Case story GelliPlast

GelliPlast, like Frigel, confirms itself as a company focused on customer care. It dedicates significant investments in cutting-edge technology, analysis and research. Microgel Syncro proves to be a paradigm shift for GelliPlast for mold cooling.

The production area has 26 lines, with 25 injection presses from 80 tons to 1500 tons (with Cartesian robots for handling the molded products and conveyor belts that conclude the production cycle to-wards packaging) plus 1 line of laser cutting. A total of 559 active molds and 369 different types of raw materials are used, for the creation of 2147 finished products.

Investments in recent years, in fact, have allowed GelliPlast to also devote itself to the design and creation of its own product brands. Among the latest: the Flexy Dream, a modular support to be applied to the slats of the bed that has al-ready been internationally patented. Flexy Dream is a product on which GelliPlast is betting strongly and for which it has created a dedicated launch plan, which allows for the commercial distribution of the product on a large scale.

For twenty years now GelliPlast has relied on Frigel and its custom-designed solutions to optimize production processes in the plastic and rubber sector.

The RSY solution - Microgel Syncro

GelliPlast continues to place its trust in Frigel: there is at least one Frigel unit on each of the 25 presses. Microgel temperature control units intelligently manage hundreds of different molds which are alternated week after week.

In particular, the results obtained from the new Microgel Syncro model — which Frigel had initially proposed to GelliPlast for testing — were surprising. GelliPlast made it possible to install Syncro on a particular line with a technical finish. Given the performance obtained, GelliPlast has chosen the new syncro technology as standard for all new installations.

Microgel RSY Syncro is revolutionizing temperature control in the injection molding of technical parts. The new approach is based on the complete integration between the mold temperature control system and the injection molding process. It allows for a significant reduction of the cycle time, up to 40%, guaranteeing a very high quality of the finished product.

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Digitally synchronized with the mold, Microgel Syncro delivers cold water only during the cooling phase, drastically reducing the cooling time and keeping the mold cavities warm during the injection phase.

• Increases productivity up to 60% thanks to the strong reduction of cooling time
• Improves product quality in terms of dimensional tolerances, structural characteristics and aesthetic finish thanks to better mold filling
• Intelligently uses energy consumption thanks to the reduction of injection pressures, lower consumption of hot runners and lower clamping forces