New paths towards hot runners efficiency

At K 2025, Oerlikon HRSflow will showcase its groundbreaking STARgate HRS hot runner technology, which enables precise control of melt injection into the mould cavity through a revolutionary valve gate concept. Another new development is the Glow HRS solution, which allows for the direct injection of aesthetic parts in amorphous materials. Systems from the global hot runner specialist will also run live at partner companies, including an injection moulding tool for automotive parts that delivers a flawless surface and minimizes secondary operations. Beyond, visitors can expect to see interesting developments in application-specific solutions for multi-cavity systems. These include the Up nozzle series, which is specifically engineered for compact, tight-space applications with low shot weights, and new solutions designed for luxury and eco-friendly parts in the beauty and personal care industry. The upcoming K 2025 is organized in close cooperation with Oerlikon HRSflow’s sister brand, Oerlikon Balzers, highlighting the group's integrated approach to innovation and excellence.

With its newly developed STARgate HRS hot runner technology, Oerlikon HRSflow will present its revolutionary concept for the injection moulding industry to the public for the first time at K 2025. This technology is a groundbreaking development in the injection molding of PP, PE, PS, and other amorphous thermoplastics. Compared to conventional designs, production, assembly, and maintenance of various components are unnecessary; cycle time is significantly reduced; colour changes are easier; and power consumption and pressure loss are reduced. Additionally, the thickness of the back plates can be reduced. STARgate HRS hot runner technology also enables short filling and packing times. At K 2025, this technology will be on display at BMB, during the production of a bucket. This project was made possible by Oerlikon HRSflow, BMB, the Dutch plastics processors Dijkstra Plastics, Oerlikon Balzers, Piovan and R&D Plastics.

Another innovation to be unveiled for the first time at K 2025 is the Glow HRS technology, which enables the production of high-quality parts by direct injection, avoiding halos and weld lines. With precise surface temperature control and a compact design, this cutting-edge solution easily adapts to a wide range of applications.

At the booth of injection moulding manufacturer Haitian International Germany, Oerlikon HRSflow will give a live demonstration of how the FLEXflow HRS servo-controlled needle valve technology can be used to get high-quality automotive parts directly from the mould. This will be illustrated by the manufacturing of a car wheel arch. Developed in collaboration with DNP Group (producer of automotive decoration film printing) and Inevo (mould maker), this joint project impressively demonstrates that the painting of large-format injection-moulded parts can be eliminated, minimizing the need for expensive post-processing, even when using recycled materials. Other advantages of FLEXflow HRS technology include quick colour changes and reduced material waste.

With its compact gate-to-gate pitch (down to 15 mm), the new Up nozzle series is specifically engineered for tight spaces with low shot weights. With a 12-mm nozzle cutout, the series delivers exceptional performance in hard-to-reach gate areas. These features make the series ideal for industries such as beauty and personal care, packaging, beverages, and technical applications. Oerlikon HRSflow will present crystal-clear, eco-friendly parts produced with dedicated hot runner solutions for luxury cosmetic packaging. These components benefit from advantages of the technology, including crystal clarity, significant wall thicknesses of up to 12 mm, and high process repeatability.

Furthermore, at the Engel booth, a three-drop system from the Ga series of Oerlikon HRSflow’s Diamond Lux line of hot runner solutions will be demonstrated for producing a rear light concept application. In this process, a decorative foil is back-injected with Plexiglas 8N from Röhm and then overflooded with PUR. The foil enhances the visual design of the final product. This project is a collaboration between Zechmayer (toolmaker), Leonhard Kurz (LED and surface design integration), Engel (injection moulding machine producer), and Röhm (material supplier).

Also at the Haitian booth, a cable clipper made of PA 6.6 reinforced with 30% glass fibre that weighs just 1.2 grams will be produced in a 16-cavity mould. The hot runner configuration consists of 16 Oerlikon HRSflow SA series nozzles with an open gating system. These nozzles were specially developed for processing glass fibre-reinforced plastics, ensuring perfect cavity filling and outstanding process repeatability.

Last but not least, BOY's booth will feature the injection moulding of a conical blood filter using a Jestar medical demonstration mould on a BOY 35E injection moulding machine. This process utilizes Oerlikon HRSflow’s Multi Valve Plate (MVP) technology in conjunction with a 16-drop MULTIflow HRS system from the SP series. This technology offers synchronized valve actuation and reduced drop-to-drop spacing, enhancing precision in small weight applications.