Tooling Holland responds flexibel and quick to the pre-form market

Essential component

They produce complete moulds, robot systems and supply the know-how customers need in the form of initializing systems, support and the development of prototypes etc. The product development for a customer consists, among other things, of producing the basic form of a bottle. All machining techniques for making the installation for the PET machines and the mould development and manufacture are in-house operations. The PET machines make use of a robot that contains only Omron components. There are other robots on the market, but the robot developed at Tooling Holland is unique. The advantage of this robot is that it holds on to the product for four 'shots'. This means that the product undergoes after-cooling whilst the matrix goes on to produce new pre-forms.

As a result the system's production is increased by approximately 20 to 25 %, whilst at the same time the quality of the end product is improved. The factors involved are the form-stability and the optical properties of the bottle. The system was developed in 1992, and after that the prototype operated for two years in a sort of dry-run cycle. Even the prototype contained Omron components such as sensors, photo-cells and approach switches. The PLC in this system was a different Omron model than the one that is currently in use. Then the prototype was installed in Scandinavia, where it operated for a year in a production environment during which a number of teething problems were solved. Following that systems integrator JB Besturingstechniek from Oosterwolde became involved to deliver the control that customers demanded. This was achieved through the use of the Omron 'touch screen' as a replacement for the switches and push buttons, making the programming and adjusting of the installation much easier.

From pneumatic to servo

As a result of the co-operation between Tooling Holland and JB Besturingstechniek, use is now being made of the Omron PLC. This development is based on the experiences gained from the prototype. Now, the most recent systems make use of a servo-controlled robot instead of a pneumatically powered model as, in the American market in particular, there was a demand for new technology, such as servo control. The technology was already there and Omron now also supply the hardware and the motor, including the control systems. All components communicate faultlessly with each other. The PLC contains standard functions to control the servo directly.

Omron offers standard cables and blocks to connect the PLC, the control terminals and the servo with each other, without the user having to do the welding himself. The different systems find their own way to communicate without the user having to set it up and this makes the installation much quicker and simplifies the maintenance. The installation is set up in such a way that the system is very service-friendly, from both a control and maintenance point of view. And it's problem free as the components the expertise needed to operate the Omron PLCs are available world-wide. Another important fact is that all Omron components comply with both CE standards and EMC standards. For Tooling Holland this meant that the installations did not have to be inspected, and as a result the complete development process could be accelerated.

Flexible development and manufacture

As a company, Tooling Holland has a range of six products that compensate for market fluctuations; this also means that the company can respond swiftly to new developments and markets and this diversification provides a basis for stable turnover. They employ a total of 85 people at two locations in Emmen and Veenendaal. In addition to moulds for the plastics industry they also manufacture moulds for aluminum injection molding products. Tooling Holland's market area extends from Brazil to Canada and from Florida to Russia and Scandinavia. Japan is the only country that is self-sufficient in this market and, therefore, they are not active there. In conclusion it would be fair to say that the 3-way relationship between Tooling Holland, JB Besturingstechniek and Omron has proven to be an excellent exercise in co-operation. Each company contributes its own knowledge and experience, and as a result can jointly respond to market requirements.