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Injection Moulding Machine Controllers: Generations Explained
Dec 10, 2025
Ing. Andrea Balajová
A practical guide to ARBURG, ENGEL, KraussMaffei, Demag and Wittmann Battenfeld control systems When searching for a used injection moulding machine, buyers usually compare clamping force, screw diameter, shot capacity, production year and operating hours. But there is one important specification that is often overlooked: the machine’s control system. Consider two injection moulding machines from the same manufacturer, with similar specifications and comparable operating hours. One might be equipped with an older controller, while the other features a newer generation with improved process monitoring, automation interfaces and data management. Although their mechanical specifications may be almost identical, their suitability for a particular production environment can be very different. A control system affects much more than the way an operator enters parameters. It can determine how production sequences are programmed, how mould settings are stored, which robots can be connected, how process data is monitored and how easily a machine can be maintained. For buyers of second-hand equipment, understanding controller generations can also help identify the approximate technological generation of a machine. In this guide, we examine the development of injection moulding machine controllers from five major European manufacturers: 1. ARBURG: SELOGICA and GESTICA 2. ENGEL: CC100, CC200, CC300 and CC300 plus 3. KraussMaffei: MC1 through MC6 4. Demag: NC4, NC5 and NC5+ 5. Wittmann Battenfeld: UNILOG B2, B4, B6, B8 and B8X More importantly, we explain how to recognise these systems, what makes them different and what to check before buying a machine equipped with one. 1. UNDERSTANDING INJECTION MOULDING MACHINE CONTROLLERS WHAT DOES AN INJECTION MOULDING MACHINE CONTROLLER ACTUALLY DO? An injection moulding machine controller is responsible for coordinating the machine’s movements and processing parameters. Depending on the machine and its configuration, the controller manages functions such as: 1. Injection speed and pressure profiles 2. Screw rotation and plasticising parameters 3. Holding pressure and holding time 4. Clamping unit movements 5. Ejector and core-pulling sequences 6. Barrel and mould temperature control 7. Process monitoring and alarm management 8. Storage of mould settings and production recipes 9. Communication with robots and peripheral equipment Modern controllers may also support production monitoring, automatic parameter adjustment, quality documentation and communication with manufacturing execution systems (MES). However, the controller’s commercial name alone does not guarantee that all these functions are available. Manufacturers often offer optional software packages, additional interface modules and different hardware configurations within the same controller generation. This distinction is particularly important when purchasing used equipment. CONTROLLER GENERATION VS. MACHINE PRODUCTION YEAR One of the most common mistakes is assuming that a machine’s production year identifies its controller. For example, ARBURG introduced GESTICA in 2016, but this does not mean that every ARBURG machine manufactured after 2016 was equipped with GESTICA. Manufacturers frequently introduce new controllers gradually across their machine ranges. Older and newer control systems may therefore be available simultaneously. The reverse is also possible: an older machine may have received a controller upgrade during its operating life. Practical rule: Never identify an injection moulding machine controller solely by the machine’s year of manufacture. Always check the installed system directly. 2. ARBURG CONTROLLERS: SELOGICA AND GESTICA EXPLAINED German manufacturer ARBURG is particularly well known for its ALLROUNDER injection moulding machines. Its control philosophy has evolved considerably over the decades, with SELOGICA and GESTICA representing two important milestones. ARBURG SELOGICA — INTRODUCED IN 1992 ARBURG introduced its SELOGICA control system in 1992. At the time, its graphical approach to programming machine sequences represented a major development in injection moulding machine operation. Instead of relying exclusively on traditional parameter tables, SELOGICA allows machine processes to be represented through graphical sequence programming. WHAT MAKES SELOGICA DIFFERENT? One of the defining features of SELOGICA is its graphical programming concept. An injection moulding cycle involves a sequence of interconnected operations. For example: 1. Close the mould. 2. Build up clamping force. 3. Move the injection unit forward. 4. Inject material. 5. Apply holding pressure. 6. Cool the moulded part. 7. Open the mould. 8. Activate the ejector. 9. Return the ejector. 10. Begin the next cycle. On a machine equipped with SELOGICA, these operations can be configured using graphical sequence elements. The system also performs plausibility checks intended to identify conflicting or inappropriate sequence configurations. This is particularly useful when programming more complex applications involving core pulls, additional movements or automation equipment. ARE ALL SELOGICA CONTROLLERS THE SAME? No. This is a particularly important detail for buyers of used ARBURG machines. SELOGICA is a control-system family that evolved over many years, not one unchanging hardware configuration. Different machines may have different display designs, operating panels, control hardware, software versions and optional functions. You may also encounter designations such as SELOGICA direct or SELOGICA ND in ARBURG documentation. Therefore, when comparing two machines equipped with SELOGICA, the controller name alone is insufficient. The exact configuration should be established from the machine documentation and system information. WHICH ARBURG MACHINES USE SELOGICA? SELOGICA has been used across multiple generations of ARBURG ALLROUNDER machines. Examples include machines from the ALLROUNDER C and S families, as well as various later ALLROUNDER configurations. However, the machine series alone does not establish the exact controller hardware or software version. For example, knowing that a machine is an ALLROUNDER 470 C tells you considerably less about its electronic configuration than knowing its production year, controller variant and software version. WHAT SHOULD BUYERS CHECK ON A USED SELOGICA MACHINE? 1. Display and operating panel Check that the screen remains readable, without intermittent image loss, significant display defects or unstable operation. Test frequently used buttons and other operating elements. 2. Programme storage and retrieval Ask the seller to demonstrate how an existing mould setting is stored and retrieved. Confirm that settings remain available after a normal machine restart. 3. Software version Request the controller’s software identification. This may become important when replacing electronic components, restoring backups or investigating compatibility with other machines. 4. Peripheral-equipment interfaces Do not assume that every SELOGICA machine can communicate with the same robot or production monitoring system. The relevant hardware, software and interface options must be verified. 5. Electronic spare parts Investigate the availability of replacement components for the specific controller version. A functioning older controller is not necessarily a problem. However, limited availability of compatible electronics can significantly affect repair costs and downtime. ARBURG GESTICA — PRESENTED IN 2016 ARBURG introduced GESTICA at the K 2016 trade fair together with its ALLROUNDER 1120 H. GESTICA represented a major redesign of the operator interface, while retaining fundamental elements of the SELOGICA programming philosophy. SELOGICA VS. GESTICA: WHAT ACTUALLY CHANGED? The most visible difference is the operating interface. GESTICA uses a modern graphical environment with a high-resolution display, multi-touch functionality and gesture-based interaction. Its design was intended to make complex machine operations easier to understand and navigate. But the differences extend beyond appearance. 1. GRAPHICAL INTERACTION SELOGICA introduced graphical sequence programming. GESTICA retains this fundamental concept while providing a more modern interface for navigating functions, viewing information and interacting with the machine. Operators familiar with SELOGICA may therefore recognise important elements of the programming philosophy, although training is still advisable. 2. OPERATING ERGONOMICS GESTICA introduced an ergonomically adjustable operating panel and a user interface designed around modern interaction methods. This can be particularly useful in environments involving frequent mould changes and regular operator intervention. 3. ASSISTANCE FUNCTIONS GESTICA supports advanced assistance functions intended to help operators configure and optimise machine processes. The exact functions available depend on the machine’s equipment and software configuration. 4. PRODUCTION INTEGRATION GESTICA was developed with modern production environments in mind, including more advanced data handling and integration possibilities. However, actual connectivity must still be verified for each machine. ARBURG SELOGICA VS. GESTICA FeatureSELOGICAGESTICAIntroduction1992Presented in 2016Operating conceptGraphical sequence programmingGraphical sequence programming with redesigned user interfaceDisplay technologyDepends on versionModern high-resolution multi-touch interfaceGesture operationNot a defining featureYesPlausibility checkingYesYesAssistance functionsVersion- and option-dependentExpanded modern assistance conceptAutomation integrationConfiguration-dependentConfiguration-dependentTypical used-machine relevanceBroad range of older and later ALLROUNDER machinesNewer compatible ALLROUNDER generations CAN YOU TRANSFER MOULD PROGRAMMES BETWEEN SELOGICA AND GESTICA? This is a question worth asking before purchasing a newer ARBURG machine to replace an existing one. The two control systems share important elements of their programming philosophy, but this does not mean every stored programme can be transferred directly without conversion, modification or verification. Compatibility depends on factors including: 1. Software versions 2. Machine configuration 3. Available movements and hydraulic or electric functions 4. Installed options 5. Peripheral equipment 6. Differences in the physical machine Practical recommendation: If transferring existing mould programmes is essential, ask ARBURG to verify compatibility using the exact machine configurations and software versions. Do not rely solely on the fact that both machines belong to the ALLROUNDER family. 