Injection moulding & extrusion

Injection moulding and extrusion are high-volume manufacturing processes often used in the pharmaceutical and medical industry. Injection moulding involves the production of products by injecting molten materials into a mould. The materials can be metals and glasses, but most commonly food-grade thermoplastic and thermosetting polymers. Injection moulding is used to produce a variety of products that come in contact with drugs and medicines or are used as medical devices or packaging materials.

The extrusion process also includes melting and forming materials. But instead of a mould the material is pushed through (extruded) a die of the desired cross-section. This can result in many different profiles or as a film, and be used in countless applications.

Since both these processes include melting and forming material the process is very energy intensive and the heat load generated in the extrusion/injection moulding process is massive. This is also the reason it makes great sense to focus on this process when it comes to energy saving potential. Removing heat (i.e. process cooling) is important for the efficiency rate of the cooling system, and the ability to recover this heat for other purposes can be very useful for lowering OPEX costs.

Compressed air can also play an important role within the process, for example in different parts of the assembly process etc. In blow moulding (film extrusion), it plays a vital part in the production process. We can guide you through the compressed air demands and design an efficient and reliable solution suited for your needs.

The ventilation efficiency and the way the air is supplied to the production hall is also very important, both for the operational costs and for the specific process needs. Depending on the product the demand can be for low particle levels, dew point control (to avoid condensation) or temperature control. AirSon’s long experience within both the injection and extruding industries and MEP services means we can help you design and build an efficient and reliable production facility meeting your process needs.

Energy-efficient design

In a large production hall with many injection moulding machines, it’s imperative to have an understanding of the total heat load and convection flows. If there is a balance between treated fresh air and the convection air flow, it is relatively easy to create a work area around the machine with a comfortable temperature and low particle levels.

The main part of the electrical power used by the injection moulding machine is given off as heat. With a traditional mixing ventilation, this heat load must be balanced with an equally large amount of cooling. The energy needs for such systems, which are very common in the extrusion and moulding industry, have a major impact on the company’s bottom line. This is a typical challenge that we help our customers address.

Med-Tech

Medical technology is a wide definition and includes a lot of different products, services and solutions. It involves all the instruments, apparatus, medical devices, software, appliances and implants used in the industry. Most of these products needs to be produced in a controlled environment in order to meet the very high quality requirements set by the authorities. AirSon is used to helping our customers navigate a world of difficult and varying regulations.

Pharmaceutical

It is in the pharmaceutical industry where new drugs are discovered, developed and produced. Naturally, the requirements on the controlled indoor climate are the most stringent of all. Safety and quality of the medical drug is of course top of mind for the entire industry and this permeates all upstream and downstream process steps. All the pipes, apparatus, instruments, filters, containers, air, solvents, etc. that are in contact with the drug needs to meet the highest standards. AirSon has decades of experience from working with many of the global pharmaceutical companies.

R&D facilities

R&D facilities vary a lot in terms of design as well as in demands. It is crucial to have the best speaking partner when deciding on the level of cleanliness required for your specific process. AirSon can be the speaking partner you need.

Bio-tech

It is difficult, nowadays, to realize a world without bio-tech as it is all around us. Cellular and biomolecular processes help us develop technologies and products that help improve our lives and the health of our planet. Many of our everyday foodstuffs are based on a bio technology invention, no matter if we talk about bread, dairy products or beer – it all comes from a bio technology process. Turn to AirSon if you would like to know how your utility processes work in your specific bio technology process.

Hospitals

Naturally, the indoor environment in a hospital is critical for its operation. Where there are open wounds, there is a risk for infection. This risk needs to be minimized, more or less at all costs. This is why it is super critical to have control of the indoor environment and how the air behaves in a room, for instance in an operating theatre. AirSon’s vast experience from laminar air flows puts us in a position to fully understand and support our clients.

The Air Lab

We carry out investigations and tests to help you develop tailormade applications for solutions to fit your process and company’s needs.

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