Clean Room

The production of optical parts under clean room conditions requires cost-effective solutions in order to meet the conditions of a class 100,000 clean room.

The solution is based on the fully electric injection ELEKTRA evolution molding machine. Fully electric machines are ideal for clean room applications because these machines do not produce the oily mist associated with hydraulic machines – and which can contaminate moldings.

Using commodity parts, a housing is constructed around the ELEKTRA evolution upon which a clean room flowbox is mounted above the mold installation area. An ionization station ensures that the dust-free articles are discharged of static electricity before leaving the Clean room cabin. A toggle lever enclosure is also available as an option.

A side entry robot Type 7-5 PPS by Wemo Automation AB for part removal is located on the service side of the machine within the clean room housing.

To keep mold changes simple, the flowbox slides away towards the clamping unit. This allows unrestricted access to the mold installation area. This also provides access to the robot for changing the end of arm tooling whenever the mold is changed.

Ferromatik Milacron offers other clean room solutions tailored to the needs of various production tasks.

As a rule, for production under clean room conditions, either optical or hygienic criteria for the parts must be met.

Approach 1:  Clean Room Conditions in Mold Area

With this approach the injection molding machine is operated in the “grey room” – as opposed to the clean room itself. A flowbox is installed over the platen in the mold installation area (see picture 2). The flowbox produces a laminar, ionized airflow creating a constant air pressure in the mold installation area and preventing an exchange with ‘dirty’ outside air. Finished parts are then transported into the actual clean room for further processing by means of an enclosed conveyor with a lock .

This simple and cost-effective design will establish 1,000 class clean room conditions. Whenever servicing or installation work has to be done, clean room conditions can be quickly re-established because of the small air volume. This allows manufacturers to get back into production more quickly.

Approach 2: Machine Partially in Clean Room (clamp only) 

This approach is particularly effective with the MAXIMA series 2-platen machines. Here, the injection side of the machine is in the grey room and the clamp unit and mold are in the clean room.

Approach 3: Entire Machine in Clean Room

Operating a complete injection molding machine inside the clean room is actually a contradiction in terms. Hydraulic machines in particular are sources of emissions (for example, oil mist) which do not belong in an expensive Clean room. However, if this approach must be taken, the use of definite low emissions-, fully electric machines offer a functional solution.