3. ENGEL CONTROLLERS: CC100, CC200, CC300 AND CC300 PLUS Austrian manufacturer ENGEL has developed several generations of machine controllers under the CC designation. The transition from CC100 and CC200 to CC300 marked a particularly significant change in operator interaction. ENGEL CC100 — EARLIER CONTROLLER GENERATION CC100 belongs to an earlier generation of ENGEL electronic control systems. It can be encountered on older ENGEL injection moulding machines, including machines from earlier generations of the company’s established product families. Its operation reflects the control technology available when those machines were manufactured. Compared with current systems, the interface is more traditional, and available functionality depends heavily on the individual machine configuration. WHAT SHOULD YOU KNOW ABOUT CC100? When buying a CC100-equipped machine, its main limitation is not necessarily the control philosophy itself. A properly maintained machine may still be suitable for straightforward production. The more important questions concern its electronics and long-term maintainability. For example: 1. Is the operating panel fully functional? 2. Can all machine parameters be accessed? 3. Are stored mould settings retained reliably? 4. Are compatible replacement electronic components available? 5. Is the required service documentation included? For older controllers, the condition and supportability of the electronics may be more important than the appearance of the operator interface. ENGEL CC200 — THE NEXT GENERATION CC200 succeeded the earlier CC100 family and became an established controller on ENGEL injection moulding machines. It can be found on numerous used machines, including configurations from the ENGEL victory, duo and other product families. Its development brought improvements in machine operation, parameter management and integration possibilities. However, CC200 itself existed in different configurations and software versions. CC100 VS. CC200: WHAT IS THE PRACTICAL DIFFERENCE? The most relevant improvement is the evolution of the control environment and the way machine functions are presented and managed. CC200 offers a more developed operating concept than the earlier generation. But it would be misleading to claim that every CC200 machine supports a specific function that no CC100 machine could provide. ENGEL offered different configurations and optional features, and individual machine capabilities must be checked against their technical documentation. CAN YOU TRANSFER PROGRAMMES FROM CC100 TO CC200? Do not assume direct compatibility. Even where parameter data can be transferred or adapted, differences in machine equipment and controller software may require verification or reconfiguration. A successful file transfer does not necessarily mean that the receiving machine will reproduce the same process without adjustment. If programme migration is important, request a compatibility assessment before purchasing the replacement machine. ENGEL CC300 — INTRODUCED IN 2013 ENGEL introduced its CC300 controller at K 2013. Unlike a simple update to the previous interface, CC300 introduced a substantially redesigned approach to machine operation. WHAT MAKES CC300 DIFFERENT? The key concept is operation organised around the user’s tasks and the individual components of the production cell. This allows operators to work with machine functions and integrated equipment in a more coordinated environment. 1. THE E-MOVE CONTROL ELEMENT One of CC300’s most distinctive features is e-move, a rotary operating element used for controlling machine movements. Instead of relying exclusively on conventional individual movement buttons, the operator can use e-move to control selected movements within the machine’s operating concept. This is particularly relevant during mould setup and manual operation. The exact available movements depend on the configuration and safety conditions. 2. A MODERN OPERATOR INTERFACE CC300 introduced a redesigned interface with an emphasis on clear navigation, operator tasks and graphical information. The controller family uses a large touchscreen display and adjustable operating arrangement. This can reduce the complexity of navigating between machine functions. 3. INTEGRATED PRODUCTION CELLS CC300 was designed to support the operation of more complex production cells. Depending on the machine configuration, integrated automation can be operated within the control environment. This is useful when working with ENGEL robots or additional equipment. However, compatibility with a particular robot must always be established individually. 4. OPERATOR PERSONALISATION CC300 supports user-oriented interface arrangements and configurable operating functions. Such functionality can be useful when several operators with different responsibilities work with the same production equipment. ENGEL CC300 PLUS — INTRODUCED IN 2023 ENGEL presented CC300 plus at Fakuma 2023. Despite its name, CC300 plus is not an entirely unrelated controller family. It is an evolution of the CC300 operating concept, with particular attention to ergonomics and manual machine operation. WHAT CHANGED FROM CC300 TO CC300 PLUS? 1. Three-part operating panel The CC300 plus operating unit consists of three main sections: 1. Switch-on panel 2. Visualisation panel 3. Manual pushbutton panel These sections are connected through an adjustable mechanism. 2. Improved positioning The operating panels can be positioned independently, improving accessibility during different working tasks. 3. Configurable pushbuttons The new manual panel includes eight pairs of pushbuttons. These can be assigned to different functions, allowing operators to configure controls for tasks such as robot operation, core movements or other machine functions. 4. Improved e-move interaction CC300 plus provides additional visual information about the selected movement sequence. This makes it easier for operators to understand which movement will be executed. 5. User-specific settings The operating arrangement supports user-specific positioning and access functions. CAN EXISTING CC300 MACHINES BE UPGRADED TO CC300 PLUS? Yes — ENGEL explicitly offers this possibility. According to ENGEL, machines equipped with CC300 can be upgraded to the CC300 plus operating unit. However, the scope, cost and feasibility of a particular upgrade should be confirmed with the manufacturer. This is an important advantage when evaluating certain used ENGEL machines. ENGEL CONTROLLER COMPARISON FeatureCC100CC200CC300CC300 plusGenerationEarlierSuccessor to CC100Introduced 2013Introduced 2023Operating interfaceTraditionalDeveloped electronic interfaceModern task-oriented interfaceEnhanced CC300 interfacee-moveNoNoYesYes, with enhanced interactionThree-part adjustable panelNoNoNoYesConfigurable modern manual panelNoVersion-dependent controlsYes, different arrangementEight pairs of configurable pushbuttonsAutomation capabilitiesConfiguration-dependentConfiguration-dependentIntegrated automation conceptIntegrated automation conceptModernisationIndividual assessmentIndividual assessmentCC300 plus upgrade offeredCurrent CC300-family development WHICH ENGEL CONTROLLER SHOULD YOU CHOOSE? For straightforward production on a well-maintained machine, an older controller may be entirely sufficient. If the production environment involves frequent mould changes, extensive manual setup or integrated automation, CC300 may offer practical advantages. CC300 plus is particularly interesting where operator ergonomics and frequently repeated manual movements are important. For used-machine buyers, the most important question is not simply CC200 versus CC300, but whether the specific machine provides the functions required by the intended application. 