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EPCO helps thermoformers and die-casters achieve greater productivity
Thermoforming equipment, all makes and models, being rebuilt by EPCO
Installation and start-up completed for 16 of 17 new custom thermoformers for Visteon
Complete machine assembly and sub-assembly that’s quick, competitively priced and highest quality
Farrel-Lombard OEM parts and service business acquired by EPCO
EPCO expands plant relocation services capabilities
Advanced injection molding and blow molding controls now offered by EPCO
EPCO advances injection moldingand blow molding controls with its newest Windows-based system
Retrofit, upsize or downsize, your existing machines to fit your customers’ requirements – and improve your profitability
It’s easy and cost-effective to retrofit your existing machine(s) for upsized or downsized injection capacities. EPCO’s proven retrofit packages are the ideal way to tailor individual machines for specific applications that meet customer requirements – while helping you attain improved profit margins. EPCO offers two methods for changing injection capacities to fit exact molding requirements. A minor change in capacity is easily accomplished by retrofitting an EPCO barrel and screw kit to your existing injection unit. Where more dramatic changes in capacity are needed, EPCO provides complete injection unit conversion packages. One such example is a customer who recently purchased a 400-ounce EPCO conversion package to replace the existing 232-ounce injection unit on a 1500-ton Milacron machine. The EPCO package included a new injection unit and all the hydraulic and electrical components required to adapt the system to the existing machine. The result: higher productivity, improved quality and less waste. In other words, greatly improved profitability. Best of all, these conversions are quick, easy and can be provided for a fraction of the cost of complete machine replacement. They can be done in your plant, or at EPCO, and can be combined with other services and products offered by EPCO. For complete information, visit the Conversions & Retrofits page of this website or contact the Sales Department.
sales@epcollc.com |
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SIG Kautex
contracts with EPCO to convert and retrofit KB-250 machine for greater production versatility Fremont, Ohio, USA, February, 2004 ---- Selected because of its unparalleled history in major machinery modifications and its extensive experience with Barber-Colman MACO controllers, EPCO was the clear choice of SIG Kautex for this complex remanufacturing assignment. SIG Kautex had a customer who needed to modify an existing KB-250 blow molding machine that had been used for the production of fuel tanks. The machine was now needed for molding a versatile array of other products and needed significant modifications to do so. Essential to the machine’s new capabilities was the full integration of an EPCO E-6500 control system. The E-6500 programmable blow molding control system is one of EPCO’s industry-preferred systems. It has expandable capabilities, including control of up to four parisons, and is perhaps the fastest of its kind available. EPCO also had complete responsibility for electrical engineering on this project. Wolfgang Meyer, SIG Kautex President, added, “Our experience is that Kautex blow molding machines typically retain their value, even after many years of service. That’s why it’s been easy for us to offer pre-owned equipment, obviously after it has been thoroughly checked out, and if needed, modified for future use. Working jointly with EPCO’s engineers and manufacturing personnel has enabled us to put together what many consider to be the best rebuild / retrofit program in today’s blow molding industry.” For complete information about EPCO’s blow molding machinery services, contact the Sales Dept. sales@epcollc.com 877-702-4142 989-435-2821 fax |
EPCO helps thermoformers
and die-casters achieve greater productivity, improved quality…
and higher profitability
with trim press rebuilding services
Regardless of make or model…or application, EPCO has the know-how to rebuild your time-worn trim press to new-machine efficiency and quality. Our engineering staff and technicians are experts at “re-newing” equipment that may be service weary, but is still fundamentally sound and has plenty of productive life hidden in it.
And best of all… it can be done for a fraction of the cost of a new machine. Often it can be done in your plant… very quickly… with little or no down-time.
For complete information, visit our Remanufacturing Services pages on our website, or contact –
sales@epcollc.com
877-702-4142
989-435-2821 fax
Thermoforming equipment, all makes and models, being rebuilt by EPCO
Having built its reputation on the remanufacture of injection molding, blow molding, extrusion and die-casting machinery over the past 44 years, EPCO is now rebuilding thermoforming equipment. EPCO’s experience and expanded capabilities cover all types of in-line, rotary, cut-sheet and shuttle equipment, as well as auxiliary systems, including robotics.
