FRANCO-DUTCH-JAPANESE PLASTIC INJECTION PLANTS TO CONQUER EUROPE

"In just three years, Iris Ohyama France has become an undisputed leader in plastics processing in France and Netherland. Specializing in the manufacture of durable plastics, the subsidiary of the Japanese group known for being the first industrial manufacturer to create the transparent plastic box, has one of the largest fleets of injection moulding machines in France. In 2022, 44 new robotic electric injection moulding machines of the JSW brand will be added to the existing French fleet, bringing the total number to 116 machines. These workshops, offers a wide range of solutions and can cover a large part of the European demand from professionals in the DIY, decoration, interior storage and pet accessories sectors and will soon be able to meet the demand from distributors of small household appliances.”

At the start of the new year 2022, Iris Ohyama announces the arrival of 44 new robotic electric injection moulding machines at its Lieusaint site in the Ile-de-France region. This 65,000m² plant was equipped with 26 presses when it was launched in 2019, additional to the exisiting fractorie establish in Netherland since 20 years ago. From 2020, in the midst of the Covid 19 crisis, in France, the brand added 15 new presses to meet growing demand, particularly from European E-commerce activity. Today, Iris Ohyama continu to develop the French factory : the 250m long workshop has 70 highly technological robotic presses, ranging from 220t to 1300t, compatible with more than 250 moulds offering various moulding possibilities. An investment of more than 10 million euros that has involved various changes in productivity, technique and organisation.

AT THE HEART OF CHANG

Plastic injection moulding, also known as injection moulding, is a process for transforming thermoplastic materials. This expertise has a long history within the Iris Ohyama Group, which has 1,265 injection moulding machines worldwide, of which almost 10% of its machinery is now in Europe. Many adaptations were necessary. High-voltage substations, more powerful air compressors, chillers and air coolers were added to the existing installation to speed up the cooling process and reduce energy consumption. The raw material storage space has doubled from 5 to 10 storage silos for a total capacity of 450 tons of raw materials. By the end of the year, daily production is estimated at 50t, i.e. nearly 500 pallets of products per day, 46% of which are made of recycled materials. This huge investment is in line with the plastics giant's diversification strategy from storage to expanding its product portfolio to include pet accessories (such as dog parks and litter boxes for cats). In the near future, the launch of a line for the manufacture of Made In

France fans will be deployed in order to offer this seasonal product and enrich the range of small household appliances.

A CONCENTRATE OF TECHNOLOGY

The plastic injection process is particularly suitable for mass production and is feasible for all types of series from a few hundred pieces. Injection moulding allows a wide variety of shapes.

At Iris Ohyama France, all the injection moulding machines are from JSW, a market leader. They are fully electric, of AD and ADS generation for the most resilient. Horizontal and mono injection, they have the capacity to process various plastic materials such as polypropylenes (PP), polystyrenes (PS) and acrylonitrile-butabiene-styrene (ABS) a thermoplastic widely used for appearance parts.

Each machine is equipped with a six-axis Yaskawa robot, boosted by various high-tech peripheral equipment such as cameras, stand-alone labelers and other conventional equipment such as thermoregulators, dryers and shredders for recycling materials

The many possibilities of setting and controlling the moulding parameters combined with the very high performance of the injection unit allow the production of parts of impeccable quality. Extremely robust and equipped with proven electric servo technology, Iris Ohyama machines are very safe and reliable. Due to their fully electric design, i.e. without hydraulic circuits, these presses are cleaner (no oil leakage) and much quieter than hydraulic presses. In terms of profitability, the decisive advantage of a fully electric press over a conventional hydraulic press is its very low operating costs: up to 60% lower power consumption, very low cooling water consumption, no waste oil disposal and low maintenance. The increase in productivity is achieved through shorter cycle times. Improved production quality and lower scrap rates also contribute to a significant improvement in the profitability of the presses.

HUMANS-ROBOTS COLLABORATION

Operators were recruited to accompany the machines in their daily work. Nothing could be done without the employees, whose work is evolving with more responsibility. Internal development has been encouraged: 3 assembly/adjustment technicians have been trained and have obtained their Professional Qualification Certificate (CQP). This increase in operator skills will continue with other sessions of this type, but also with management training for team leaders and robotics training for technicians. These new presses also require organisation and logistical resources, which includes training staff to drive forklifts. Safety is a priority and Iris Ohyama relies on awareness and prevention actions as well as a risk assessment process.

SOLUTIONS FOR EVRIDAY LIFE !

For more than 60 years, our passion for aesthetics and technology has resulted in products that are truly part of your contemporary life. We have always designed exclusive solutions in Japan. Through each of our ever-expanding ranges, we offer reliable, quality products that meet your interior needs: storage, household appliances, furniture for adults and children, pet accessories, hygiene products, accessories for organising the kitchen, the bathroom, the garage, the garden...

There is everything for the home!