THE MAXIMA MG SERIES INJECTION MOLDING MACHINES

2-PLATEN TECHNOLOGY FOR LARGE PARTS

FEATURES AND BENEFITS

1100 1300 1500 1800 2000 23002600 3000 3300 4000 4400

ROBOSHOT S2000i-B High-Speed,High-Precision All-Electric Machines.6 through 385 tons.

POWERLINE NT High-Value All-ElectricMachines. 220 to 1125 ton clampcapacities.

MAGNA V Vertical Insert Machines.30 to 300 tons. Horizontal, shuttle,rotary table models.

K-TEC High Speed Hydraulic Machines.44 to 500 ton clamp capacities.

MAGNA MTG Advanced HydraulicToggle Technology. 170 through 450 ton capacities.

MAXIMA MM Mid-Size 2-PlatenTechnology. 310 to 880 tons.

MAXIMA MG Advanced 2-PlatenTechnology. 1100 to industry’s largest 6600 tons.

Full line of Auxiliary Equipment, frompellet to part handling.

No other injection molding technology suppliercan offer what MILACRON can offer you. Inexperience, technology, longevity, products andservices. We have the broadest product range,with the highest speeds, precision and largest

tonnage range in the industry. We’re the globalleader in all aspects of multi-component-material-color. We offer the best in after-saletechnology. Maintenance and operator training.A full range of auxiliary equipment. MRO

products and supplies. Around-the-clockreplacement parts, service and support. Frominjection end products to retrofitting andcomplete machinery remanufacturing. Yoursingle source supplier in a total package.

T E C H N O L O G Y, E Q U I P M E N T, S E RV I C E A N D S U P P O RT

Milacron Inc. Milacron Marketing Company 4165 Half Acre Road Batavia, Ohio 45103 T 513-536-2000 F 513-536-2624 www.milacron.com

All specifications reflect average values based upon typical machine layouts. Actual figures will vary depending on final machine configuration. If you require more specific data, consult a certified

installation print for your particular machine. Performance specifications are based upon theoretical data. Due to continual improvements, specifications are subject to change without notice.

© 2006 MILACRON Inc. MILACRON, CINCINNATI MILACRON, MAXIMA, MAGNA, MOSAIC, POWERLINE, K-TEC, SERVTEK, MELTSTAR, WEARSTAR, PVCSTAR, KLEARSTAR and the Globe Graphic are

registered trademarks of MILACRON Inc. ROBOSHOT is a trademark of FANUC. VBET is a trademark of Barr. Printed in USA. 05/06 PM906

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THE MAXIMA MG SERIES OFLARGE 2-PLATEN INJECTIONMOLDING MACHINES.Bringing a new era in large partinjection molding machineperformance with compact, versatileand adaptable production systems.

MAXIMA MG Series machines bringyou production in a reducedfootprint, using 10% to 20% lessfloor space than comparablemachines. MAXIMA MG’s efficientuse of floor space brings more profitper square foot.

MAXIMA MG machines can beconfigured for various applicationsby combining a large range of clampand injection units with a selection ofoptional pumping packages. Realizethe benefits of configuring a machinethat is perfectly suited to yourproduction requirements. Optimize yourprocess for highest part productivity,part quality and operational profitability.

Modularity and Flexibility: Configureyour optimal MAXIMA MG InjectionMolding Machine with these possiblecombinations of clamp units andinjection units with available injectionshot sizes.

ModelClamp Force

Platen Size(h x v)

Tie Bar Spacing(h x v)

Maximum Daylightwith ejector

Maximum Daylightwithout ejector

US Tons inches inches inches inches

MG1100 1125 79.5 x 64.8 61.0 x 47.2 94.5 n.a.

MG1300 1292 86.6 x 70.0 65.7 x 52.4 110.2 n.a.

MG1500 1461 86.6 x 70.0 65.0 x 51.6 110.2 n.a.

