For more than a decade, activeFlowBalance (aFB) has helped injection moulders overcome common manufacturing defects such as short shots, flash and warpage. In this article, Technical Sales Manager Kris Thacker explains how the software works and the cost and sustainability benefits it continues to deliver for plastic processors.
“Developed by
Sumitomo (SHI) Demag for its all-electric machine range, activeFlowBalance has enabled leading automotive and medical manufacturers to reduce reject rates by up to 40%. When integrated with the IntElect series, the software also provides significant environmental benefits, including a reduction in clamp force of up to 40% and energy savings of as much as 85%.
“The technology manages the transition from the injection phase to the holding pressure phase, ensuring that all cavities fill evenly without the need for additional pressure. Instead of relying on manual adjustments to the injection profile, activeFlowBalance holds the screw in a fixed position for a defined period once injection is complete. This is made possible by Sumitomo (SHI) Demag’s highly precise direct-drive control system.
“During this hold period, the process makes use of the melt compression already present within the barrel. Because the screw remains stationary and no extra pressure is applied to the material, cavity pressure within the melt is able to stabilise and equalise throughout the entire system. As the compressed melt expands, it naturally flows into underfilled cavities while avoiding additional pressure in cavities that are already full. Once the pre-set activeFlowBalance period has elapsed, the machine automatically returns to the standard holding pressure setting.
“Existing IntElect users can retrofit activeFlowBalance across their machine fleet with minimal technician input. While the resulting savings can benefit any high-volume moulder, the technology is particularly valuable for applications requiring exceptional dimensional stability and precision. It is also highly effective for reducing reject rates in thin-wall components with long flow paths, as well as small parts with high sprue weights.
“A key advantage of activeFlowBalance is its ability to reduce clamp force by up to 40%. Because the technology achieves a more balanced fill without creating pressure peaks, the machine requires less force to keep the mould closed. This not only lowers energy consumption but also helps extend the service life of both the machine and the tooling.”
For a live demonstration of activeFlowBalance in production, visit one of Sumitomo (SHI) Demag’s technical centres in Limerick or Leighton Buzzard.