4. KRAUSSMAFFEI CONTROLLERS: MC1 TO MC6 KraussMaffei provides one of the clearest documented histories of injection moulding machine control development. The manufacturer’s MC controller family dates back to 1980. Interestingly, the evolution of this family reflects several major technological transitions in industrial control systems. MC1 — 1980 MC1 represented an early stage in the transition from conventional relay-based machine control towards electronic control technology. It marked the beginning of the MC controller family. Today, MC1 is primarily of historical interest when examining considerably older machinery. MC2 — PROGRAMMABLE ELECTRONIC CONTROL MC2 introduced a freely programmable, microcontroller-based electronic system. This was an important step beyond earlier relay-oriented control concepts. It enabled more flexible management of machine functions through software-controlled electronics. MC3 — INTRODUCED IN 1987 MC3 introduced monitor-based operation using a movable operating console. This represented a significant development in the interaction between operators and machine control systems. In 1991, the system was further developed with a flat-screen monitor. WHAT IS MC3-F? When reviewing older KraussMaffei machines, buyers may encounter the designation MC3-F. This designation is particularly relevant because KraussMaffei identifies MC3-F as one of the controller versions supported by its smart MC6 upgrade programme. This does not mean that every MC3-equipped machine can automatically receive the upgrade. The exact version and machine configuration matter. MC4 — INTRODUCED IN 2003–2004 MC4 marked another significant development in the KraussMaffei control family. One of the important milestones associated with this generation was improved integration of robots into the machine’s control environment. For buyers of used machinery, MC4 is especially relevant because of the possibility of manufacturer-supported modernisation. CAN AN MC4 MACHINE BE UPGRADED? Yes, certain KraussMaffei machines equipped with MC4 can be upgraded using the manufacturer’s smart MC6 solution. The upgrade is designed to retain suitable elements of the existing machine while modernising the control technology. We will examine this option in greater detail below. MC5 — TOUCHSCREEN OPERATION The MC5 generation introduced touchscreen operation to the KraussMaffei control family. Early versions used a film-based touchscreen, followed by glass-based technology during subsequent development. This represented a significant change from conventional operating-panel concepts. For buyers evaluating an MC5-equipped machine, the condition of the touchscreen and associated electronics should be checked carefully. MC6 — MODERN CONTROL AND CONNECTIVITY MC6 introduced a more modern operating environment with Windows-based visualisation. Since 2015, MC6 has been available with a capacitive full-glass display that supports gesture-based operation. But MC6 is more than a touchscreen upgrade. WHAT MAKES MC6 TECHNICALLY DIFFERENT? 1. Modular architecture MC6 uses modular hardware and software concepts. This provides flexibility in adapting the control system to different machine configurations. 2. Real-time communication The system architecture uses real-time Ethernet communication for connecting relevant machine components. 3. Production monitoring Depending on configuration, MC6 can support advanced production data collection and analysis. For example, KraussMaffei’s DataXplorer functionality is designed to record and analyse machine measurement data. 4. Modern connectivity MC6 supports integration with contemporary industrial communication technologies, including OPC UA-based solutions. 5. smartCube integration Since 2021, KraussMaffei has supplied MC6 with its smartCube module as standard. The module supports the integration of digital production and Industry 4.0 functions. MC6 DOES NOT ALWAYS MEAN IDENTICAL HARDWARE An important detail is that MC6 itself has evolved. An early MC6 configuration and a later MC6 system equipped with smartCube should not automatically be considered identical. Buyers should verify the installed hardware and software rather than relying on the designation MC6 alone. KRAUSSMAFFEI SMART MC6 UPGRADE: AN IMPORTANT RETROFIT OPTION One of the most interesting features of the KraussMaffei control family is the availability of a manufacturer-supported upgrade for selected older machines. KraussMaffei offers the smart MC6 upgrade primarily for compatible machines equipped with MC3-F or MC4 controllers. The upgrade can include: 1. Modern MC6 control hardware and software 2. Integration with suitable existing electrical systems 3. Transfer and adaptation of customer-specific software 4. Updated operating and control functions 5. Additional connectivity options 6. Associated service and technical documentation This may allow an older machine to remain in production while benefiting from more modern control technology. However, the upgrade does not automatically transform the entire machine into a mechanically equivalent modern model. Its mechanical design, drive technology and other original characteristics remain relevant. IS AN MC6 UPGRADE ALWAYS WORTH IT? Not necessarily. Before proceeding, buyers should compare: 1. Upgrade cost 2. Condition of the existing machine 3. Expected remaining service life 4. Cost of a replacement machine 5. Required production capabilities 6. Available service support A controller upgrade can be economically attractive when the machine is mechanically sound and suitable for its intended application. KRAUSSMAFFEI CONTROLLER COMPARISON ControllerIntroduction / MilestoneImportant DevelopmentMC11980Early electronic controlMC2Following MC1Programmable microcontroller-based electronicsMC31987Monitor-based operationMC3 update1991Flat-screen monitorMC42003–2004Improved robot integrationMC52004Touchscreen operationMC6Subsequent generationWindows-based visualisation and modular architectureMC6 development2015Capacitive full-glass displayMC6 development2021smartCube supplied as standard Practical tip: If you are considering an older KraussMaffei machine with MC3-F or MC4, investigate upgrade possibilities before dismissing it solely because of its controller generation. 5. DEMAG CONTROLLERS: NC4, NC5 AND NC5+ Demag injection moulding machines are common on the European second-hand machinery market. Different generations can be found under Demag and Sumitomo (SHI) Demag branding. The NC control family is particularly important when comparing older Ergotech machines with later Systec and other machine generations. DEMAG NC4 — EARLIER CONTROL GENERATION NC4 represents an earlier generation of Demag machine control technology. It can be found on older machines, including configurations from the Ergotech family. The system uses a more traditional operating concept with parameter-oriented displays. Although less visually advanced than later generations, this type of interface may be familiar to operators with experience on older Demag equipment. WHAT SHOULD BUYERS CHECK? Pay particular attention to: 1. Display functionality 2. Operating keyboard and buttons 3. Storage of mould settings 4. Electronic spare parts availability 5. Controller documentation 6. Compatibility with existing peripheral equipment The exact NC4 configuration should be identified from the machine documentation. DEMAG NC5 — A MAJOR DEVELOPMENT IN OPERATOR INTERACTION NC5 introduced a more graphical operating environment with touchscreen-based interaction. One of its particularly interesting features is the ability to switch to an operating view resembling the earlier NC4 interface. WHY IS THIS IMPORTANT? Imagine a production facility operating several older Demag machines equipped with NC4. When introducing a newer machine with NC5, operators may initially prefer an interface they already know. The NC5 classic mode allows familiar tabular information to be displayed in a format resembling the previous generation. This can make the transition to newer equipment easier. WHAT ELSE CHANGED WITH NC5? 1. Graphical process overview NC5 provides a more visual representation of machine functions and important process phases. This can simplify the interpretation of machine settings. 2. Improved alarm information The system can provide additional information about certain alarm conditions and possible causes. This may help operators identify problems more efficiently. 3. Peripheral integration NC5 supports integration possibilities for peripheral devices. Depending on configuration, additional equipment can be incorporated into the operating environment. 4. Data storage The controller supports USB-based storage and transfer of machine settings and related data. This can be useful for production environments involving frequent mould changes. 5. Production monitoring NC5 provides options for monitoring and documenting process-related information. The available capabilities depend on the installed configuration. DEMAG NC5+ — FURTHER DEVELOPMENT NC5+ represents a later development of the NC5 control concept. Sumitomo (SHI) Demag documentation describes functions including: 1. Graphical process analysis 2. Reference-cycle visualisation 3. Automatic production documentation 4. Machine setup assistance 5. Automatic mould-height and clamping-force adjustment on supported machines 6. Additional process-support functions These features can reduce setup effort and improve process transparency. However, not every function should be assumed to be available on every NC5+ machine. Some capabilities are dependent on the machine’s equipment and application. NC4 VS. NC5 VS. NC5+ FeatureNC4NC5NC5+Operating conceptTraditional parameter-oriented interfaceGraphical interfaceDeveloped graphical interfaceNC4-style classic viewNative operating conceptAvailable classic modeVerify by configurationTouchscreen operationNot a defining featureYesYesUSB-based data storageVersion-dependent; verifyDocumentedConfiguration-dependentGraphical process monitoringMore limitedYesYesAutomated setup functionsMachine-dependentMachine-dependentExpanded functions on supported machinesProduction documentationConfiguration-dependentSupported functionsExpanded functions AN IMPORTANT DETAIL ABOUT NC5 The presence of NC5 does not automatically guarantee a particular robot interface, central-computer connection or remote-service option. For example, manufacturer documentation describes optional remote-maintenance functionality and integration with external production systems. Such capabilities must be confirmed individually. Practical recommendation: When buying a used Demag machine, request both the controller identification and a list of installed software and communication options. 6. WITTMANN BATTENFELD CONTROLLERS: UNILOG B2 TO B8X Wittmann Battenfeld has developed its UNILOG control family through several generations. Older Battenfeld machines may use UNILOG B2, B4 or B6, while more recent machines increasingly feature B8 or B8X. UNILOG B2 AND B4 — EARLIER GENERATIONS UNILOG B2 and B4 belong to earlier generations of Battenfeld electronic control systems. They can be encountered on older machines still available on the second-hand market. As with other manufacturers, the exact equipment varies between machines. For buyers, the important questions concern the operating condition of the electronics, the availability of compatible components and the ability to preserve and restore machine settings. UNILOG B6 — THE PREDECESSOR TO B8 UNILOG B6 represents a later stage in the development of the Battenfeld control family. It was used before the introduction of UNILOG B8 and remains relevant when evaluating used Wittmann Battenfeld machines. The most important distinction between B6 and B8 is the technological development of the operator interface and the level of integration offered by the newer generation. UNILOG B8 — INTRODUCED IN 2016 Wittmann Battenfeld presented UNILOG B8 at K 2016. The controller introduced a redesigned interface with an emphasis on intuitive operation and integration of production-cell equipment. WHAT MAKES UNILOG B8 DIFFERENT? 