Depending on each customer’s needs, these services can be performed in the customer’s plant, or in EPCO’s facility.
EPCO also offers complete field maintenance and service parts for all makes and models of thermoforming, injection molding, blow molding, extrusion and die-casting equipment through its “24-7 Parts & Service hot-line.
For complete information, visit our Plastics Remanufacturing, 24-7 Parts and / or 24-7 Field Service pages on our website, or contact –
parts@epcollc.com
service@epcollc.com
877-702-4142
989-435-2821 fax
Operating as general contractor, EPCO’s Plant Relocation and Equipment Installation Team has completed start-up of the 16th of 17 large custom thermoformers being used throughout North America for production of next-generation thermoformed fuel tanks.
Working in conjunction with its affiliate, BROWN Machine LLC, EPCO contracted for complete responsibility for transportation, rigging, installation and start-up of all 17 machinery lines, which included integration of auxiliary equipment utilized by four other manufacturers.
For additional information, contact our Plant Relocation and Equipment Installation department –
877-702-4142
989-435-2821 fax
Complete machine assembly
and sub-assembly that’s quick, competitively priced and highest
quality
Looking for better, faster, smarter ways to assemble your equipment while reducing your liabilities? Talk to EPCO. Since 1959 we have been a recognized pioneer in all types of machinery services for a complete range of plastics and die-casting machinery.
In addition to our large comprehensive manufacturing / remanufacturing machine shop that’s fully supported by our dedicated in-house engineering department, we have probably built and re-built more different makes and models for more diverse applications than any other machinery manufacturing / services company in the world.
For complete information, visit our Custom Machinery page on our website, or contact –
877-702-4142
989-435-2821 fax
Farrel-Lombard OEM parts and service business acquired by EPCO
EPCO's Brian Conover, parts department
manager (L), and Steve Mitchell, customer
service manager (R), are pleased about their
company"s acquisition of Farrel-Lombard
parts and service assets.
Having all the OEM drawings and technical data gives EPCO service technicians an added advantage which translates to greater overall efficiency and cost-effectiveness for owners of these Farrel and Lombard machines.
"Although we're very familiar with both brands, these added resources will simplify everything from emergency trouble-shooting to routine maintenance," stated Steve Mitchell, EPCO's customer service manager. "Having exacting specifications and reference drawings not only accelerates the service process and lowers costs, it adds value for our customers through OEM precision and that typically equates to longer service life," Mitchell continued.
EPCO was founded in 1959 as a dedicated injection molding machinery services provider, specializing in conversions. Perhaps best known for remanufacturing, conversion and retrofitting of injection molding machines of all sizes and descriptions, EPCO also provides a full range of services for blow molding, thermoforming and extrusion equipment. Additionally, turnkey plant relocation, machinery assembly and equipment installation services are majoroperations in today"s business mix. EPCO's parts department maintains a $1 million inventory which is supported by its 24-7 service and parts hotline. Used injection molding machines are also sold through a specialized brokerage network services.
Turnkey plant relocation and equipment installation
packages are offered by EPCO for molders of all
types and sizes throughout North America.
"By expanding our capabilities and packaging them with other services and products, any molder or fabricator in North America can now enjoy fast and cost-efficient turnkey relocation programs simply by dealing with one single-source contractor," said San Seckel, senior project engineer at EPCO. "We're moving complete plants and remanufacturing some of the equipment being moved, plus doing safety audits and upgrades and other component retrofits--all through the same contract, and on the same master schedule," he added.
What EPCO did to expand its relocation offerings sounds simple for a company who pioneered many different machinery service innovations over the past 44 years. That's especially true when you analyze it from the customer's turnkey perspective. The largely unseen and complex side of these programs involves large scale planning and coordination endeavors. Offered as single-source responsibility packages, these relocation programs are particularly ideal for maximizing the utilization of existing equipment in outdated plants, or those being liquidated.
Throughout its history EPCO has always promoted programs that delivered machinery that performed as good as new, if not better than new, for a fraction of the cost of new machinery. In today's bargain-priced used machinery market, molders are able to buy entire plants that are being sold at deep discounts, and have all the necessary upgrades made to the equipment to optimize quality and productivity. Then locate the plant wherever in North America that best meets operational targets. According to EPCO officials, this can be done on a surprisingly short time-line for a fraction of the cost of building green-field facilities filled with new equipment. And because there are no measurable productivity differences between these two approaches, more and more companies are choosing the relocation / remanufacturing approach as a means to higher productivity with less investment.
