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E N T E R T H E A L L - E L E C T R I C W O R L D O F M I L A C R O N

E N T E R T H E A L L - E L E C T R I C W O R L D O F M I L A C R O N. The Current And Future State-Of-The-Art Of All-Electric Injection Molding Technology. FEW COMPANIES CAN CLAIM LEADERSHIP IN ALL-ELECTRIC INJECTION MOLDING TECHNOLOGY. FEW CAN EVEN CLAIM LENGTHY EXPERIENCE IN

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E N T E R T H E A L L - E L E C T R I C W O R L D O F M I L A C R O N

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  1. E N T E R T H E A L L - E L E C T R I C W O R L D O F M I L A C R O N The Current And Future State-Of-The-Art Of All-Electric Injection Molding Technology

  2. FEW COMPANIES CAN CLAIM LEADERSHIP IN ALL-ELECTRIC INJECTION MOLDING TECHNOLOGY. FEW CAN EVEN CLAIM LENGTHY EXPERIENCE IN ALL-ELECTRIC MOLDING TECHNOLOGY VERY FEW, IN FACT, CAN CLAIM PIONEERING ALL-ELECTRIC TECHNOLOGY AND PRODUCT DEVELOPMENT

  3. MILACRON CAN EASILY OFFER CREDENTIALS IN ALL THREE. THIS IS THE EXPERIENCE WE PRESENT, AND PLACE AT YOUR DISPOSAL, IN THIS PRESENTATION.

  4. ENTER THE ALL-ELECTRIC AGE • A New Age of All-Electric Technology, Power and Processing Capability • Why Electric Molding Technology • Comparison Charts: All-Electric Injection Molding vs. Existing Processing • Capability • Economic of Good Parts • Shot Control Variation • Shot Weight Variation • Energy Usage vs. Throughput • Electric Usage vs. Regeneration • Overall Power Consumption • Overall Power Regeneration: Power Storage and Reuse • Noise EvaluationThe History of All-Electric Injection MoldingDrafting Your Own Technology and Productivity Plans for the Future

  5. A NEW AGE OF ALL-ELECTRIC TECHNOLOGY, POWER AND PROCESSING CAPABILITY Return to Index

  6. The Technology, the Power, the World has turned the corner It happened to industrial robots. It happened to machine tools. Precise, consistent all-electric machines replaced oily, maintenance-prone hydraulic equipment on the factory floor. Milacron slugged it out in both these markets, and began applying those electric-technology lessons to plastics machinery as early as the mid ‘80s. Return to Index

  7. The turning point is in our rear view mirror Today Milacron leads the revolution in all-electric injection molding machinery, while dozens of other companies are waking up to the revolution. We sold more than 400 electric IMMs in 1998, an increase of 50 percent over ‘97. Our new designs, new technology - developed and improved through years of experience - bring you market-leading electric machines today, while the rest of the industry introduces first-generation equipment… or none at all. Return to Index

  8. In addition to co-pioneering the development of a precision • all-electric machine with Japan’s Fanuc in 1985, Milacron: • Developed its own proprietary high-tonnage, large shot capacity all-electric IMMs by 1995. • Mainstreamed the ultra-high-speed, all-electric machine technology developed by Ferromatik Milacron in Germany. • Broke all known shot-size limitations for electric IMMs in 1998 with a patented two-stage electric injection unit needed for large-part molding on electric machines • Is uniquely positioned as a global company to synthesize and mass-market electric molding technologies from Europe, Asia, and the U.S. Return to Index

  9. In an industry at a technology turning point, we have already lapped the field. Return to Index

  10. WHY ELECTRIC MOLDING TECHNOLOGY? Return to Index

  11. From the day the machine starts up, your cost per part is lower, part quality is higher. All-electric machines use less energy than hydraulic machines, they are more reliable, cycle times are faster because of independent clamp/injection functions, and part quality is higher because of unbeatable repeatability. Return to Index

  12. Here’s why molders buy all-electric machines for low-tech products such as pet food dishes and beverage crates - not just for cleanroom work or precision parts. 1. Electric IMMs are in a class by themselves Electric machines consistently hold tolerances one-half those of a Hunkar Class 1 hydraulic machine. They stand out in a class of their own. 2. They start that way, they stay that way Accuracy, repeatability and consistency are inherent to all-electric machines. They are digitally controlled, mechanically driven, just like precision machine tools and coordinate measuring machines. They do not vary over time, because there’s no hydraulic fluid to heat up or compress, no hoses that expand, no valves that stick. Molders say these machines make good parts by the third or fourth shot, and then run without attention until it’s time for a mold change. Return to Index

  13. 3. Precision shot control saves material, reduces mold-in stress You can’t afford to give a customer more resin, colorant, or additive than the part needs. Electric machines let you mold closer to the threshold of just-the-right-amount of material, without falling below that threshold. Screw position for fill and pack is controlled with digital precision, eliminating overpacking and greatly reducing molded-in stress - ideal for top quality headlight lense, optics, etc. 4. Predictable performance facilitates “lights out” molding Consistent machine performance allows labor cost reductions with unmanned shifts at night, on weekends. Utilization of skilled labor is greatly enhanced. 5. Electric molding turns an art into a science Electric machines turn injection molding into a predictable, robotic operation. With a more consistent machine, process setups can be used repeatability without adjustment, without changes in part consistency or quality. Return to Index