1. Large multi-touch display UNILOG B8 introduced a pivotable 21.5-inch full-HD multi-touch display. This allows operators to interact with process functions through familiar gestures such as swiping and zooming. 2. Separation of operating functions An important design decision was the combination of touchscreen interaction with physical controls. Process functions are accessed through the touchscreen, while frequently used movement functions can be operated using tactile keys. This arrangement is particularly useful during manual machine operation. 3. Split-screen functionality The controller allows different functions to be displayed simultaneously. For example, an operator may be able to view machine settings alongside relevant peripheral-equipment information. 4. Integrated peripheral control UNILOG B8 was developed as part of Wittmann Battenfeld’s integrated production-cell concept. Compatible Wittmann robots and auxiliary equipment can be integrated into the operating environment. This can reduce the need to operate each device through a completely separate interface. 5. Operator assistance The system includes assistance functions intended to simplify machine setup and process configuration. One example is QuickSetup, which can generate suggested process settings based on supplied application information. These suggestions must still be reviewed and adapted for the actual moulding process. UNILOG B8X — FURTHER DEVELOPMENT OF B8 UNILOG B8X builds on the operating concept established by B8. It retains familiar interface principles while introducing more advanced hardware capabilities. Wittmann describes improvements including higher internal processing performance and faster reaction to sensor signals on relevant machines. The system retains a large touchscreen interface and integrated production-cell operating concept. B8 VS. B8X: WHAT IS THE DIFFERENCE? The distinction is not simply the presence of a touchscreen. Both generations use modern graphical operating concepts. B8X represents a further technological development, particularly in terms of underlying control hardware and processing performance. However, the actual benefits depend on the specific machine. A controller with faster internal processing does not automatically make every injection moulding process faster. The achievable cycle time depends on the machine’s mechanical and drive characteristics, mould design, material and processing conditions. WHICH MACHINES USE B8X? Wittmann Battenfeld uses B8X on various recent machine families. Documented examples include configurations from the SmartPower, EcoPower and newer MacroPower ranges. The exact controller fitted to a particular machine should always be verified individually. WITTMANN BATTENFELD CONTROLLER COMPARISON ControllerGenerationMain CharacteristicsUNILOG B2EarlierTraditional electronic controlUNILOG B4EarlierDeveloped electronic operating functionalityUNILOG B6Pre-B8Established machine control generationUNILOG B8Introduced 201621.5-inch multi-touch interface and integrated peripheral operationUNILOG B8XLater B8 developmentUpdated hardware and improved processing performance WHAT TO CHECK ON A USED WITTMANN BATTENFELD MACHINE If the machine is equipped with a robot or other Wittmann peripheral equipment, verify whether the integrated control functions are included and fully operational. The availability of compatible hardware alone does not necessarily mean all integration functions are enabled. For machines intended to replace existing equipment, programme compatibility and available communication interfaces should also be checked. 7. CAN DIFFERENT INJECTION MOULDING MACHINE CONTROLLERS USE THE SAME PROGRAMMES? One of the most important questions when replacing an existing injection moulding machine is whether its mould settings can be transferred to another machine. The answer is not always straightforward. WHAT IS STORED IN A MOULD PROGRAMME? Depending on the controller, a stored programme may include: 1. Injection speed profiles 2. Injection pressure limits 3. Holding pressure and time 4. Screw rotation speed 5. Back pressure 6. Barrel temperature settings 7. Cooling time 8. Mould opening and closing movements 9. Ejector movements 10. Core-pulling sequences 11. Robot and peripheral-equipment parameters 12. Process monitoring limits However, a mould programme does not necessarily contain every element needed to reproduce the original process. Some information may depend on the machine’s installed equipment, calibration, software options or separate peripheral controllers. WHY PROGRAMMES MAY NOT BE COMPATIBLE Two machines may differ in: Controller software: File structures and supported parameters can change between versions. Machine configuration: One machine may have additional core pulls, valve-gate controls or hydraulic functions. Injection unit: Different screw diameters or injection-unit characteristics may require process adjustments. Drive technology: Hydraulic, servo-hydraulic and electric machines may respond differently to equivalent parameter settings. Automation: A programme developed for a machine with an integrated robot may not operate correctly on a machine with different automation equipment. PRACTICAL EXAMPLE Suppose a production facility replaces an older ENGEL machine equipped with CC200 with a newer CC300 machine. Even if the replacement machine has similar clamping force and screw diameter, the original mould programme should not be treated as automatically transferable and production-ready. The operator must verify programme compatibility and validate the process on the replacement machine. WHAT SHOULD YOU ASK BEFORE PURCHASING? If retaining existing mould programmes is essential, request confirmation of: 1. Programme export possibilities on the original machine. 2. Programme import or conversion possibilities on the replacement machine. 3. Software-version compatibility. 4. Differences in installed machine equipment. 5. Requirements for process verification after transfer. Ideally, the relevant programme should be tested before the replacement machine enters production. 8. ROBOT COMPATIBILITY: WHY CONTROLLER GENERATION MATTERS Many used injection moulding machines are purchased for production cells that already contain robots, conveyors or other automation equipment. In these situations, controller compatibility becomes particularly important. EUROMAP 12 AND EUROMAP 67 EUROMAP standards define interfaces used in the plastics machinery industry. For robot integration, two important electrical interface designations are EUROMAP 12 and EUROMAP 67. EUROMAP 12 is associated with older electrical interfaces, while EUROMAP 67 provides a more modern interface concept with provisions for safety-related signals. However, compatibility depends on the specific implementation. A machine and robot should not be connected solely because their connectors appear physically compatible. The electrical interface, signal assignments and safety functions must be verified. EUROMAP 77 IS NOT THE SAME AS EUROMAP 67 This distinction is often misunderstood. EUROMAP 67 concerns the electrical interface between an injection moulding machine and handling equipment or a robot. EUROMAP 77 concerns communication between injection moulding machines and manufacturing execution systems. EUROMAP 77 is based on OPC UA technology and was developed to standardise production-data exchange. Therefore, the presence of EUROMAP 77 does not automatically establish robot compatibility. For modern machine-to-robot data communication, EUROMAP 79 is another relevant specification. WHAT SHOULD BUYERS VERIFY? Before buying a machine intended for robotic production, determine: 1. Which robot interface is installed? 2. Is the corresponding connector physically present? 3. Is the interface operational? 4. Are the necessary software functions enabled? 5. Does the interface support the required signals? 6. Is additional hardware required? 7. Can the existing robot be integrated safely? Important: Robot interface modifications and safety-related integration must be carried out and validated by qualified personnel. 9. HOW TO IDENTIFY A CONTROLLER ON A USED INJECTION MOULDING MACHINE If you are evaluating a machine without complete documentation, identifying its controller may require several steps. STEP 1: EXAMINE THE OPERATING PANEL The control panel often provides the first indication of the controller family. Look for: 1. Manufacturer and controller markings 2. Display shape and size 3. Physical buttons and keyboards 4. Rotary operating elements 5. Touchscreen design 6. Arrangement of movement controls For example, ENGEL CC300 is particularly recognisable because of its e-move operating concept. ARBURG GESTICA features a distinctly modern operating-panel design compared with many earlier SELOGICA configurations. However, appearance alone should not be considered definitive proof of the exact software or hardware version. STEP 2: CHECK THE MACHINE DOCUMENTATION The original operating instructions, electrical documentation and machine specifications may identify the controller. If the documentation is incomplete, the machine serial number can help the manufacturer identify its original configuration. STEP 3: FIND THE SOFTWARE INFORMATION Many controllers provide a system-information or service screen containing technical identification details. Where available, record: 1. Controller designation 2. Software version 3. Hardware version 4. Relevant identification numbers 5. Installed options The exact menu location varies by manufacturer and software version. STEP 4: CHECK WHETHER THE CONTROLLER WAS UPGRADED A machine’s current controller may not be the one originally installed. Signs of modernisation may include additional documentation, changed hardware or manufacturer upgrade records. Do not assume an upgrade has occurred merely because the operating panel looks newer than the machine. Request confirmation. STEP 5: ASK THE MANUFACTURER When precise identification is required, provide the manufacturer with: 1. Machine serial number 2. Production year 3. Machine model 4. Photographs of the control panel 5. Available controller information 6. Any documented modifications This is particularly useful when checking electronic spare parts or programme compatibility. 