MG1800 1820 94.5 x 77.5 72.2 x 55.3 129.9 155.3

MG2000 2025 94.5 x 77.5 71.6 x 54.7 129.5 155.3

MG2300 2330 106.3 x 88.6 79.3 x 63.6 145.6 174.4

MG2600 2585 106.3 x 88.6 78.7 x 63.0 145.6 174.4

MG3000 2990 115.0 x 96.5 84.0 x 66.9 145.6 174.4

MG3300 3315 115.0 x 96.5 83.5 x 66.3 145.6 174.4

MG4000 3950 122.0 x 106.3 90.5 x 74.8 165.4 195.1

MG4400 4385 122.0 x 106.3 89.8 x 74.0 165.4 195.1

MAXIMIZE YOUR LARGE PART PRODUCTION AND PROFITS

Model Injection Frames Sizes and Shot Sizes*

4880 6610 10100 16000 23000 34000 48000

MG1100 85/105 116/140 179/232 288/362

MG1300 116/140 179/232 288/362 413/540

MG1500 116/140 179/232 288/362 413/540

MG1800 179/232 288/362 413/540

MG2000 179/232 288/362 413/540

MG2300 288/362 413/540 607/769

MG2600 288/362 413/540 607/769

MG3000 288/362 413/540 607/769

MG3300 288/362 413/540 607/769

MG4000 413/540 607/769 854/1054

MG4400 413/540 607/769 854/1054

*Shot sizes in oz. based on conversion factor of 0.95 g/cc polystyrene

Optional tie bar retraction

Clean, clear access tothe injection purge area

Optional high-efficiencyelectric extruder drive

W I D E O P E N S P A C E SWith a long clamp stroke, largedaylight and spacious tie barclearance, there’s plenty of room forover-sized molds and stack molds.

The MAXIMA MG Series is built to provide continued, repeatableperformance throughout years ofdemanding production, while givingyou the ability and versatility torespond quickly to changing marketdemands.

Whether it is generic products ortechnically challenging parts, theMAXIMA MG Series brings you thespeed, precision, capacity andrepeatability demanded by largeinjection molded parts for all majorindustry segments:

AutomotiveHousewares and ApplianceStorage and Transport ContainersFurniture, Construction, Businessand Industrial

EASY MOLD LOADING ACCESSAutomatic tie bar retraction (optional) enables quick installation of bulky molds and low overhead crane situations. Reduces set-up to a fraction of the usual time.

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Tie bar retracted

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The MAXIMA MG tie bars arefully supported end to end by a rigidframe structure. Ensures:

Platen parallelismLong mold lifeLess scrapClamp durabilityReduced maintenanceIncreased productivity

The MAXIMA MG also features arigid I-beam and plate constructionbase. Benefits:

Maximum strength, rigidity,durabilityCarries weight to floorLower machine centerlineWide open clearance from clamp to machine end

Split locking nuts on buttressedgrooved tie bar threads ensurealigned clamp lock-up.

Two small cylinders pre-positionthe clamp for tonnage build andassist with clamp decompression.

Rapid traversing cylinders openand close the clamp.

The moving platen and cylinderplaten together form a deep boxstructure for minimal deflection andoptimal support for the mold.Benefits:

The large, wide platen skatedesign assures platen and moldhalf parallelism.The robust skate design

accommodates a 2/3 maximummold weight to be mounted oneither moving or stationary platen.Results in longer mold life, lessscrap and reduced maintenance.

The moving platen adjustableskates ride on hardened steelways, and can be preciselyadjusted as needed. This enablesyou to protect your mold and

machine investment as wearoccurs over time.Automatic lubrication of themoving platen skates assurescontinuous low friction.Bronze bushings andautolubrication provide longlife and precision guidance forsuperior parallelism.

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EJECTOR/DAYLIGHT FLEXIBILITYThe ejector mechanism is open

and accessible for easy mold set-up.The ejector can be removed for evengreater mold daylight on MG 1800and larger models.

To achieve the increased daylightwith the ejector removed, the mountingblock for the traversing cylinder isrelocated to the adjacent mountingposition. The yellow “position” plugis inserted into the receptacle tosignify the correct daylight.

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FAST AND EASY ON THE MOLDS

TONNAGE IS BUILT DIRECTLYBEHIND THE MOLDDirect acting ram builds tonnage inthe center, directly behind the mold.

CLAMP CLOSING: Rapid traversecylinders pull the moving platen

to close the mold.

CLAMP LOCKING: After mold close,the split locking nuts close overthe grooves on the tie bars.

TONNAGE BUILD: During tonnagebuild, high pressure hydraulic oilin the cylinder platen pushes the Direct Acting Ram to buildtonnage directly behind the mold.

INJECTION: After tonnage is built,the injection unit fills the mold.

CLAMP UNLOCK-DECOMPRESS:Just prior to the cooling timer timingout, the clamp decompresses and isheld closed by the rapid traversecylinders and the split locking nuts

open.

CLAMP OPEN-EJECT: The rapidtraverse cylinders move the platenback to open position. As the mold is opening, the SPI knockout bar,driven by the ejector cylinderejects the part.

