For over 40 years Uniloy has produced low pressure Structural Foam Machines. Over time, machines wear down and technology advances. Let Uniloy be your guide to the future by showing you how to expand your machine capabilities with the advances we are incorporating in our new machines. Uniloy has the rebuild advantage because we are the original equipment manufacturer. This means we have all of the documentation for your machine and have the ability to produce genuine replacements for any broken, worn, or missing components.

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The Rebuild Process

We perform all rebuilds at our Afton, Ohio manufacturing facility. We start by completely stripping your machine down to its base. We then clean, paint, and systematically build it back up by either repairing or replacing components as specified. The process is completed by running the machine off for your approval. We tailor the depth of our rebuilds to meet your needs.

Typically, our Rebuild Program consists of 2 distinct areas:

1. Machine Upgrades – includes areas of the machine where components can be upgraded over what was originally supplied. 18 specific upgrades are detailed below.

2. Machine Reconditioning – includes areas of the machine where components are repaired or replaced to achieve a “like new” condition. 6 areas of reconditioning are presented below.

Section I: Machine Upgrades
Upgrade 1: State of the art B&R PLC controls

  • Replaces obsolete Maco 8000 and Siemens systems
  • Stock parts eliminate down time caused by obsolete, hard to find parts
  • Control cards are lower cost
  • Elimination of expensive delta closed loop card
  • Faster process control 1 millisecond response time
  • Faster screen updates
  • Faster screen navigation with tabs
  • Improved precision, accuracy and repeatability
  • Improved data collection and storage
  • Historical data management files
  • Expanded diagnostics and alarms
  • Closed loop position based clamp control for faster open/close time
  • Heater band burn out detection
  • Compact flash memory – no hard drive to wear out
  • Unlimited recipe storage on USB memory stick
  • USB port for program uploads and print outs
  • Ethernet connection possible to customers network
  • Software improvements can be uploaded in the future
  • Larger 15 inch color high resolution touch screen
  • Swing away operator station for easy set up & operation
  • Multi lingual screens – English – Spanish – Chinese etc.

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15″ Color Monitor

Upgrade 2: Independent sequential nozzle control

  • Eliminates need for manual nozzle adjustment
  • Nozzles independently open or close as function of shot position
  • Shot size control for each cavity
  • Closed loop speed control
  • Shot size distribution control within each cavity
  • Wave flow reduces weld lines
  • Sequential closing to prevent over packing
  • Settings can be saved on pc
  • Improves overall process control
  • Reduces part weight, cavity pressure, flashing and stresses

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Nozzle manifold and control valves

Upgrade 3: Solid state contactors for all temperature zones

  • Replaces mercury contactors
  • More reliable
  • “Earth friendly”
  • Longer life expectancy
  • No “bounce”
  • Low contact resistance
  • Quick on-off cycling capability
  • Quiet action

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Upgrade 4: Safety gate assembly

  • ANSI compliant
  • Stronger
  • More reliable

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Gate assembly

Upgrade 5: Safety gate interlock switches

  • ANSI compliant
  • More reliable
  • Longer life
  • More durable
  • Non- contact magnetically coupled

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Safety interlock switch

Upgrade 6: AC Vector air cooled extruder drive

  • More reliable
  • Variable speed
  • More durable
  • The most energy efficient

Upgrade 7: Air barrel cooling

  • Eliminates liquid cooled barrel components
  • Eliminates maintenance and associated downtime
  • Provides more accurate temperature zone control
  • Temperature control is gradual without line shock

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Air barrel cooling

Upgrade 8: Melt relief cylinder and stand-offs improvement (for 3 ¼ inch bore cylinders only)

  • New improved rod seal design will increase the seal life by a factor of two
  • New stainless steel piston rod helps keep heat away from seals by dissipating it faster
  • Stainless steel stand-offs decreases the area of heat retention and also helps dissipate the heat
  • Temperature control is gradual without line shock

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Melt relief cylinder and stand offs

Upgrade 9: Melt shut off

  • Shuts off the plastic flow between the extruder and the melt injection unit while the motor is not running which keeps the plastic from backing up into the extruder when injecting
  • Improves shot to weight repeatability
  • Reduces bridging of plastic in the feed section
  • Reduces head pressure during injection which helps prevent stress on the melt relief