EPCO now offers any one or all of its many machinery services and related products in streamlined single-source relocation packages. Following are a few of the many diverse offerings available via this one-stop shopping concept: complete machine remanufacturing (for injection molding, blow molding, thermoforming, and extrusion equipment); individual component remanufacturing; control upgrades of all types; ANSI and SPI safety upgrades; machine conversions of all types; design and building of custom equipment of all types; evaluation and testing services; 24-7 field service; 24-7 parts department; complete engineering and re-engineering.
Additionally, EPCO representatives emphasize that everything their company offers in these plant relocation and equipment installation programs is geared to molders' fast and easy start-ups, including getting utilities turned on and complete testing of each installed piece of equipment. Once the customer approves and takes over, EPCO offers after-the-sale support with a full complement of services, including: preventive maintenance, contracts; emergency repair services (if needed); 24-7 parts department; lubrication and routine maintenance checks; calibration and trouble-shooting services; retrofit services; safety audits and equipment evaluation services.
Three new control systems from the EPCO / Siemens
affiliation deliver lots of capabilities for the money and
are designed to fit a wide range of injection molding
and extrusion applications.
"These three new control systems are being very well received in the field," said Sam DeBartolo, EPCO's national sales manager. "These packages offer lots of capabilities not typically found in this price range, and they're extremely easy to operate," he added. The SIJECT IM16-170, the open loop IM control, is a low-cost solution for small to medium-size injection molding machines. This system controls all timing, counting and machine sequencing, as well as clamp, eject and injection control. It provides diagnostic messages and stores mold recipes. Barrel P-I-D temperature control is multi-lingual.Options available on the SIJECT IM16-170 include: specialized machine functions; interfacing for auxiliary equipment such as dryers, loaders, hoppers, conveyors, etc.; SPI robot interfacing; and Ethernet connectivity. Additionally, screen format customization utilizing standard nomenclatures is available.
The new closed loop IM control, the IM16-270, has all the capabilities of the open loop system plus a great deal more, including selectable open or closed loop pressure control and speed control. This package comes with a 10" TFT touch / color operator interface, a Windows CE based 32 bit microprocessor, screen print capability, and a 2 MB memory. It has 10-step profiles for injection, hold pressure, pack pressure and back pressure control, plus a transfer switch for time, position and pressure. Other standard features of the IM16-270 are: 16-step profile clamp control; 4-step profile ejector control; pressure / flow line graphs; high-speed data collection; uptime / downtime reports with alarming; Images or Acrobat pdf document capabilities;and a multi-lingual Ethernet port. SPC / SQC capabilities are optional.
The new open loop extrusion control, the SIJECT EX16-170, is a low-cost replacement based on standard SIMATIC S7-300 programming with Step 7 Tool, with an MP170 operator interface. This system has these standard features: multiple-zone temperature control; multiple-drives control; auxiliary mechanism control; recipe storage on compact flash card; recipe handling for the complete machine (upload, download, save and load); plus intuitive and easy-to-use HMI (human machine interface). Other standard features of the SIJECT EX16-170 extrusion control include: color-coded status displays for easier trouble-shooting; temperature plotting with zoom and scroll functions; alarm handling with audio / visual alarm output; and multiple levels of security.
EPCO's E-7000-I for injection molding (left) and the
E-7000-B for blow molding (right) provide greater accuracy,
improved productivity and profitability for end-users.
The E-7000-I injection molding control and the E-7000-B blow molding control, introduced at NPE-2003, offer molders new production and quality advantages. Both systems provide extremely accurate real-time data that enables molding machine operators to make quick and informed decisions for optimal productivity, quality control and minimal waste of material. "These systems provide accurate tracking and fast, easy adjustment to optimize process efficiency," said Larry Shivak, EPCO's manager of controls engineering. "This technology is beautifully simple and easy to use," he added.