BENEFITS:

Short stroke tonnage build using asmall volume of oil to compressresults in faster tonnage build time.Reliable tonnage build. Only onepiston to control, not four.Centrally actuated tonnage forcedirectly behind the mold providessymmetrically distributed clampforces across the mold area.Direct and even clamp force.Simple and proven design,resulting in improved uptime.Reliable and durable.Better alignment, assuringreduced mold wear.Better part quality and higherproductivity.

MAXIMIZE CLAMP SPEEDSWHILE PROTECTING MOLDSMAXIMA MG has the fastest clampin the industry and provides the bestmold protection.

Benefits:Closed loop speed and pressurecontrol ensure consistent cycles.Up to 3 clamp closing and 5clamp opening speeds.Closed loop pressure differentialmold protection is provided forTrue Force Control.

Up to 3 mold protection stagesare available.Closed loop tonnage control enablespart consistency and quality.Clamp motions are easilyconfigured for 3 plate molds andlonger leader pins.

OPERATOR FRIENDLYPower operator gate allowsconvenient and safe access to the mold area.Full ANSI safety complianceprotects your personnel.

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MAXIMA MG 2 Platen Direct Acting Ram withhigh pressure build up.

Typical 2 Platen deflection with tonnagecylinders at corners.

ENERGIZED RAM SEAL SYSTEMProven and tested to provide long lifewith low friction, low wear, and noheat generated between theEnergized Teflon Seals.

RIDER RING The ultra high mole-cular weight polyethylene rider ringsupports the ram and keeps it centered.

ENERGIZED TEFLON SEALTwo (2) glass/molybdenum-filledteflon seals provide a low friction ride

on the chrome-plated ram. The sealsare energized with a rubber “O” ringthat does not take a compression set.

WIPER Keeps contamination outof the system.

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DETAIL: ENERGIZED TEFLON SEAL

NYLON BACKUP

CHROME-PLATED RAM

PRESSURE

NYLONBACKUP

CLAMPCYLINDER

CLAMPCYLINDER

ENERGIZER

GLASS/MOLYBDENUMFILLED TEFLON SEAL

FA S T A N D D U R A B L E C L A M PFASTEST CLAMP SPEEDS INTHE INDUSTRYMAXIMA MG clamps have fast and repeatable acceleration anddeceleration, with dry cycle timesone to two seconds faster than any comparable clamp in theindustry.

Clamp decompression and unlockingof nuts are concurrent with partcooling to reduce cycle time.

The MAXIMA MG4400 has animpressive clamp speed of 30 inches per second.

SPLIT LOCKING NUTTECHNOLOGY

The MAXIMA MG features splitlocking nut technology forincreased precision and productivity:

Reliable and durable technology.This design is proven by adecade of performance on our

hydraulic machines.Design distributes load acrossthreads.Buttressed groove threads areangled to ensure precision lock-up.Compensates for out-of-squaremolds.Fast and accurate unlocking/lockingLocking nuts are individually andaccurately actuated, not relyingon complex linkage.

Clamp tonnage is built after all four lock nuts aresimultaneously fully engaged.Locking nut assemblies areequipped with automaticlubrication.Interlocked with limit switches.

Clamp CloseNuts LockBuild TonnageFillPackHoldCoolDecompressNuts UnlockClamp Open

(Clamp Decompression and Nut Unlocking

are Concurrent with Part Cooling to Reduce Cycle Time)

Effective Dry Cycle Process Time Effective Dry Cycle

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Clean and clear access to the purge area onoperator and non-operator side of machine.

Powered injection unit swivel enables quick and easy access to maintain the screw tip or remove/install feed screws.

Larger tapered conical hole in the stationaryplaten provides excellent access to purgingsand injection tip for removal.

INJECTION UNIT FEATURESDual injection unit pull-in

cylinders assure alignment andcenter-balanced force.

Precision ways reducemisalignments affecting screw pick-up and cylinder leaks.

Dual injection cylinders reducemachine footprint.

Barrel support (optional) isprovided to assure alignment oflarge injection units.

Separate injection base and

transition base facilitatesshipping and installation.

Optional high-efficiency ACelectric extruder drive providesindependent/parallel clamp andextruder operation for cycle timereduction and energy savings.

P R E C I S I O N P R O C E S S I N G H I G H P E R F O R M A N C E ,A P P L I C AT I O N S P E C I F I C

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The MAXIMA MG Series offers awide selection of injection units andscrew geometry. This meansapplication specific solutions forevery material formulation andplasticizing rate, including:

High performance, highthroughput Lower melt temperaturesBetter mixing and homogenizationWear resistant protection

High Performance Variable Barrier Energy Transfer feedscrewincreases conductive melting for higher rates with less energy.