10. USED INJECTION MOULDING MACHINE CONTROLLER INSPECTION CHECKLIST Before purchasing a used injection moulding machine, controller functionality should be assessed as part of the overall machine inspection. The following checks can help identify potential problems. Inspection ItemWhat to VerifyWhy It MattersController identificationExact controller and software versionHelps determine compatibility and supportDisplayStable image and readable informationDisplay replacement may be expensiveOperating elementsButtons, switches and touch functions respond correctlyFaults can affect daily operationMachine startupController starts without unexplained errorsMay reveal electronic or storage problemsAlarm historyReview available alarms and diagnostic informationCan reveal recurring issuesProgramme storageSave and retrieve a test programmeConfirms basic data-management functionalityData backupDemonstrate supported backup procedureEssential for recovery after failuresCommunication interfacesVerify required connections and optionsImportant for automation and MESIntegrated peripheralsDemonstrate communication with connected equipmentHelps identify missing functionalityDocumentationObtain operating and electrical manualsImportant for maintenanceService supportConfirm support for exact controller versionHelps assess future repair optionsController modificationsCheck upgrade and repair historyReveals changes from original configuration HOW TO TEST PROGRAMME STORAGE A useful inspection includes demonstrating that a programme can be stored, retrieved and retained after a normal restart. If the machine supports external backups, ask for a demonstration using the procedure specified by the manufacturer. Never assume that saving a programme internally is equivalent to having a complete system backup. A mould-setting file may not contain the controller software, machine calibration data or other information required after a major electronic failure. WHAT ABOUT BACKUP BATTERIES? Some older industrial controllers use batteries to retain certain data or system information. However, the presence, type and function of such batteries depend on the actual hardware. A controller should not be assumed to use battery-backed memory solely because it is old. If relevant, confirm the manufacturer’s maintenance instructions and whether any backup battery requires replacement. WHY TESTING ONLY THE DISPLAY IS NOT ENOUGH A controller may start successfully and display its menus while other functions remain defective. A meaningful inspection should include operation of the machine under appropriate conditions. Where possible, the seller should demonstrate a representative production cycle and the relevant controller functions. Such tests must be performed by qualified operators following the machine’s safety instructions. 11. ARE OLDER INJECTION MOULDING MACHINE CONTROLLERS STILL WORTH BUYING? An older controller does not automatically make an injection moulding machine a poor investment. The suitability of a machine depends on the intended application. For example, a well-maintained hydraulic machine used for a stable, straightforward production process may not require the newest graphical interface or advanced MES connectivity. Conversely, a production facility relying on extensive automation, frequent mould changes and centralised production monitoring may benefit significantly from more modern control technology. WHEN AN OLDER CONTROLLER MAY BE SUFFICIENT 1. The production process is relatively straightforward. 2. The machine is mechanically sound. 3. The controller operates reliably. 4. Required spare parts and service support are available. 5. Existing automation is compatible. 6. Programme management meets production needs. WHEN A NEWER CONTROLLER MAY OFFER ADVANTAGES 1. Frequent mould changes are required. 2. Complex production sequences must be configured. 3. Advanced automation is used. 4. Centralised process monitoring is important. 5. Production data must be exchanged with other systems. 6. Improved operator ergonomics are a priority. The condition and suitability of the individual machine remain more important than the controller generation alone. 12. QUICK REFERENCE: CONTROLLER GENERATIONS BY MANUFACTURER The following table summarises the main controller families discussed in this guide. ManufacturerEarlier ControllersIntermediate ControllersLater ControllersARBURGEarlier electronic systemsSELOGICAGESTICAENGELCC100CC200CC300 / CC300 plusKraussMaffeiMC1 / MC2 / MC3MC4 / MC5MC6DemagNC4NC5NC5+Wittmann BattenfeldUNILOG B2 / B4UNILOG B6UNILOG B8 / B8X This comparison is intentionally simplified. It does not include every controller revision, regional variant, optional interface or software update. A commercial controller designation identifies a family of technology, not necessarily the exact capabilities of an individual machine. 13. FREQUENTLY ASKED QUESTIONS CAN I DETERMINE THE PRODUCTION YEAR OF A MACHINE FROM ITS CONTROLLER? Not reliably. Controller introduction dates provide useful historical information, but manufacturers often use several control generations simultaneously. Machines may also receive upgrades during their service life. The machine serial number and manufacturer documentation are more reliable sources. DOES A TOUCHSCREEN MEAN THE CONTROLLER IS NEWER? Not necessarily. Touchscreen technology has been used in industrial machinery for many years. The presence of a touchscreen does not establish the exact controller generation or production year. CAN AN OLD CONTROLLER BE REPLACED WITH A NEWER ONE? Sometimes. Certain manufacturers offer dedicated upgrade programmes, such as KraussMaffei’s smart MC6 upgrade for selected machines. However, a controller retrofit may require changes to hardware, software, electrical systems and safety-related components. The feasibility and cost must be evaluated individually. ARE CONTROLLERS FROM DIFFERENT MANUFACTURERS COMPATIBLE? Not directly. Each manufacturer uses its own control architecture and software environment. Standardised interfaces can enable communication with external systems, but this does not mean that controllers or mould programmes are interchangeable between manufacturers. CAN I CONNECT A MODERN ROBOT TO AN OLDER INJECTION MOULDING MACHINE? Potentially, yes. Compatibility depends on the available interfaces, required signals, control functions and safety requirements. Additional interface hardware or modifications may be necessary. IS CC300 BETTER THAN CC200? CC300 offers a more modern operating concept and additional capabilities. However, whether it is the better choice depends on the application, machine condition, automation requirements and available support. A well-maintained CC200 machine may still be suitable for many production tasks. IS GESTICA BETTER THAN SELOGICA? GESTICA provides a more modern operating interface and advanced assistance functions. However, SELOGICA remains a capable control family, and the actual functionality of an individual machine depends on its specific configuration. DOES THE NEWEST CONTROLLER INCREASE PRODUCTION SPEED? Not automatically. Cycle time depends on many factors, including machine mechanics, drive systems, mould design, processing conditions and material properties. A more advanced controller may support optimisation, monitoring or faster internal processing, but it does not guarantee a shorter cycle. 14. FINAL THOUGHTS: THE CONTROLLER IS ONLY ONE PART OF THE MACHINE Understanding controller generations can reveal important differences between injection moulding machines that otherwise appear similar. A controller can influence operating convenience, automation possibilities, process monitoring and long-term maintenance. But there is no universally best controller for every production environment. When evaluating a used injection moulding machine, consider the controller together with the machine’s mechanical condition, specifications, maintenance history and intended application. Most importantly, identify the exact installed system rather than relying on the machine’s age or general model designation. At BASTA MACHINES, we specialise in buying and selling used injection moulding machines and other industrial equipment. Our goal is to help customers make informed decisions by providing clear information about machine specifications, configurations and available equipment. Looking for a used injection moulding machine? Explore our available machinery at www.bastamachines.com [http://www.bastamachines.com] or contact our team to discuss your requirements. RELATED READING How to Read Injection Moulding Machine Model Numbers: A Beginner’s Guide [https://www.bastamachines.com/en/blog/how-to-inspect-a-used-injection-moulding-machine-before-buying-BLG25003] Not sure what the numbers in an ARBURG, ENGEL or Demag model designation mean? Our related guide explains how to interpret injection moulding machine model numbers and understand important technical specifications. Sources 1. ARBURG – Company History and Controller Development Official ARBURG publication documenting the introduction of SELOGICA in 1992 and GESTICA in 2016, including the development of the ALLROUNDER range. ARBURG Today 81/2023 – Company