With the launch of a specially developed, fully electric 2K injection molding machine, Wirthwein Medical is expanding its production capacities for high-precision and ultra-small multi-component parts, including container closure systems and components for pharmaceutical primary packaging. The new injection molding machine was customized to the specific requirements of the Mühltal-based company and offers a combination of maximum precision, innovation and automation.
2K technology for advanced applications
A special feature of the new 2K injection molding machine is the two flexibly configurable plasticizing units. Each of these units can be equipped either with a standard cylinder or a micro-module with an 8-mm screw. This versatility makes it possible to efficiently realize both high-precision micro 2K injection molded components and standard 2K injection molding applications.
Particularly noteworthy is the innovative micro-module that allows the processing of the smallest quantities of material. A significantly better material homogeneity is achieved by using a screw plasticizing unit instead of a conventional piston, as is the case with other micro-injection molding machines. This leads to a consistently high melt quality and more efficient series production.
“The micro-module is a real innovation in injection molding technology. It enables us to process the smallest quantities of material with extraordinary precision in series production, which is particularly important for the production of delicate medical technology components,” emphasizes Timo Reifenberger, responsible for application technology at Wirthwein Medical.
The machine is also equipped with advanced automation and a 6-axis robot that removes the molded parts by cavity and sets them down in a defined manner. To further increase process reliability, the injection molding machine can be equipped with a 100 percent camera inspection system that enables automatic quality inspection in real time. It also meets the most stringent cleanliness requirements and is located in an ISO Class 7 clean room, so that pharmaceutical and medical products can be manufactured under optimal conditions.
The input of specialists from Wirthwein Medical's own ranks was particularly beneficial during the development with the machine manufacturer. With their in-depth knowledge and industry-specific experience, they made a significant contribution to developing and implementing this cutting-edge technology.
Manufacturing of sustainable components for pharmaceutical primary packaging materials
Essential components for the pharmaceutical industry are manufactured on the 2K injection molding machine using the smallest shot weights. The soft components made of TPE that are used ensure that pharmaceutical products, in particular liquids or sterile preparations, are securely packaged and sealed, thus protecting them from contamination and environmental influences. Defective primary packaging could jeopardize the quality and safety of the product, with serious consequences for patients.
Using the example of the Container Closure System, it was important for Wirthwein Medical to develop a solution for the soft components that not only met the complex requirements in the field of primary packaging materials but also allowed for 100% recyclability. This was achieved by using a specially developed, patented TPE material. As a result, Wirthwein Medical offers an environmentally friendly, functional and safe packaging solution.
The presently smallest 2K component for use in prefillable syringes weighs less than 0.5 g, with the soft components under 0.1 g. The design as a 2K component also allowed various functions to be integrated, including the optimization of the barrier properties.
“We are proud to contribute to the reduction of waste in the pharmaceutical industry and to offer environmentally friendly packaging solutions in this area,” emphasizes Andreas Dunz, project manager at Wirthwein Medical.
The production of these systems requires maximum precision, in particular due to the very low shot weights. With the new innovative 2K injection molding machine, Wirthwein Medical ensures that the material quantities are precisely metered in order to precisely form the delicate components.
This technological advancement strengthens Wirthwein Medical's position as an innovation leader in medical technology and contributes to the development of sustainable, high-quality packaging solutions for the pharmaceutical industry.
About Wirthwein Medical
Wirthwein Medical, founded in 1946, is a leading supplier of plastic solutions for diagnostics, medical technology and pharmaceuticals. The company offers customized components, packaging and systems. In addition, the company's product portfolio includes its own products in the pharmaceutical sector. Wirthwein Medical is part of the international Wirthwein Group, which employs over 3,000 people worldwide.
