The ifw Group is known as a technology leader in the manufacture of pipe fittings. The injection moulds from ifw mould tec GmbH have always impressed with their innovation, durability and precision. In addition, all injection moulds are designed to be maintenance-friendly and easy to handle in production. Based on this fundamental understanding, ifw develops modern solutions to make production more efficient. The ifw Group presented its innovative SE system (Smart Ejection System) at K 2016, and this is being continuously expanded in the portfolio. The demoulding system is designed so that the pipe fittings are rotated by 90° in the mould. This minimises the projected area of the moulded parts and therefore reduces required clamping forces. With the same mould and machine size, it is usually possible to double the number of cavities. A real plus for production consolidation: costs for machines, moulds and production space can be reduced. Energy savings are in the region of 40%, which is another added value. The SE system runs with the usual ifw reliability and is available to ifw customers worldwide.

Efficient 2K production with integrated assembly using the ifw mould

For Sanitärtechnik Eisenberg GmbH (Roca Group Competence Center), ifw has now taken compact production a step further and is showcasing its latest development at K 2025: on a 220-tonne ENGEL Victory injection moulding machine, the company is presenting its understanding of efficiency in a three-stage process: First, two base components are injection moulded from PP. In the second step, sealing elements are injection moulded from TPE. Finally, the two moulded parts are assembled by the injection mould and leak-tested in the compact production cell. Compared to conventional injection moulding processes, the number of injection moulding machines can be reduced from two to one. In addition, subsequent assembly and testing stations are no longer required. This significantly increases the output per production area and demonstrates ifw's understanding of production consolidation. Bernhard Mücke, R&D Director at Sanitärtechnik Eisenberg GmbH, is also enthusiastic: ‘The collaboration with ifw allows us to produce complex components with maximum efficiency. The consistently high-quality results in virtually zero scrap and significantly reduces personnel costs.’ The high degree of automation for assembly and quality control minimises sources of error and thus increases process reliability.

Modular mould concepts and comprehensive after-sales service

From standard to high-tech moulds, ifw mould tec relies on modular mould concepts in which different articles can be manufactured by exchanging various mould components. These long-proven concepts reduce manufacturing costs and increase flexibility in production. The modular design allows rapid adaptation to changing market requirements and product variants without the need to invest in completely new injection moulds. If, for example, the required production quantity increases, the modular mould components can be reused in a new injection mould with a higher number of cavities. Thanks to these highly developed ifw standard parts, additional items can be integrated into an mould even years later. All this saves time and resources and increases investment security for customers. When designing moulds, ifw focuses on maintenance-friendly concepts. These enable easy handling, reduced downtimes and permanently smooth production with the longevity typical of ifw.

‘ifw places strong emphasis on a high level of standardisation in mould components to ensure fast spare parts supply worldwide - a real competitive advantage for our customers,’ explains Harald Schicklgruber, Sales Director at ifw mould tec. The service also includes the delivery of comprehensive documentation for operation and maintenance, which guarantees long-term and smooth production.

ifw kunststofftechnik: Flexible contract manufacturing with state-of-the-art machinery

Within the ifw Group of companies, ifw kunststofftechnik complements the portfolio with flexible contract manufacturing on more than 20 machines with clamping forces ranging from 120 to 3,200 tonnes. Real added value for customers: ifw acts as a one-stop shop and supplies everything from the component idea to the moulded product. Customers can also flexibly adapt their production capacities and benefit from the company's high level of manufacturing expertise.

Research & development: ifw rethinks mould concepts and manufacturing processes

The experienced ifw development team, supported by state-of-the-art production facilities and its own technical centre, forms the foundation for success. With its current activities, the ifw Group is proving its expertise as a reliable development partner and international technology leader. When it comes to customised injection moulds, the aim is always to develop solutions that enable the customer to achieve the greatest possible success. Based on a detailed requirements analysis, the ifw development team designs creative concepts and develops them consistently into successful solutions.