Moretto at Fakuma 2021: digitalization and circular economy

After the 2020 stop to exhibitions and events due to the pandemic, Moretto is glad to announce its participation to Fakuma (Germany, 12-16 October 2021 - Hall B3, Stand 3208), one of the most important events for the plastics industry.

Connectivity is the future

In line with the theme of the 27th edition “Digital meets circular economy”, Moretto will focus on solutions developed for the smart factory as well as products dedicated to recycling, a business which is increasingly growing and requires equipment able to treat used materials which are intended for re-entry in the production cycle.

Now more than ever innovation means developing solutions which take into account how global economy is affecting our every day life.

Moretto, headquartered in Padova (Italy), designs and produces industrial automation for the plastics processing business (5 plants in Italy and 8 subsidiaries worldwide). Currently almost all systems produced by the company are in line with the smart factory requirements, a world where connectivity and performance are the main drivers. And in fact Moretto’s stand will feature MOWIS, the supervision and management software developed to manage the whole production process. Mowis is modular and self-configurable, it can be used on-site or remotely, a software totally integrated to the local network via communication protocol OPC UA. Mowis enables connectivity between machines, departments and facilities making the management of complex systems easy.

Improved performance for the new compact conveying line

Production sites require compact equipment in order to optimize the use of space. This is a common request coming from plastic processors, which has prompted the restyling of the conveying product line. The new Compact hopper loader range is on average 30% smaller than the equivalent product available on the market. This range is highly efficient and suitable also for critical applications such as the food industry, thanks to the stainless steel design which prevents contamination.

The Compact series features a new “zero” size with capacity 0,5 dm3 and throughput 30 kg/h, suitable also for master and micro-feeding. The single-phase and One Wire versions are also available.

Compact serie

The single-phase range includes the new brushless models available in two sizes (F12 / F24). Brushless motors are more efficient since the system does not include parts subject to wear and tear. This model includes all the other features typical of the Compact range - low noise level <73dBA, soft-start, self-cleaning filter, assisted opening with safety device.

The Venturi series hopper loaders are suitable for small quantities of plastic material, masterbatch and/or additive. Thanks to the six versions now available, their scope of application is extended to:

• volumetric dosing units
• mini dryers
• loss-in-weight dosing units
• small injection molding machines

All versions are available with ratio valve.

Usability has always been one of the main drivers for Moretto when developing a new product. The new Quick Release Devices for hopper loaders, receivers and maintenance hoppers allow a super fast disconnection of the equipment in order to carry out cleaning and service procedures, even in a controlled environment. These devices are made of anticorrosive material, they are available in two models (with square or round base) and allow a fast and practical vs. the standard hinges.

The restyled three-phase Suction Units on display at Fakuma have been reduced dimensionally and mount the new Vortex filters. These units have a modular design and can be equipped with several extra accessories depending on the application:

• the Vortex filter separates dust thanks to a centrifugal force which protects and increases the system efficiency. It is also possible to mount an automatic cleaning device which eliminates the need of servicing,
• the Bypass valve shortens loading times and increases the unit longevity,
• the Duo valve can be connected to two different containers,
• the Cooling Ring enables the conveying of hot material (up to 180°C).

A brand new range of Flexible Hoses will be introduced during the event. This new addition to the Moretto product portfolio is based on very specific needs of plastics processors. The whole series - made of 100% polyurethane – is entirely produced in-house in six versions: vacuum line, material line (2 different weights), medical sector and wear-resistant, which combined with the different available sizes create a range of 60 different models. These wear-resistant flexible hoses “made by Moretto” are 5 times more resistant than the standard product available on the market, solving one of the major issues often present in conveying systems, especially when mineral additive or fiberglass are involved.

Counter is the in-line weighing system able to weigh plastic materials transferred from the container/receiver to the drying hopper. Counter supplies real-time information on material consumption allowing a very accurate monitoring of the production process. Counter is made by Contrex, a Moretto brand specialised in loss-in-weight systems.

Kruisekontrol is another system dedicated to the conveying process, a top of the range product covered by patent. KruiseKontrol is the only intelligent system in the world able to automatically define the ideal speed for each type of material. KK manages the material flow avoiding the starting and final speed peaks. Consistency eliminates all issues typical in conveying such as dust, wear and tear, angel hair and material stress. KruiseKontrol is integrated to One Wire 3 and requires just two inputs - material type and receiver – it then automatically activates a customised process which achieves efficiency and increased productivity.