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Melt shut off

Upgrade 10: Melt diverter improvements

  • Replaces the steel body with a special lined body or lined sleeves depending on your current style
  • Replaces the bronze diverter rods with special coated rods.
  • Increases the life span of the diverter by more than 3 times

Upgrade 11: Melt diverter program change

  • Changes the function of the melt diverter to act like a shut off when injecting

Upgrade 12: ANSI/SPI b151.1 safety requirements other than the safety gates and interlock switches

  • Emergency stops inside the platen area.
  • Purge pan/melt relief interlock
  • Safety signs
  • Double acknowledgement gate safety devices
  • Melt relief guarding
  • Catrac guarding

Upgrade 13: Hopper low level alarm and extruder shut down

  • Notifies operator of low material in hopper
  • When it reaches the lowest operating level it shuts the extruder and nitrogen gas off
  • Prevents gas from blowing back to hopper
  • Prevents extruder from running when dry

Upgrade 14: Clamp hydraulic reservoir low level alarm and shut down

  • Notifies operator of low oil level
  • Shuts down hydraulic system before critical damage can be caused

Upgrade 15: Hydraulic reservoir oil temp control and alarm

  • Ability to set hydraulic oil temperatures
  • High and low temperature alarms notify operators of potential problems
  • Shuts down machine hydraulics when high level set point is met

Upgrade 16: Extruder rupture disc shut down

  • Adds a proximity switch device to the rupture disc
  • Shuts down the extruder in the event that high pressure sets off the rupture disc
  • Prevents plastic over filling the melt relief valve area

Upgrade 17: Melt manifold flat plate heaters

  • Replaces cartridge heaters
  • Ease of replacement
  • Longer working life
  • More consistent temperature control


Flat plate heaters

Upgrade 18: Light weight melt manifold extensions

  • Approximately half the weight of original design
  • Improved ergonomics
  • More reliable heat control
  • Easier to maintain

Section II: Machine Reconditioning

R&R 1: Clamp restoration

  • Clean and surface grind platens
  • Restore mounting hole integrity
  • Restore t-slot integrity
  • Clean and polish tie bars or replace
  • Replace platen bushings
  • Replace tie bar nuts
  • Replace tie bar collars
  • Replace shock pads for safety bar
  • Repaint non mold mounting surfaces


Before

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During

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After

R&R 2: Hydraulic restoration

  • Repair accumulators (replace seals and/or bladders)
  • Replace specified hydraulic components
  • Replace hydraulic hoses as needed
  • Replace O-rings and seals as needed
  • Test, clean and repair or replace heat exchangers
  • Refurbish prefill valves
  • Refurbish clamp and/or traverse cylinders
  • Refurbish melt injection cylinders
  • Replace filters

R&R 3: Extruder and melt relief valve

  • Test and replace heater bands as needed
  • Test and replace thermocouples as needed
  • Replace melt relief seals, seats and stems
  • Replace metal O-rings

R&R 4: Fill pipes and melt diverter/shut off

  • Test and replace heater bands as needed
  • Test and replace thermocouples as needed
  • Replace metal O-rings
  • Replace shut off rods

R&R 5: Melt accumulator, melt tube, and melt manifold

  • Test and replace heater bands as needed
  • Test and replace thermocouples as needed
  • Replace or repair barrel and tip
  • Replace metal O-rings
  • Replace fire rods
  • Replace insulators
  • Repair mounting holes

R&R 6: Pneumatics and high pressure gas system

  • Replace gauges and valves as needed
  • Replace or repair regulators
  • Replace nitrogen gas valve
  • Replace mufflers

Rebuild warranty
A rebuild carries a one year warranty on all components that are added or replaced. Although we cannot guarantee a “leak free” machine, we strive to minimize leaks.

Delivery
Upon receipt of order, typically 10 weeks are required to engineer and procure components. After this period, we will require your machine to be delivered to our facility for 10 weeks of rebuild activities. Therefore, total lead time is typically 20 weeks.

Choosing your level of customization
Uniloy will work with you to customize your rebuild by first performing a complete audit of your machine. You will then be able to pick and choose how much or how little you want to upgrade and or restore. Remember, in order to maximize the effectiveness of your rebuild, we typically recommend the upgrades we have available; however, we can simply repair/replace components with similar technology if that meets your needs.

Sales and service
For more information, or to begin planning for your machine rebuild project, please contact your local Uniloy Parts Sales Representative. Trained Uniloy Service Representatives are also available to assist in the installation of your rebuild or any of these packages at your facility.