High speed, high throughput, superior mixing without shear and without sacrificing recovery or cycle time.

Lubricity properties and corrosion resistance for optimal processingof polycarbonate without black specks.

Ultra high wear resistance package including super-alloy feedscrewplus super-wearing alloy barrel and screw tip.

Anti-corrosive package of feedscrew, smear-head tip and end capeliminates all corrosive effects of PVC/CPVC processing.

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MOSAIC CONTROL15 Inch Diagonal ScreenTFT Flat PanelTouch Screen (Analog, Resistive)Dual Intel ProcessorsSwing Arm MountIP65 Protection (against dirt andcontaminants)

MOSAIC FEATURESTwo USB 2.0 PortsEthernet port - TCP/IP and FTPprotocolsAll -digital positions feedback forhigh accuracy

Direct Menu AccessMachine History NotepadSet Point OverviewEnhanced Operator IDAlarm LogChange LogProcess MonitorStatistical Process Control (SPC)Volume/Position/PressureInjection SetpointsMelt or Hydraulic Pressure TransferFreely Configurable I/OEnhanced Plotting Graphics withCursorsBuilt-in Web Server

MOSAIC OPERATOR SCREENSScreen layouts are clear, conciseand easy to understand.Direct Group Access Keys forquick machine setup.Pop-up keyboards for data andtext entry.Drop down selection boxes forchoosing items from a list.Lighted On/Off buttons.Choice of Language and Units ofMeasurement.

PRECISION CONTROLTECHNOLOGY FOR ALLAPPLICATIONSThe MOSAIC Control is the high-performance control system thatcontrols and communicates allMAXIMA MG machine functions andrelated parts producing processes.MOSAIC Control provides improvedreliability, performance, and user-friendliness to keep your process incontrol. Individual forward andretract manual movement keys foreach axis. Factory programmablebuttons for added options. Logicalgrouping and separation of themachine function and manualoperator keys. Swing-arm mountcan be optimally positioned for eachoperator, allowing for an unobstructedview of the mold area.

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Alarms

Overview

Mold Data

Temperatures

Clamp Unit

Cores

Injection

Production

Automation

Home

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Help

Screen Export

Data ExportForeground/Background DataDiagnostics

System

Message Bar: Displays the active alarm text or the current menu if no alarm exists

Group Access Keys Special Function Keys

Status Bar: The always visible Status Bar provides a quick glance at the current status of critical machine parameters, including actualfeedback from sensors, current cycle count and current logged-in user.

SET POINT OVERVIEW- Single screen for setting clamp, ejector,

injection and extruder- Follows the configurations that are defined on

the Primary Set Up tabs- Great for quick setups and adjustments- Improves operator setup efficiency

CONFIGURABLE I/O- Ultimate flexibility for signal interfaces- Eight 24 Volt DC Input or Output signals- Signals are configured to machine to Machine

Cycle Status- 41 Output Cycle States and 14 Input Permissions- Configurable Pulse Timers for inputs

PROCESS MONITORING TREND GRAPHICS- Monitors trends on-line using trend graphics- Select from any of the monitored variables

(over 50 to select from)

PROCESS MONITORING- Track your process for consistency- High resolution timers and position feedback- Selectable Alarm Bands- Choose up to 16 parameters from a list

of over 50

ENHANCED PROCESS GRAPHICS- Ability to display one or two graphs- Enables comparison to stored reference point- Easy to use Cursor Control and Zoom Control- Adjustable “Y” scaling

FLEXIBLE INJECTION SETUP- Up to 10 segments of Injection Velocity- Transfer each segment on Position, Volume,

Pressure or Time- Up to 10 Pack/Hold Pressure/Time/Velocity steps- Display either Hydraulic or Melt pressure- Graphic display of Pressure and Velocity

actual values

INTUITIVE OPERATIONOPERATOR PANEL15 Inch touch screen framed by a Keyboard

INTUITIVE OPERATION TOUCH SCREEN

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SERVO-CONTROLLED VARIABLEVOLUME PUMPSServo-controlled variable volumepumps provide the highest levelof hydraulic circuit control. Thesystem uses only the oil you needwhen you need it. Utilizes proven andreliable A4 and A10 piston pumps forbest performance and uptime.

MAINTENANCE-FRIENDLY POWER Pumps and motors are located ineasily accessible enclosures.

Sound absorbing covers keep thecomponents clean.

SETUP-FRIENDLYExtra space is provided in the cat track to accommodate utility linesto the mold. Wide and spaciousaccess is also provided for moldsetup and utility connections.

