Netstal debuts all-electric Elion 3200 CAP at Fakuma

Netstal is presenting the Elion 3200 CAP at Fakuma as a new all-electric configuration for the high-performance production of beverage closures. The machine extends the Elion series with a solution designed for short cycle times, high process stability, maximum availability and reduced energy consumption. The system combines a newly developed clamping unit with 3,200 kN of clamping force and the new electric injection unit 2000. According to Netstal, the development follows the principle of "technology follows application". In the future, customers will be able to choose between hybrid and all-electric configurations in the clamping force range from 2,200 to 4,200 kN, depending on the requirements of the specific application.

At Fakuma, the new machine is being shown in an application for beverage closure production. The all-electric injection molding machine operates with a 72-cavity mold from Z-Moulds and a hot runner system from MHT to produce 26 mm HDPE closures. The shot weight is 72 g, and the system demonstrates a cycle time of 1.8 seconds. TotalEnergies supplies the material, while Piovan is responsible for material preparation. Downstream equipment, including a cooling conveyor, bunker and optical quality inspection, is supplied by IMDvista. The chiller is provided by ef cooling.

"Our new all-electric solution achieves the high dynamics required for closure production. At the same time, our customers benefit from high energy efficiency, process stability and availability, and thus from clear competitive advantages," says Renzo Davatz, CEO at Netstal.

Optimized clamping unit increases availability

The optimized geometry of the toggle lever is designed to enable the shortest dry cycle times, while improved force application increases the stiffness of the clamping plate. This supports process stability and contributes to a long service life of the electric clamping unit.

Maintenance requirements were also considered during development. The newly designed protective cover can be installed quickly and has smooth surfaces intended to be easy to clean. Depending on production needs, the ejector can be specified as either electric or hydraulic.

Automatic grease lubrication is available as an option. It lubricates the linear guides of the clamping unit and injection unit, as well as the ejector guide of the clamping unit, automatically and at regular intervals during operation. This is intended to reduce maintenance interruptions and extend the service life of the guides.

Electric injection unit for precision and dynamics

The newly developed electric injection unit 2000 has a screw stroke of 260 mm. Depending on the screw diameter, it achieves an injection pressure of up to 2,400 bar. Netstal states that the coordinated injection dynamics enable short injection times and broaden the range of possible applications in closure and packaging production as well as in medical technology.

Synchronously controlled injection spindles provide symmetrical load distribution. This reduces mechanical stress and supports a long service life of the injection unit. As a specific feature of Netstal technology, pressure changeover during injection is force-dependent and operates independently of material properties. The company states that this results in high precision and shot weight consistency, also at very fast cycle times.

Energy efficiency, operation and networking

The Elion has also been further optimized with regard to energy efficiency. Electric injection and high-efficiency servo drives reduce energy demand, energy costs and associated CO2 emissions. Intelligent load distribution and an optimized feed-in concept enable additional energy savings of up to 5 percent. According to Netstal, this also reduces grid load and increases resilience to short-term power outages and grid fluctuations.

The Axos 9 controller combines flexibility in application development with safe and intuitive operation in daily production. Separate touchscreens and haptic controls support machine programming and operation. The integrated Smart Operation function guides operators through predefined procedures, reducing the risk of input errors.

Standardized interfaces based on OPC UA allow networking with higher-level control systems and peripheral components. Thanks to HTML5 integration, complex system components can also be integrated into the machine control system.

Electric or hybrid, application determines the choice

"For us, electric and hybrid drive concepts are not competing technologies, but complementary technologies. The decisive factor is which solution best meets the requirements of the respective application, both technically and economically. That’s why we will continue to offer our customers both technologies in the future," explains Davatz.

Netstal is currently gradually converting the Elion series to a new platform. Since 2025, clamping units with 1,200 and 1,750 kN, as well as electric injection units 270 and 530, have been available. They are followed by clamping units with 3,200 and 4,200 kN and the electric injection unit 2000.

A clamping unit with 2,200 kN and the new electric injection unit 940 are planned for summer 2027. The established hybrid injection units from 450 to 4200 will remain in the portfolio. Up to a clamping force of 4,200 kN, the Elion can be configured as hybrid or fully electric.