History (PDF) 2. ENGEL – CC300 and CC300 plus Control Systems Official manufacturer information covering controller functionality, operating concepts, ergonomics, the e-move system and upgrade possibilities from CC300 to CC300 plus. ENGEL – Injection Moulding Machine Controllers 3. KraussMaffei – From MC1 to MC6 Control with smartCube Official technical article documenting the development of KraussMaffei controllers since 1980, including major technological milestones, touchscreen development, connectivity and smartCube integration. KraussMaffei – Controller Generations Explained 4. KraussMaffei – Smart MC6 Control Upgrade Official manufacturer documentation explaining controller modernisation options for selected injection moulding machines equipped with MC3-F and MC4. KraussMaffei – Retrofit & Modernisation 5. WITTMANN BATTENFELD – UNILOG B8 Controller Official manufacturer publication introducing the UNILOG B8 generation at K 2016 and explaining its operating concept and integration capabilities. WITTMANN Innovations 4/2016 (PDF) 6. WITTMANN BATTENFELD – UNILOG B8X Controller Official technical specifications describing the UNILOG B8X control system, including its touchscreen interface, machine-control functions and available features. WITTMANN – EcoPower B8X Technical Documentation (PDF) 7. WITTMANN BATTENFELD – Control Software and Assistance Functions Technical report describing the Quick Setup function and advanced process monitoring available within the UNILOG B8 and B8X control generations. WITTMANN – Innovations in HiQ Application Software 8. EUROMAP – Technical Recommendations Official European industry standards covering electrical interfaces between injection moulding machines and robots, including EUROMAP 67. EUROMAP – Technical Recommendations 9. EUROMAP 77 – Injection Moulding Machine to MES Communication Official specification describing standardised data exchange between injection moulding machines and manufacturing execution systems using OPC UA. EUROMAP 77 – Official Specification 10. EUROMAP 79 – Injection Moulding Machine to Robot Communication Official technical specification describing standardised data communication between injection moulding machines and robots. EUROMAP 79 – Official Specification
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Hydraulic vs. Electric vs. Hybrid Injection Molding Machines
Jun 10, 2025
Ing. Andrea Balajová
When choosing an injection molding machine, one of the most important decisions is selecting the right drive technology: hydraulic, electric, or hybrid. Each type has its own advantages, limitations, and ideal applications. Understanding these differences can help manufacturers improve efficiency, reduce operating costs, and choose the right machine for their production needs. In this article, we’ll explain the key differences between hydraulic, electric, and hybrid injection molding machines, their advantages, and how to choose the best option for your business. HOW DRIVE TECHNOLOGY IMPACTS INJECTION MOLDING PERFORMANCE The main difference between hydraulic, electric, and hybrid injection molding machines lies in how their movements are powered and controlled. Hydraulic machines use oil-driven systems to control clamping, injection, and other movements. Electric machines rely on servo motors for precise control of each axis. Hybrid machines combine both technologies, using electric drives for precision and hydraulics for power. This difference directly affects energy consumption, precision, maintenance requirements, and overall production efficiency. HYDRAULIC INJECTION MOLDING MACHINES Hydraulic injection molding machines are the traditional and most widely used type in the industry. They are known for their robustness, reliability, and ability to handle high clamping forces. Key characteristics of hydraulic machines: • High clamping force suitable for large parts • Lower initial investment compared to electric machines • Strong and durable construction • Suitable for a wide range of applications Hydraulic machines are particularly effective in heavy-duty production, such as automotive parts, large containers, and thick-walled products. However, they also have some limitations: • Higher energy consumption • Lower precision compared to electric machines • Oil maintenance and potential leakage issues • Higher operating noise Despite these drawbacks, hydraulic machines remain a popular choice, especially on the used machinery market, where they offer excellent value for money. ELECTRIC INJECTION MOLDING MACHINES Electric injection molding machines use servo motors to control all movements, providing a high level of precision and repeatability. Key characteristics of electric machines: • High precision and repeatability • Lower energy consumption • Clean operation (no hydraulic oil) • Quiet performance Electric machines are ideal for applications requiring tight tolerances, such as medical devices, electronics, and micro-molding. Advantages in practice: • Reduced energy costs (often 30–70% savings compared to hydraulic machines) • Faster and more consistent cycle times • Better process control and quality stability Limitations: • Higher initial investment • Lower maximum clamping force compared to hydraulic machines (in some cases) • Higher sensitivity to environmental conditions Electric machines are becoming increasingly popular, especially in industries where precision and cleanliness are critical. HYBRID INJECTION MOLDING MACHINES Hybrid injection molding machines combine the strengths of both hydraulic and electric systems. Typically, they use electric drives for injection and dosing, and hydraulic systems for clamping. Key characteristics of hybrid machines: • Balance between power and precision • Improved energy efficiency compared to hydraulic machines • Better performance than traditional hydraulic systems • Suitable for a wide range of applications Hybrid machines are often used in packaging, automotive, and high-speed production environments where both speed and force are required. Advantages: • Lower energy consumption than hydraulic machines • Higher clamping force than fully electric machines • Faster cycle times in many applications Limitations: • More complex system design • Maintenance may require expertise in both technologies • Higher cost than standard hydraulic machines MAIN DIFFERENCES BETWEEN HYDRAULIC, ELECTRIC, AND HYBRID MACHINES Energy Consumption Electric machines are the most energy-efficient, followed by hybrid machines. Hydraulic machines typically consume the most energy due to constant pump operation. Precision and Repeatability Electric machines offer the highest precision. Hybrid machines provide good precision, while hydraulic machines are less accurate in comparison. Clamping Force Hydraulic machines excel in high clamping force applications. Hybrid machines offer a strong balance, while electric machines may be limited in very high-tonnage applications. Maintenance Hydraulic machines require oil maintenance and monitoring. Electric machines have fewer maintenance requirements but need specialized service. Hybrid machines combine both aspects. Cost Considerations Hydraulic machines have the lowest initial cost. Electric machines require higher investment but offer lower operating costs. Hybrid machines sit in the middle. Typical Applications by Machine Type Hydraulic machines: • Automotive components • Large plastic parts • Industrial applications Electric machines: • Medical devices • Electronics and connectors • Precision parts and micro-molding Hybrid machines: • Packaging (thin-wall containers) • High-speed production • Multi-purpose manufacturing BRANDS AND MACHINE TYPES Different manufacturers are known for their strengths in specific machine types. Hydraulic and hybrid specialists: • Engel (duo, victory) • KraussMaffei (CX, GX) • Haitian (Mars series) Electric machine specialists: • Sumitomo (SHI) Demag (IntElect) • Fanuc (Roboshot) • Nissei (NEX series) Many modern manufacturers offer all three technologies, allowing customers to choose based on application and budget. When to Choose Hydraulic vs. Electric vs. Hybrid Choose a hydraulic machine if: • You need high clamping force • You are working with large or thick-walled parts • You want a lower initial investment Choose an electric machine if: • You require high precision and repeatability • You want to reduce energy consumption • You produce medical or electronic components Choose a hybrid machine if: • You need a balance of power and precision • You want improved energy efficiency without losing performance • You operate in high-speed production environments Conclusion Hydraulic, electric, and hybrid injection molding machines each have their place in modern manufacturing. The right choice depends on your production requirements, budget, and long-term operating costs. Hydraulic machines offer power and affordability. Electric machines provide precision and energy efficiency. Hybrid machines combine the best of both worlds. At BASTA Machines, we offer a wide range of high-quality used injection molding machines, including hydraulic, electric, and hybrid models from leading brands. Whether you are looking for a cost-effective solution or a high-performance machine, we can help you find the right option. Looking for a reliable, ready-to-run machine? 👉 Explore our stock of used injection molding machines [https://www.bastamachines.com/en/machines/c/plastic-machines-2000/s/injection-moulding-2001?sorting=latestAdditions&page=1] or contact our team today [https://www.bastamachines.com/en/contact]. If you’d like to better understand how different drive systems work in practice, this video provides a clear overview of hydraulic, electric, and hybrid injection molding machines and their key differences: Watch Differences Between Hydraulic, Electric, and Hybrid Injection Molding Machines [https://www.youtube.com/watch?v=TpzYBKmdk8w]
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Vertical vs. Horizontal Injection Molding Machines: What’s the Difference?
