techniqueAfter injection of the first materialcomponent, a slide is drawn insi-de the mould to provide newspace for the second materialcomponent.

Application examples:

SealsClosuresSealing lips

Clear overview of the controlThe actions of both injection units can befollowed on the monitor at the same time,so that control and programming inputsare considerably facilitated.

The second injection unit is firmly connectedto the base frame in L-shape

New operating unit with sequence displayof both injection units

View of the mould compartment with the nozzleof the second injection unit

More possibilities.

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To many modern injectionmoulding applications there ismore than just selecting themachine. What matters in thesecases is the optimal configurationof a complete production systemof which the moulding machine isan important success factor, ofcourse. Beyond this, however, solidknow-how is required to pick theright mould, handling and onwardprocessing devices.

High performance in the system.

Prerequisite to an efficientproduction is that all these systemcomponents are ideally matched.Netstal is well prepared to copewith this issue and able to offercomplete system solutions. We relyon a wide network of competentpartners and are always in aposition to assemble the mostappropriate system for theparticular customer's products.

Competent for:repetitive systemsOur experts are highly experienced also inthe planning and implementation ofrepetitive systems. Typical applications:media packaging such as DVD boxes (2+2or 4+4-imps.), CD boxes, Jewel Boxes, SlimBoxes, petri dishes, etc.

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Competent for:individual systemsNetstal supplies individual injectionmoulding systems configured to meetspecific requirements.Typical applications: bottle closures,decorated packaging products, medicalmouldings.

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Consultancy with a systematicapproachGet in touch with us. We advise youintensively and in detail on the mostefficient system for your purposeson the basis of a SynErgy.

After-Sales Service

TrainingProject Work

Consultancy

Research /Development

Netstal Support Concept

Comprehensive: Netstal

The services surroundingNetstal's actual core business,the manufacture and marketingof injection moulding machines,are becoming ever more impor-tant in view of the customers'increasing call for extra value.Netstal has identified this needat an early stage and developeda label which stands for thecomprehensive services offeredunder the name of “NetstalSupport Concept”.

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Service doesn't start with thepurchase of a machine, anddoesn't stop thereafter, either, fora very long time. The “NetstalSupport Concept” has beeninitiated to provide our customerswith comprehensive support fromA to Z. Important parts of this areNetstal's Tech-Center in Näfels andcompetent customer care beforeand after equipment is bought.

1 Mature technology:Research & DevelopmentNetstal invests 5% of sales in its researchand development department each year.This is important on the one hand to holdthe position in the international market,and on the other to live up to the promiseof not just following the field, but con-tributing actively towards setting bench-marks again and again with innovativenew and future developments.

2 Individual consultancy:Netstal's Tech-CenterThe specialists employed at Netstal's Tech-Center are highly competent consultantsin all application-technical and commercial/administrative matters in the context ofinjection moulding. The maxim of theseexperts is to solve complex issues, to adviseclients comprehensively in their projectsand to find customised solutions. A highlyqualified team of engineers and techniciansis available to you especially when it comesto the planning and implementation ofcomplete production systems or whenspecific problems need to be solved.

Support Concept.

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3 Meeting requirements:specific trainingSolid training at Netstal's training centreputs you and your employees in a positionto get the best out of our mouldingmachines and to operate them efficiently.Training courses tailored to the customers'needs are the answer. The participants'level of know-how and experience is takeninto account in the planning of thesecourses.

4 Reliable: flexible after-sales serviceHaving acquired a machine, Netstalcustomers can count on a reliable, non-bureaucratic and fast after-sales service.Thanks to a tight sales and service networkour technicians are soon on the spot tocope with any problems. Many subsidiaries

5 Fast: delivery of spare partsworldwideWhat characterises a good spare partsservice are the total availability and quicktransaction of the orders. Netstal providesthese prerequisites in full with a 24-hourservice on 7 days per week and comprehen-sive stocks of spare parts at their head-quarters and with their global subsidiaries.

Research in the context of new and furtherdevelopments of the products as well asapplication-technical process optimisationis carried out at Netstal's own labs.

Most modern infrastructures and interactiveteaching are ideal prerequisites for specific,individual training.

A tight global sales and service networkwith nine subsidiaries and numerous agentsguarantees closeness to the customer anda fast service in about 40 countries. Moreon this under www.netstal.com

and agents all over the world and theheadquarters in Switzerland can offersupport without delay thanks to well-trained employees and a comprehensivestock of spare parts. As an option andextending beyond the normal warrantypackage, Netstal offers a variety of servicesto meet individual requirements in the areaof customer care.

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For a successful future.

Netstal-Maschinen AG8752 Näfels / Schweiz

Telefon + 41 55 618 61 11Telefax + 41 55 618 66 05Internet www.netstal.comE-mail synergy@netstal.com

Netstal is one of the pioneers of the injectionmoulding technology and draws from 60 yearsof experience. Machines and production systemsfrom Netstal stand out by their reliability, precision,speed, user-friendliness and economic efficiency.

It is not least on the basis of our global sales andservice network that we guarantee lasting goodrelations in the spirit of a genuine partnership.

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