Moretto at NPE 2018

Moretto USA LLC, daughter company of Moretto S.p.A., the leading Italian provider of Material Handling, Drying, Blending, Heat Transfer and Size Reduction equipment, will attend NPE 2018 in Orlando, Florida, the world's leading trade show event for the plastics industry.

Since 1980, Moretto has been providing plastic processors with integrated systems and auxiliary equipment solutions, enabling process automation and optimization, particularly for the high precision requirements of the injection molding of PET preforms.

Providing innovative standard as well as customized systems, Moretto’s goal has always been to maximize process efficiency, guarantee final quality and energy savings for their worldwide injection molding, extrusion and PET processing customers. Moretto strengths include not only precise, innovative equipment, but in-depth pre and post-sale service targeted to measurably improve the customer's production processes, and assure easy and intuitive operation by users of all skill levels.

Moretto USA, celebrating multiple years of both commercial success in the US and their recent relocation to a new, centrally located facility in Western Pennsylvania, will be proudly displaying the complete Moretto product range at NPE 2018.

Central in their presentation will be the integration of every device through Moretto Smart Factory 4.0, showing how machines and software are inter-connected, allowing constantly-refreshed data to always be available for achieving the highest possible levels of efficiency. Plus, particular attention will be dedicated to the resin-drying process, with the presentation of the revolutionary Moretto Eureka Plus drying system.

At NPE 2015, Moretto originally introduced Eureka, an innovative drying system designed to continuously reduce energy consumption and improve drying performance, particularly for PET, where energy efficiency can make the difference in profitability for processors. Steeped in continuing research, the ambitious Eureka project included more than 15 years of studies, tests and simulations. And now, at NPE 2018, Moretto is proud to present the latest evolution, Eureka Plus, claimed to be “the most advanced low consumption drying system available on the market”. Processors that have adopted Moretto Eureka PLUS drying systems have enjoyed an average 56% reduction in energy consumption compared to conventional drying systems.

Eureka Plus is comprised of four Moretto-patented technologies:

• Moisture Meter Manager, a revolutionary, real-time moisture analyzer,
• X MAX, a high performance, multi-bed dryer with consistant dewpoint,
• Flowmatik, a dynamic airflow management device, and
• OTX, drying hoppers with superior mass flow drying characteristics.

The highly innovative, Moretto Moisture Meter Manager effectively closes the loop on resin drying by in-line measurement of each granule’s residual moisture and applying this data to the adaptive drying system.

This on-going, closed loop system is integrated and monitored by Moretto’s Smart Factory 4.0 software. Ever-responsive, the system essentially provides “drying on demand”, based on the real drying needs of the polymer at any given time.

Managing drying functions in direct response to environmental variables that typically interrupt predictable polymer moisture levels, the Moretto drying system can guarantee production certification and maximum energy efficiency.

The entire Eureka Plus drying system integrates seamlessly with Moretto’s Smart Factory 4.0 software, where data to and from connected devices is constantly exchanged to push all functions to the highest possible level of efficiency.

The brain and human interface with Smart Factory 4.0 is Moretto’s Mowis and all the technologies of Eureka Plus are integrated via this revolutionary supervision system. Self-configurable, with intuitive object programming, MOWIS unifies all machines in the plant, allowing integrated process control, monitoring and management from anywhere… on-site or remote.

OTX (Original Thermal Exchanger) hoppers, have completely changed the concept of drying hoppers for savvy processors. Moretto’s sophisticated and extensive thermodynamic simulations have resulted in a revolutionary hopper geometry, giving OTX hoppers the ability to evenly dry pellets and regrind to low, uniform humidity levels, faster than traditional hoppers. Available for small and medium-sized productions, distinctive OTX hoppers are equipped with a Spyro stainless steel exterior, providing high performance insulation against heat loss and making them resistant to mechanical damage, typical of other hoppers. In addition to being an important part of Eureka Plus drying systems, OTX hoppers can be coupled with X-Comb mini-dryers, for versatile, compact, robust drying systems, all offering Moretto X-Technology for drying and highly-adaptable, variable drying capacity.

Moretto also excels in resin conveying technology, and at NPE 2018, will display:

• One Wire3, a versatile, easily installed control system for centralized management of resin conveying systems,
• Kasko, a range of resin hopper loaders and receivers,
• Dolphin, a pneumatically-operated manifold for sophisticated routing of resin flow from multiple sources to multiple destinations,
• Kruise Kontrol automatic speed control created for overcoming the limits of traditional conveying systems by preventing the formation of angel hair, dust and abrasion in conveying tubing, and
• Loader F24, a high capacity, self-contained hopper loader.

Being introduced at NPE 2018, and designed specifically for US custom processors, Moretto will be introducing the Loader F24, a stainless-steel, high capacity, self-contained hopper loader that operates on common, single phase power. Large quantities of resin can now be transferred automatically as required, without the use of a central vacuum system.

The combining of resins will be spotlighted at NPE 2018 by Moretto’s gravimetric blender Gravix, representing what has come to be known as perfection in gravimetric batch dosing, both for the integrity of its blended output and its quality of construction.

Featuring rugged, foolproof “double eyelid” dose metering devices, a precision batch weighing hopper, a fully homogenous and easily cleaned mixer and Moretto’s exclusive Vibration Immunity System that assures accurate weighing, even on injection machines that suffer from shaking during platen movements.

Gravix blenders are offered in 8 models for processing ranging from 11 to 11,000 lb/hr and up to 12 simultaneous materials. The advanced, color, touchscreen interface provides intuitive use of the blender for set-up, use, troubleshooting and maintenance and accommodates storage of up to 200 recipes.

Also featured at Moretto booth will be an extensive range of stainless steel TEKO liquid temperature controllers in both water and oil mediums, guaranteeing absolute, automatic temperature precision for IMM molds as well as extrusion dies, barrels, rollers and baths. Models range from 0.6 to 54 Kw and up to 574 °F.

In the Bottle Zone, Moretto will recreate PET pre-form and cap molding operations, clearly displaying the essential technologies for resin conveying, blending and drying along with complete supervisory control for the successful production of PET pre-forms for bottles and HDPE caps.

Featured equipment shown in this real-world simulation will be:

• A “smart” conveying system interconnected via Moretto ONE WIRE3,
• The Moretto Gravix DGM 900, a high-accuracy gravimetric batch blender,
• The advanced Moretto Eureka Plus drying system equipped with:
• A Moretto Purex condensate separator, and
• A Moretto Mowis supervisory control system, operating
• Moretto Smart Factory 4.0

The system is also equipped with a Moretto Mold Dryer, designed to prevent the formation of condensation in the molding area, regardless of factory location, environmental conditions or the speed of processing. Avoiding condensation assures higher product quality, and enables production efficiency by actually reducing cycle times.

Targeted to fully meet all of the expectations of the PET industry, Moretto’s pre-form molding display will provide real, demonstrable, technological solutions, applicable to the entire process for reliability, performance, process consistency and energy optimization. In fact, over the years, Moretto customers themselves have found that Moretto’s high standards guarantee an optimal final product both in structural integrity and aesthetics, providing “a certified quality-constant over time, zero waste, and a production efficiency increase with a consequent strong reduction in operating costs”.

Source: Moretto S.p.A.