May 2, 2025
Ing. Andrea Balajová
When choosing an injection molding machine, one of the first decisions you’ll face is whether to go for a vertical or horizontal configuration. While both types use the same basic injection molding process, their design and application differ significantly. Choosing the right type can improve efficiency, reduce costs, and ensure better product quality. In this article, we’ll explain the key differences between vertical and horizontal injection moulding machines, their advantages, and when each type is the better choice. HOW MACHINE ORIENTATION AFFECTS YOUR PRODUCTION The main difference between vertical and horizontal injection molding machines lies in their orientation. This may seem like a simple design variation, but in reality, it has a major impact on production efficiency, automation, and part quality. In horizontal injection molding machines, the mold opens sideways, allowing finished parts to be automatically ejected, often directly onto a conveyor belt. This makes horizontal machines ideal for high-volume production and fully automated manufacturing environments. In vertical injection molding machines, the mold opens upward and downward. This allows operators (or automation systems) to easily place inserts into the mold before injection. Gravity helps keep inserts in position, which is critical for precision applications such as overmolding and insert molding. HORIZONTAL INJECTION MOLDING MACHINE In these machines, the clamping unit and injection unit are aligned horizontally. This setup is widely used for high-volume production and standard plastic parts such as packaging, automotive components, and household products. Key characteristics of horizontal machines: • Easy automation and integration into production lines • Suitable for large parts and high clamping forces • Gravity causes parts to fall out automatically after ejection • Ideal for fast cycle times and mass production Horizontal machines are the industry standard because they are highly versatile and efficient for most applications. They are also easier to scale in automated environments. VERTICAL INJECTION MOLDING MACHINE Vertical injection molding machines operate with the clamping unit in a vertical position. This design is particularly useful for insert molding, where components such as metal parts, connectors, or electronics need to be placed into the mold before injection. Key characteristics of vertical machines: • Ideal for insert molding and overmolding • Inserts can be placed easily using gravity • Compact footprint compared to horizontal machines • Often used with rotary tables for higher productivity Vertical machines are commonly used in industries like electronics, automotive connectors, medical devices, and cable assemblies. ROTARY TABLES, SHUTTLE TABLES AND SPECIAL CONFIGURATIONS IN VERTICAL MACHINES One of the biggest advantages of vertical injection molding machines is the ability to integrate special configurations that significantly improve productivity and process stability. The most common solution is the rotary table (rotary platen). A rotary table typically has two or more stations. While one side of the machine is in the injection phase, the operator (or robot) can safely load inserts or remove finished parts on the other side. Once the cycle is complete, the table rotates, and the process continues without stopping the machine. This setup offers several key benefits: • Reduced idle time and higher overall productivity • Increased operator safety • Consistent cycle times in insert molding applications In addition to rotary tables, vertical machines often use: • Shuttle tables (sliding tables) for larger or heavier inserts • Tilt tables for ergonomic loading of complex parts • Multi-station rotary systems for high-volume insert molding In practice, rotary table machines are widely used in automotive (connectors, sensors), electronics (cable overmolding), and medical applications. For used machinery buyers, machines with rotary tables are highly valuable, but it is important to check wear on the indexing mechanism and table alignment. MAIN DIFFERENCES BETWEEN VERTICAL AND HORIZONTAL MACHINES Orientation Horizontal machines operate side-to-side, while vertical machines operate top-to-bottom. This affects how parts are handled and how the machine fits into production. Automation Horizontal machines are easier to automate fully, especially in high-volume production lines. Vertical machines often require manual or semi-automated insert placement, although automation is also possible with rotary tables or robots. Applications Horizontal machines are best for standard plastic parts and high-output production. Vertical machines excel in insert molding and applications where precision placement of components is required. Floor Space Vertical machines typically take up less floor space, making them suitable for smaller production areas. Horizontal machines require more space but offer higher throughput. Part Handling In horizontal machines, parts are ejected automatically using gravity. In vertical machines, parts may remain in the mold and need to be removed manually or by automation. DIFFERENCES IN TECHNICAL PARAMETERS BETWEEN VERTICAL AND HORIZONTAL MACHINES Although vertical and horizontal injection molding machines perform the same core function, their technical parameters and typical configurations differ significantly in practice. Clamping Force Horizontal injection molding machines are available in a much wider range of clamping forces, from small machines (around 50 tons) up to very large systems exceeding 3000 tons. They are the standard choice for large parts and high-pressure applications. Vertical injection molding machines are typically found in the range of 20 to 500 tons, although some larger models exist. Most insert molding applications do not require extremely high clamping force, which is why vertical machines are generally smaller. Shot Size and Injection Units Horizontal machines usually offer larger shot sizes and more powerful injection units, making them suitable for thicker parts and larger molds. Vertical machines are often optimized for precision rather than volume, with smaller shot capacities. Mold Size and Accessibility Horizontal machines allow easier handling of large molds using cranes and automation. Vertical machines, on the other hand, provide better access to the mold area for insert placement, which is critical in manual or semi-automated processes. Cycle Time and Productivity Horizontal machines typically achieve shorter cycle times in fully automated production. Vertical machines may have slightly longer cycles due to insert handling, unless equipped with rotary or multi-station systems. From a practical standpoint, buyers of used machines should always compare not only tonnage but also tie-bar spacing, platen size, injection capacity, and compatibility with existing molds. BRANDS AND HOW TO IDENTIFY VERTICAL VS. HORIZONTAL MACHINES Different manufacturers specialize in different types of injection molding machines, and understanding brand positioning can help when searching for used equipment. Horizontal machine specialists Most major European and Japanese brands focus heavily on horizontal injection molding machines, including: • Arburg (Allrounder series) • Engel (e-motion, duo, victory) • KraussMaffei (CX, GX series) • Sumitomo (SHI) Demag (IntElect, Systec) Vertical machine specialists Some brands are known specifically for vertical injection molding machines and insert molding solutions: • Engel (vertical series, insert machines) • Arburg (vertical Allrounder V series) • TOSHIBA / Shibaura Machine (vertical insert machines) • Nissei (vertical FN series) • Multiplas and other Asian manufacturers Vertical machines are typically labeled differently. You may see designations such as: • “V” or “Vertical” in the model name (e.g., Arburg Allrounder 375 V) • “Insert” or “Rotary Table” in the specification • Specific series names dedicated to vertical configurations In contrast, horizontal machines are often identified by standard series names without special designation, as they are the default configuration. Typical tonnage ranges by type • Horizontal machines: 50 – 3000+ tons (most common: 100 – 800 tons) • Vertical machines: 20 – 500 tons (most common: 50 – 200 tons) Vertical machines are less common on the secondary market, especially with rotary tables, which makes them more valuable but also more application-specific. PRACTICAL INSIGHTS FROM PRODUCTION AND MACHINE SELECTION From a practical manufacturing perspective, the choice between vertical and horizontal machines is rarely just about orientation. It is about the entire production concept. Insert stability In vertical machines, gravity helps hold inserts in place, reducing the risk of movement during injection. In horizontal machines, inserts often require additional fixing systems, magnets, or robotic placement. Operator dependency Vertical machines are often more operator-dependent, especially in manual insert loading. This can introduce variability if the process is not properly controlled. Automation (rotary tables, robots) helps reduce this risk. Maintenance considerations Rotary tables and special mechanisms require regular maintenance. Worn bearings, misalignment, or indexing issues can affect precision and cycle time. When buying used vertical machines, these components should be carefully inspected. Flexibility vs. productivity Horizontal machines are typically optimized for maximum output and repeatability. Vertical machines offer higher flexibility for complex parts but may sacrifice some throughput unless properly automated. WHEN TO CHOOSE VERTICAL VS. HORIZONTAL Choose a horizontal machine if: • You need high-volume production • Your parts are large or require high clamping force • You want fully automated production lines • You produce standard plastic components Choose a vertical machine if: • You are working with inserts (metal, electronics, connectors) • Your process requires manual or precise placement of components • You need a compact machine footprint • You are producing smaller, more complex assembled parts CONCLUSION Both vertical and horizontal injection molding machines have their place in modern manufacturing. The right choice depends on your production goals, part design, and level of automation. Horizontal machines offer speed, efficiency, and scalability, making them ideal for mass production. Vertical machines provide flexibility and precision, especially for insert molding and specialized applications. At BASTA Machines, we offer a wide range of high-quality used vertical and horizontal injection molding machines from leading brands. Whether you need a machine for high-volume production or specialized applications, we can help you find the right solution for your business. If you’d like to see how a rotary table works in a vertical injection molding machine, this video clearly demonstrates the process and shows how it improves productivity and operator efficiency: Watch Rotary Table in Vertical Injection Molding [https://www.youtube.com/watch?v=vd6fpf4Lrtg] Looking for a reliable, ready-to-run machine? 👉 Explore our stock of used injection moulding machines here [https://www.bastamachines.com/en/machines/c/plastic-machines-2000/s/injection-moulding-2001?sorting=latestAdditions&page=1] or get in touch with our team [https://bastamachines.com/contact].