Kruisekontrol

Efficient drying for both small and large throughput

One of the latest products developed this year is the manual DRY AIR mini dryer. This series has undergone a technical update which now includes the OTX hopper and a simplified touch screen display. The new model has a double tower circuit and manual airflow adjustment, ideal for the treatment of technical polymers. Six different sizes are available and both the smallest (D0 TX) and the largest (D5 TX) will be present in the Moretto stand.

Visitors will be able to view also X Comb, the super compact mini dryer suitable for lower throughput of technical polymers. Fully electric (no need of compressed air), X Comb is equipped with self-optimizing variable speed turbo-compressors, molecular sieves which deliver -52°C dew point and the exclusive OTX drying hopper. This dryer is specifically designed to efficiently treat very hygroscopic technical polymers, particularly for critical industrial sectors such as medipharma, optical and electronics.

Compactness and usability are the key features of the new CRX Trolley. This is a very compact all-in-one solution available in 3 configurations. The standard configuration includes a dryer+hopper with One Power electrical supply and a 7” touch screen control panel mounted on the dryer. It is possible to add a VS DUO suction unit for conveying the material to the hopper and suck it out after it has been treated, and a Moisture Meter, the device which measures moisture levels in-line. All parameters are always managed by the touch screen control panel mounted on the dryer after the material type and required throughput are entered.

Dosing is a technological matter

Gravimetric dosing is a process which requires high accuracy. Moretto systems are extremely sophisticated and represent the widest range available on the market. DGM Gravix is equipped with a patented double-eyelid shutter with a reaction time of 25ms. The weighing hopper is free from any mechanical interference thanks to the Vibration Immunity System and therefore gives very accurate readings even if installed directly on top of the processing machine. Eight different components can be configured. Hoppers are removable, interchangeable and available in 10 models such as antistatic, pulsated, with fluidification, large, reduced, insulated, double, blind and for flakes.

Connectivity is a great feature of this product (Modbus, Ethernet, USB) enabling traceability of material consumption and recipe certification. Gravix can be integrated to the Mowis software for a full monitoring of the production process including stock availability.

Real-time polymer analysis

Technopolymer are hygroscopic and therefore more difficult to treat, especially in innovative or certified applications such as in the medical and optical sectors.

Moisture Meter is the high-tech device analyzing residual moisture levels in polymers after they have been dried and before they are fed to the processing machine. Power Peak is the technology used to measure in-line and in real time the polymer residual moisture without the use of expensive equipment and/or external laboratories. MM is able to measure up to 15ppm by analysing the material non-stop, eliminating the risk of waste and downtime. Moisture Meter is available in 3 versions depending on how critical the application is – Control, Sentinel and Loop. MM can be installed on any type of processing machine regardless its dimensions.

Innovation supports circular economy

Moretto has been very active in the recycling industry for years, offering energy efficient solutions suitable for grinding, treating, conveying and storing flakes and regrind from pre and post consumer waste.

The GR grinders have a modular design. Different types of cutting chambers are available for specific applications, such as the wear resistant or cooling types. The GR chamber shape is particularly efficient with voluminous material and the scissor-like action ensures clear cuts with no dust and very low noise levels.

One of the most important phases of the recycling process is the crystallization of amorphous material. Fakuma will launch the new version of MPK Krystallizer, a patented system designed for heavy duty use. The version available at the exhibition will display all the original design features which make this system so usable and efficient – the lower cone which can be opened for cleaning and maintenance, the mixing chamber with removable blades which can be adjusted based on the material type, the wing-shape agitators which mix evenly and prevent clumps.

Spyro is the stainless steel shockproof finish which protects and insulates MPK, a distinctive feature which makes Moretto products unique in the market.

The MPK system is entirely managed through a 10” touch screen control panel mounted on the dryer with intuitive user interface.

MPK can be completed with Vortex - the filtering system able to capture dust particles up to 20 micron – and Purex -  the condensate separator which filters oily and resinous contaminants, typical of PCR material.

Moretto is attending Fakuma (Friedrichshafen, Germany) from 12 to 16 October 2021, Hall B3 – 3208.