PERFORMANCE VALIDATIONPerformance Validation Tool (PVT)software testing is run on allmachines during the final phase of

manufacturing. PVT validates precisionand accuracy for the following criticalmachine control functions:

Injection PressureInjection VelocityEject Forward Velocity & PositionEject Retract Velocity & PositionClamp Forward Velocity & PositionClamp Retract Velocity & Position

MAXIMA MG machines are availablewith higher performance injectionoptions capable of substantiallyhigher injection rates. Highperformance options include:

Accumulator assisted injectionfor high speed injection rates.

High efficiency AC electric extruderdrive provides independent andsimultaneous clamp and extruderoperation for reduced cycle time and greater energy savings.

The hydraulically powered rotarynozzle shut-off valve preventsmaterial from flowing into the moldrunner system while the screw isrotating and the clamp is openingduring independent operation.

HIGH PERFORMANCE

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RELIABLE AND SERVICE FRIENDLY

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StandardMAXIMA MG

MAXIMA MG with Electric

Extruder Drive

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On BoardElectronics

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Cylinder Velocity,Pressure

SMART VALVESThe MAXIMA MG Series uses “smart”proportional valves with internalcontrol circuits. The valves have noLVDT’s to tune, and are less sensitiveto contamination. Precision repeatabilitymaintains your process values overlong production runs, cycle to cycle.

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This graph shows how the MAXIMA MG equipped with an electric screw drive saves energy with eachcycle compared to both a standard MAXIMA MG and a standard hydraulic machine.

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SMART VALVE: TRUE CLOSED LOOP SYSTEM

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PERFORMANCE VALIDATION INJECTION PROFILE DIAGRAM

Acceptable Time Range (+/-) Actual timeT1 0.465 +0.04/-0.01 0.496T2 0.900 +0.02/-0.01 0.916T3 0.180 +0.03/-0.01 0.193T4 0.500 +0.03/-0.01 0.500T5 0.170 +0.01/-0.02 0.165

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The MAXIMA MG product platformis designed to be easily adapted to

support your application needs andhandle next generation products.The MG Series machines aredesigned with modularity to readilyequip you with multi-material processtechnology. Multi-componentMAXIMA MG machines enable you torealize the added value from multi-material design flexibility, functionalintegration, parts consolidation,assembly reduction, increasedproductivity and reduced cost.

Milacron’s extensive experience ininjection molding machines andprocesses enables us to provide you full system solutions for yourcomplex molding productionchallenges. Our machinery andsystem services range from singlecell injection molding machines withbasic automation to complete plantsystems. Our products and servicesextend from the planning phasethrough production start up.

Material conveying, storage,drying and blending systemsIntegrated heat transfer systemsMold changing and moldclamping systems

Robotics and conveyor systemsDegating, assembly and othersecondary operation systems

HEAT TRANSFERPrecise and efficient heat removal andproper mold cooling means productivityand profitability. Milacron integratedheat transfer systems offer youcomprehensive and optimumtemperature control through allprocess phases and supportingsystems.

MATERIAL MANAGEMENTFrom receiving to process, MilacronMaterial Management equipment andsystems are precisely engineered foryour specialized operations. Materialconveying, storage, drying orblending, Milacron delivers advanceddesign and highest quality at themost competitive prices as part of our total support.

PART HANDLINGPart handling and secondaryoperations can add profitability. Highspeed automation is the tool whichenhances productivity. Milacronprovides a comprehensive line ofrobots and conveyor systems tohandle degating, assembly and many other operations.

ADD ING VALUE THROUGHMULT I -MATER IAL TECHNOLOGY

S Y S T E M S A U T O M AT I O N

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STACK MOLD TECHNOLOGYThe MAXIMA MG’s strong and rigid clamp with extensive daylightreadily supports stack molds andcan be configured quickly withoffset injection units and meltdelivery systems.

CO-INJECTION APPLICATIONSFoamed core for reduced weightand noise transmissionGlass filled cores for improvedphysical propertiesLow cost core for cost savingsHigh gloss skin material overstructural core material for

combination of aesthetic and structural propertiesPost consumer or industrialrecycled material forenvironmentally friendly core

STACK-TURNING TECHNOLOGYAdvantages:

Doubled number of cavities withthe same clamp force.Vertical axis of rotationCenter platen is guided by tiebars and supported by baseHeavy molds are easy to handleNo harmonic arm required

In-line assembly is possibleVertical turning of 180 degrees inless than 3 secondsMelt delivery system for secondcomponentPart removal has no influence oncycle timeCost reduction for parts up to25% possible

Stack Turning Technology Stack Mold with Offset Injection Units