Both systems use an advanced screen set designed for easier use by machine operators and both have print-screen capability via Windows-driven printer ports. Stored documents (work instructions, manuals, images at the point of operation, etc.) are easily accessible. Both the injection module (on the E-7000-I) and the parison module (on the E-7000-B) utilize Barber-Colman's Impact II for maximum control via valve linearization, fill-pressure profile and advanced algorithms.
"Both these controls have been carefully fashioned to reduce maintenance and operating costs," stated Mr. Shivak. A plant can be programmed to work at maximum efficiency with less downtime and with full maintenance scheduling," he continued. EPCO further explains both systems are easy and cost-effective to maintain because they utilize common and readily available components, such as Barber-Colman's next-evolutionAlpha System, which uses common modules of the MACO 4000. The E-7000-I and E-7000-B also utilize Barber-Colman's terminal block common I/O hardware for auxiliary equipment.
These two new control introductions are the most recent control product introductions produced through the collaborative efforts of EPCO and Barber-Colman, a relationship that has now spanned decades and delivered countless innovative solutions for molders throughout North America.
ControlLogix™ control systems from EPCO are
custom-programmed for a complete range of
injection molding and blow molding applications.
The ControlLogix system utilizes Rockwell Automation's Logix-based control system and an Allen-Bradley 6181P Windows 2000-based PC interface through an A-B DeviceNet network. Data transfer is very efficiently handled from the ControlLogix controller via the system's Ethernet control module. Injection molding models use a Bosch-Rexroth injection and clamp controller. The fast loop closure time makes the ControlLogix also ideal for transfer molding, extrusion, rubber molding and accumulator head blow molding.
"It would be an understatement to say the ControlLogix system simplifies today's injection molding and blow molding challenges," stated Larry Shivak, EPCO's manager of controls engineering. "It's more like a leading-edge masterpiece," he added.
Founded in 1959, EPCO is a diversified plastics machinery services provider and controls integrator. For over 40 years EPCO has helped controls manufacturers like Allen-Bradley pioneer many of the popular control upgrades in use today throughout North America.
Having successfully completed thousands of control upgrades on nearly every make and model of injection molding machine in use today, EPCO has also designed and/or customized controls for many special application machines, including blow molding, thermoforming and extrusion equipment.
National Polymers awards EPCO multiple
repeat contracts for retrofitted IMMs with upgraded
automation / control systems
EPCO has been awarded multiple contracts for upgrading injection molding machines at National Polymers, Inc. (NPI), Lakeville, Minnesota. The new contracts are the direct result of the first machine EPCO recently upgraded for NPI, which was completed through an initial single-machine contract.
EPCO recently integrated a Siemens SIJECT 16 compact control system programmed with SIMATIC Step 7 software, connected via MPI to a SIMATIC MP 270 B color HMI (programmed with SIMATIC ProTool software). This custom solution successfully improved the productivity, flexibility and profitability to levels that convinced NPI management to award additional contracts to EPCO.
“Our search and competitive review of automation vendors and system integrators convinced us to select EPCO to help find us a solution for our increasing downtime and decreasing productivity problems… and they delivered,” said Wes Anderson, NPI vice president. “We now expect EPCO will have 18 of our machines completed in the next 60 days.”
As a custom injection molder, NPI produces more than 400 variations of polypropylene cups and advertising specialty products that are marketed by other companies. The need to automate and upgrade aging mechanically-operated machines in this highly competitive arena was critical for NPI’s future.
“NPI was looking for a quicker return on investment than buying a new machine, plus they needed greatly improved uptime and flexibity, so we gave them a package that included a system that simplifies auxiliary equipment interfaces, like parts pickers,” stated Sam DeBartolo, EPCO’s National Sales Manager. “And because of the efficient teamwork between our staff and Siemens’, we handled the engineering, layout of system and software very cost-effectively.”
Other user benefits enjoyed by NPI include: multi-lingual operations (NPI employs both English and Spanish speaking employees); better utilization of workers (only one worker required to set up and start a machine); greater machine utilization (digital media cards are easily moved from machine to machine). Additionally, the SIJECT 16 and SIMATIC MP 279B HMI (which are Ethernet connected) automatically adjust linear positioning units determining mold and injection part measurements.
“I think this solution is one of the most progressive out there, and it attacks a lot of issues,” Anderson continued. “And if a problem does arise, EPCO and Siemens are here when we need them.”