  14. 6. Huge energy savings cut molding cost, plant construction and • operating costs • Whether small or large, all-electric machines dramatically • reduce operating costs, using 50-90 percent less power than • equivalent hydraulic machines. Connected power requirements • for an electric machine are only 25% those of a hydraulic • machine. Utility companies sometimes even help pay the cost • for more efficient electric machines to reduce generating • capacity needs for a market area. • 7. Less electricity means lower cost for new plant construction • Because electric machines use less energy and throw off less waste • heat, new plant construction is reduced through: • Smaller electrical service connection software • Smaller busbars, etc. throughout the plant • Smaller air conditioning compressors for temperature-controlled plants • Cooling needed only for feedthroat • Elimination of oil storage and disposal facilities Return to Index

  15. 8. Cooling water costs are eliminated An electric IMM is air cooled, with no plumbing or hoses, no heat exchanger to clog, no cost for cooling water. A hydraulic 55-ton molding machine runs up an annual bill of $3800 for cooling water alone. 9. Electric machines use no oil Electric IMMs eliminate the costs and headaches of hydraulic oil: purchase, disposal, monitoring, leaks, burst hoses, clean-up, slips and falls sticking valves, fire hazard, etc. 10. Electric machines are cleanroom ready Electric machines are ideal for molding optical media, medical parts, and other dirt-sensitive parts. Return to Index

  16. 11. Low noise levels improve plant environment Molding machine noise is coming under closer scrutiny from workers compensation insurance agencies, but electric machines are so quiet, it’s hard to tell they are running. They typically operate at less than 70 dB. That’s about two-thirds the noise of a hydraulic machine, greatly reducing fatigue and stress for operators. 12. Electric machines allow more flexibility in plant layout, workflow Clean, quiet operation allows relocation of the injection molding process into areas such as assembly, shipping areas and warehouses. 13. Electric machines are more reliable, have fewer parts, need less maintenance Fanuc servomotors have failure rates below 0.2% for total parts produced. Milacron all-electric average warranty costs are less than $135 per machine per year. High voltage components are circuit board mounted with automated assembly techniques. In contrast, hydraulic machines use a complex network of pumps, hoses, filters, tubes and valves requiring extensive maintenance. Return to Index

  17. A tighter window of process capability allows operations to be moved confidently toward the lower specification limit where savings accrue in material, scrap, energy, etc. Return to Index

  18. Typical plot of repeatability of electric injection machine shot weights Return to Index

  19. A two-cavity, polycarbonate lens was running consistent cycles at .35% total variation of part weight. As a test, the shot size was arbitrarily reduced by about 40% and the mold was allowed to continue running in “short” condition for four consecutive cycles. After the fourth cycle the shot size was reset to the previous value with the results shown. Return to Index

  20. All-electric machines dramatically reduce operating costs, using 50-90 percent less power than equivalent hydraulic machines. Connected power requirements for an electric machine are only 25% those of a hydraulic machine. Return to Index

  21. All-Electric machines use a smart regenerative power circuit to produce electricity during clamp deceleration and other functions. This power is stored and re-used. Return to Index

  22. Comparison of power consumption between all-electric and a hydraulic machine for applications involving molding of food packages. Return to Index

  23. Electric machines use a smart regenerative power circuit to produce electricity during clamp deceleration and other functions. The power is stored and re-used. Return to Index

  24. All-electric machines typically operate at less than 70 dB. That’s about two-thirds the noise level of a hydraulic machine, greatly reducing fatigue and stress for operators. Return to Index

  25. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1952 - Numerical control (NC) of machine tools is established by MIT equipping a Milacron milling machine with a computer control. The MIT report becomes “the bible” for a research team at Fujitsu 1959 - Electro-hydraulic pulse motor (an NC-controlled hydraulic servomotor) is patented by Dr. Eng. Seiuemon Inaba of Fujitsu. MN controlled hydraulic servodrives are widely adopted for machine tools during the 1960s. In 1972, Fujitsu spins off it’s motor and NC control technology in a new company, Fanuc (Fuji Automatic Numerical Control), with Dr. Inaba as executive vice-president. Return to Index

  26. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1973 - World oil crisis prompts Fanuc to develop a more energy efficient, all-electric servomotor, culminating in full development of NC servomotors by Fanuc. Electric servomotors sweep through the machine tool industry, obsoleting hydraulic drives. Milacron’s Machine Tool group becomes a major technology partner with Fanuc. 1983 - Recognizing the mutually beneficial potential for electric servodrives in traditionally all-hydraulic injection molding machinery, U.S. Market leader Milacron begins strategic partnership with Fanuc, licensing it’s toggle machine technology to Fanuc for development of a CNC-controlled all-electric injection molding machine. Long range objective for Milacron is to “leapfrog” competitors for inevitable shift to all-electric injection molding. Return to Index

