5-axis machining centers are heart of production at mold maker

Blomix's molds are used worldwide for a wide variety of applications in the packaging industry. The Dutch company has been a mold maker since 1971. Everything is done under one roof, enabling flexible response to customers' requirements, reliable delivery times and the ability to offer the highest quality every time. Three automated 5-axis machining centers from Hermle form the heart of production.

Plastic has a bad image, but according to Luk Beenders, CEO of Blomix B.V., this is totally unjustified. "The material used to manufacture packaging, cans and bottles can be recycled many times over. Moreover, no waste is created during plastic processing, as any residue is reintroduced into the production process each time." 

Beenders' company, based in Brunssum, the Netherlands, designs, constructs, manufactures and assembles blow molds for the packaging industry - all in-house. These dies are used to produce plastic bottles, cans, barrels and pressure vessels for juices, shampoo and household cleaners, among others, as well as for packaging petrochemical and medical substances. They range in capacity from 20 milliliters to 500 liters - that is not the challenge, however, but the accuracy with which everything is produced. A blow mold always consists of several parts, for example to integrate cooling channels or realize complex geometries. To ensure that no seams or burrs are visible, the transitions are worked out as precisely as possible.

High production hall

However, this is easier said than done. The dies sit on the machine for up to 15 hours in a single fixture, and during that time thermophysical properties, such as heat effects, can cause everything to be less than accurate. To prevent that, Blomix had a modern, extra-high production hall built. A height of 9 meters and adiabatic cooling keep temperature fluctuations on the shop floor relatively limited. The machinery, including three 5-axis machining centers from Hermle, is also a guarantee of quality and precision. In 2007, the company invested in a C 30 U. When Luuk Beenders took over in 2014, he put even more emphasis on flexibility, innovation and quality. The previously purchased C 30 U fit into that concept, in 2018 a C 400 U was installed and in 2020 an old machine was replaced by a C 650 U.

Precision accelerates assembly

The accuracy of Hermle's milling centers is so high that one saves a lot of time during assembly at Blomix. The individual parts fit much better and thus less rework is required. Furthermore, the reliable automation solution also played a role in choosing Hermle. "Automation is the only way to remain competitive. It is a great advantage that machine and automation solution are from the same manufacturer, as this increases ease of operation and technical availability. If there are problems, it is clear that Hermle can solve them and they also respond very quickly," Beenders states. "With the C 30 U the pallets are changed by a robot, but with the other 5-axis milling centers we chose the HS-flex. We were looking for a solution to flexibly process workpieces of different sizes. When we invested in the C 400 U, we ended up with the HS-flex automation introduced just before. The C 650 U machining center is combined with the HS flex heavy system, suitable for workpieces up to 1,200 kg and for storing up to twelve pallets. We currently use ten pallets, which is more than enough given the long run times."

Uniform operation

HS-flex and HS-flex heavy are both controlled and managed via Hermle Automation Control System (HACS). This is an additional advantage for Blomix, because it not only makes it easy to exchange parts between the machines, but the operators immediately control all Hermle machines as well. This increases flexibility and capacity. "We don't use the full capacity of the machine to respond quickly to questions from our customers. However, it has to pay off. By using automation optimally, we can increase profitability. During the day, workers complete complex tasks, test and prepare shifts without people. At night and on weekends, the 5-axis machining centers ideally run fully automatic and unmanned. We don't want to be the biggest, but we do want to be the best at what we do. Then we must meet our deadlines and be able to guarantee our customers the highest quality time and again. And that is only possible with a partner like Hermle, who keeps his promises in terms of accuracy, reliability and service."