Most industry analysts believe that 2025 will represent the next chapter when automation gets smarter, faster and even more accessible. Testament to this confidence, mass manufacturer Broanmain Plastics ushers in 2025 installing the company’s first ever fully automated injection moulding machine cell.
At the end of February 2025, UK-based mass moulder Broanmain Plastics took delivery of a fully automated 320-ton Haitian injection moulding machine featuring a Hilectro cartesian robot. The significance of Broanmain’s latest investment is indicative of the wider industry push focused on optimising performance in order to create a smarter, more predictive and sustainable production foundation for the future.
For mass-produced plastic components in particular, Broanmain is resolutely focused on addressing the scale of the sustainability challenge by reducing waste and being more resource efficient overall. This includes ensuring productivity from each unit of raw material and component manufactured at the Dorking facility is maximised.
The Generation 5 Mars machine is a servo hydraulic machine equipped with an electric screw motor as standard. This has a massive impact on energy efficiency as the use of a traditional hydraulic screw drive is the most energy hungry phase of the injection moulding process. It is also incredibly quiet and delivers exceptional precision and reliability that mass manufacturers depend upon, reports head of the Haitian UK sales team Veronica Edmunds.
“Compared to fixed pump hydraulic machines, these energy-efficient servo-hydraulic moulding machines can save processors like Broanmain over 70% in energy consumption,” relays Veronica.
“We intentionally selected this particular 320-ton machine to provide extra manufacturing capacity and to mould larger components for a number of new projects we have won. Having the automation option was essential for the handling of 1kg parts. As this was our first step into automation, we very much valued knowing that the whole package was being handled through Haitian,” notes Operations Manager Thomas Catinat.
The weight and aesthetics mean that each part must be carefully removed from the tool and placed on a conveyor to prevent structural and cosmetic damage. The Hilectro cartesian robot can perform this demoulding task at a consistent pace and rate. Having a choice of end of arm tooling means that the whole cell will be very adaptable to Broanmain’s future production needs, including lights out manufacturing, highlights Veronica.
Leveraging scales of economy
“Broanmain is constantly assessing the efficiency of production runs to ensure finite resources are not being wasted or causing unnecessary pollution,” notes Broanmain managing director Jo Davis.
“The energy savings were clearly impressive. Additionally, this new machine can accommodate tools that fit into both 250 ton and 500-ton machines, which allows us to bridge the production gap in the most efficient way,” asserts Thomas.
Before and after energy tests running at the same cycle times will be performed on installation. Because the Generation 5 series includes all the additional hardware, automation and HT-X-tend software extras at no extra cost, Haitian claims that a mass manufacturer like Broanmain could reasonably expect a return of investment within the year.
Attributing this to Haitian’s scales of economy, Veronica adds: “The intelligent control system featured on the Generation 5 series can optimise the entire moulding process, ensuring repeatability, efficiency and the lowest energy consumption. This in turn extends the entire lifespan of the machine and tooling, reducing wear and tear.” The Haitian Generation 5 series is now certified to Euromap 9+.
As well as creating cost advantages per unit, the transition to efficient, cleaner production is another way to spur economies of scale. For example, deployment of more energy efficient injection moulding machines can also lead to fewer product defects and consequently less material waste, adds Thomas. “This can induce additional cost reductions, which incentivises more deployment of cleaner technology. Creating another cyclical innovation ecosystem.”
Vision of the future
According to a Gartner study, lights out manufacturing is expected to accelerate this year, with 60% of manufacturers expected to have at least two completely lights out processes in 2025. With minimal human intervention required on the new production cell, and already operating staggered early and late shifts, Broanmain is anticipating that automation will simply augment efficiencies and improve the overall worker experience.
“The focus for us is unlikely to be full lights out production, but more lights out processes. This then enables is to increase productivity and our manufacturing capacity so we can better flex to customers’ needs. Having a cartesian robot that can take components from the mould, rather than having a full-time operative stationed at the machine that would slide open the door and stop production each time a component is taken from the tool, delivers a much faster cycle time, with no interruptions. It is also far safer for the workforce too,” emphasises Thomas.
Image 1: Broanmain Plastics has taken delivery of a fully automated 320-ton Haitian injection moulding machine
Image 2: Broanmain’s Generation 5 Mars machine features an electric screw motor as standard and includes a Hilectro cartesian robot