  27. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1985 - Milacron and Fanuc introduce the jointly-developed ACT (AC Technology) all-electric injection molding machine at the National Plastics Exposition. ACT machines are initially available in 50, 75, and 150 tons clamp force. The two companies later expand this to 250 and 330 ton sizes. 1985 - Fanuc grants Milacron exclusive distribution rights to market all-electric machines in N. America. 1985 - Fanuc becomes the world’s leading producer of all-electric injection molding machines. Return to Index

  28. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1992 - Milacron commits to develop its own all-electric injection machine, aimed at the high tonnage end of the market, a market niche as yet unanswered by the industry. 1993 - Milacron purchases Ferromatik, a German injection molding machine maker, thus acquiring Ferromatik’s ultra-high-speed machine technology. Return to Index

  29. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1994 - Milacron introduces its own all-electric injection molding machine line in tonnages to 300 at the National Plastics Exposition. At the same show, Milacron and Fanuc introduced the first all-digital, servo-controlled electric molding machine, called Roboshot. Roboshot represents a fourth generation of all electric design, and is now kinematically optimized by Fanuc, totally divorced from hydraulic concepts. 1995 - Milacron introduces the world’s largest all-electric machine (725 tons) at the K show in Dusseldorf. Return to Index

  30. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1996 - Milacron is the worldwide leader in all-electric injection molding machinery, positioned with U.S., Asian and European technology, to satisfy the needs of any customer 1997 - Thirty percent of the 150 machines sold by Milacron at the triennial National Plastics Exposition are all-electric. 1997 - Milacron forms Elektron Technologies business unit with separate facility and staff to concentrate on development and sales of next generation, global-design, all-electric IMMs. Return to Index

  31. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1998 - Ferromatik Milacron introduces the DISCO all-electric IMM for replication of optical disc media and molding of smart cards. The all-electric design allows programmable coining, eliminating the need for mechanical stops and adjustments used on hydraulic IMMs. 1998- Elektron Technologies introduces new Powerline series electric IMMs with significant advances in performance, size and simplicity for the highest appeal in any molding application. First model is 330 tons clamp force. The ultra-quiet machine utilizes a blend of new and existing design features developed in both the U.S. and in Germany at Ferromatik Milacron. Fanuc is a key technology partner, providing drives and low-inertia motors. Return to Index

  32. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1998 - Elektron Technologies introduces new two-stage electric injection unit that breaks the limitation of large shot capacity that had been a de facto ceiling on the upper end of the size range for electric machines. 1998- Sixty percent of Milacron’s exhibit at the K Show (four machines out of seven), consists of electric injection molding machines, more than any other manufacturer at the show. 1998 - Milacron announces sales of all-electric IMMs surpass 400 units for the year, a 50 percent increase over 1997. Return to Index

  33. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1999 - Three new models added to Powerline machine range in 220, 440, and 550 tons clamp force with 1500 tons targeted within 48 months. 1999- Fanuc - now the world’s largest producer of all-electric molding machines - continues its significant technology relationship with Milacron. More than 8,000 Roboshot machines have been sold worldwide, approximately one-third of them in the U.S. through Milacron. Return to Index

  34. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 1999 - Fanuc/Milacron introduces new Roboshot I series machines, the first which fully exploits new artificial intelligence technologies, the first with standard ethernet capability, and featuring all-electric processing advantages like pressure trace, low mold-pressure mold protect and metering (screw recovery). The new Roboshot line includes complete tonnage capacities from 17 through 330 tons. 1999- Liquid Injection Molding (LIM) processing capability is offered by Milacron through both the Powerline all-electric line and Fanuc/Milacron Roboshot line. Return to Index

  35. WE HELPED WRITE THE HISTORY OF SERVO-CONTROLLED MACHINE TOOLS AND ELECTRIC MOLDING MACHINES 2000 - Complete Powerline line is featured at NPE 2000, with new large tonnage models introduced at show: Powerline 750 and Powerline 935. 2000- Comprehensive processing capability is offered by Milacron through it’s all-electric lines, now including: PET, multi-colored/multi-component, thermoset (BMC/bulk molding compound), ceramic and metal molding, mucell molding, gas-assist and complete integrated all-electric systems, like bucket and lid machines (5 gallon containers and up). Return to Index

  36. ENTER THE WORLD OF MILACRON ALL-ELECTRIC TECHNOLOGY Milacron would be pleased to help you draft your “White Paper” in all-electric processing technology - your plan for the future. Milacron would be equally pleased to assist in adding the power of all-electric technology to your competitive processing technology - creating your future now. Return to Index

  37. ENTER THE WORLD OF MILACRON ALL-ELECTRIC TECHNOLOGY Write, fax, call or enter the World of Milacron All-Electric Technology online: Milacron, Inc. Plastics Technologies Group Elektron Technologies Business 4165 Halfacre Road Batavia, Ohio 45103 Tel 513-536-2000 Toll Free 1-888-MILACRON (1-888-645-2276) Toll Free 1-888-368-7470 (Direct to Sales) Fax 513-536-2624 www.milacron.com

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