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Why Brand Matters: Best Brands for Used Injection Molding Machines
Apr 22, 2025
Ing. Andrea Balajová
When buying a used injection molding machine, one of the most important factors to consider is the brand. The brand not only indicates the machine’s original quality but also impacts availability of spare parts, ease of maintenance, service support, and resale value. Choosing a trusted brand can significantly reduce risks and ensure a longer, more productive life for your equipment. In this article, we’ll explain why the brand matters and highlight some of the best-known names in the injection molding industry. WHY DOES BRAND MATTER IN USED MACHINERY? Not all injection molding machines are created equal. Brands differ in design quality, durability, technological innovation, and support networks. When purchasing used equipment, reliability becomes even more important, because older machines may have wear and require parts or servicing. Established brands often provide better long-term value, even if the initial investment is slightly higher. Choosing a reputable brand ensures: • Easier access to spare parts • Availability of technical documentation • Better machine performance over time • Higher resale value if you upgrade later • Access to trained service technicians and OEM support TOP BRANDS FOR USED INJECTION MOLDING MACHINES ARBURG Arburg is one of the most respected names in the plastics industry. German-made Arburg machines, such as the Allrounder series, are known for precision, reliability, and strong after-sales support. Their modular design also makes it easier to customize machines for different applications. Arburg’s commitment to innovation includes energy-efficient systems and Industry 4.0 integration, making even older models highly adaptable to today’s production requirements. Their worldwide service network ensures that customers can receive support and spare parts quickly. ENGEL Another leading brand from Austria, Engel is famous for its innovative technology and energy-efficient designs. Engel’s fully electric e-motion and hybrid duo series are excellent choices for those looking for high-speed and high-precision molding. Engel machines are built with a focus on reducing cycle times and increasing repeatability. The company also invests heavily in research and development, ensuring that even older machines offer technological features that stay competitive in modern production environments. KRAUSSMAFFEI KraussMaffei machines are known for their rugged construction and advanced process technologies. Their hydraulic and hybrid systems are popular in automotive, packaging, and medical industries. Used KraussMaffei equipment often remains highly productive even after many years. Many KraussMaffei machines are designed with modular systems, allowing manufacturers to upgrade specific components instead of replacing entire machines. This flexibility enhances the long-term value and performance of used models. DEMAG Now operating as Sumitomo (SHI) Demag, Demag injection molding machines are known for their strong clamping units and high-speed performance. The older Ergotech models are widely used and respected for their reliability and serviceability. Now operating as Sumitomo (SHI) Demag, Demag injection molding machines are known for their strong clamping units and high-speed performance. The older Ergotech models are widely used and respected for their reliability and serviceability. Demag machines are particularly appreciated for their robust mechanical design combined with efficient hydraulic systems, making them an excellent choice for both thin-wall and precision molding applications. ZHAFIR / HAITIAN Zhafir and Haitian are major players from Asia, offering excellent value for the price. Their electric and hybrid injection molding machines have gained popularity for being cost-effective without sacrificing much in terms of quality, especially for high-volume production environments. Haitian focuses on building machines that are easy to maintain and operate, offering strong customer support and fast parts delivery worldwide. Zhafir’s all-electric Venus series, for example, is highly regarded for energy efficiency and precision. NEGRI BOSSI An Italian brand with a long tradition, Negri Bossi is known for innovation in two-component and multi-material molding. Their machines often offer flexible configurations and competitive pricing, making them a strong choice for custom applications. Negri Bossi machines are built with a focus on user-friendliness and operational efficiency. Their CANBIO and VECTOR series provide reliability and adaptability, ideal for manufacturers producing complex parts in demanding sectors. BATTENFELD Before its merger into Wittmann Battenfeld, Battenfeld was a leading European producer of molding machines. Older Battenfeld models are praised for their robust design and ease of maintenance. Wittmann Battenfeld continues to build on this legacy with modern, energy-efficient machines. Classic Battenfeld machines, such as the TM and HM series, are still widely used in many production plants, known for their simplicity, reliability, and low operational costs. SUMITOMO (SHI) DEMAG A combination of Japanese precision and German engineering, Sumitomo (SHI) Demag offers some of the best fully electric and hybrid injection molding machines in the world. The IntElect and Systec series are well-regarded for their speed, accuracy, and low energy consumption. Sumitomo’s emphasis on electric machine technology provides manufacturers with solutions that minimize downtime and maximize precision, particularly in industries like medical device production and electronics. WITTMANN Primarily known for automation and robotics, Wittmann (through Wittmann Battenfeld) also produces high-quality injection molding machines. Their SmartPower and EcoPower series combine compact design with smart technology features. Wittmann’s strong integration between machines, robots, and peripherals offers manufacturers complete production cells from a single source, improving production efficiency and reducing compatibility issues. FERROFORMATIC Based in Europe, Ferromatic was a strong brand that merged into Milacron. Many older Ferromatic machines are still highly functional and appreciated for their durability and consistent performance, especially in packaging and general industry. Ferromatic models are often sought after in the secondary market for their robust hydraulic systems and versatility across a range of applications. BOY German manufacturer BOY specializes in smaller tonnage injection molding machines. Their compact machines are highly reliable, making them a preferred choice for small part production and insert molding operations. BOY machines are designed to operate efficiently in smaller spaces and with lower energy consumption, offering high precision and excellent repeatability for micro-molding and prototyping applications. Other Notable Brands Besides the brands mentioned above, other well-regarded names include Toshiba, Nissei, JSW (Japan Steel Works), Milacron, Engel Victory, and Van Dorn. Machines from these manufacturers also hold their value well and offer excellent performance when properly maintained. CONCLUSION When buying a used injection molding machine, brand reputation should be one of your top considerations. Well-established brands not only offer better build quality but also make it easier to find spare parts, technical documentation, and service assistance. Investing in a trusted brand increases your chances of smooth operation, lower maintenance costs, and better long-term productivity. At BASTA Machines, we specialize in sourcing high-quality used machines from top brands like Arburg, Engel, KraussMaffei, Demag, Haitian, and many more. Explore our latest listings or contact us to find the perfect machine for your needs.
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How to Inspect a Used Injection Moulding Machine Before Buying
Apr 16, 2025
Ing. Andrea Balajová
Purchasing a used injection moulding machine can be a smart, cost-effective decision for manufacturers looking to expand capacity or reduce capital expenditure. However, to ensure a safe investment, it’s essential to carry out a thorough inspection of the machine before finalizing the purchase. In this guide, we’ll walk you through the key areas to inspect, what to look out for, and how to evaluate the machine’s condition to avoid surprises after delivery. 1. START WITH DOCUMENTATION AND SERVICE HISTORY Before you physically inspect the machine, ask the seller or dealer for the following: • Complete service records (maintenance intervals, repairs, upgrades) • Original technical documentation (manuals, wiring diagrams, CE certificates) • Previous usage details (type of production, operating hours, material used) A well-documented machine typically indicates that it was maintained properly, and knowing its background helps anticipate potential wear or replacement needs. 2. VISUAL CONDITION: FIRST IMPRESSIONS MATTER Begin with a visual check of the entire machine: • Are there signs of corrosion, oil leaks, or damaged components? • Is the paint original or recently reapplied to hide wear? • Are the tie bars straight and free from scoring? • Are safety guards and covers intact? While cosmetic flaws aren’t always critical, they may suggest how the machine was treated during its lifetime. 3. CHECK THE CLAMPING UNIT The clamping unit undergoes high mechanical stress and must be in good working order. Inspect the following: • Tie bars and platens for wear, cracks, or deformation • Hydraulic cylinders for leaks or inconsistent movement • Toggle or direct-locking system for smooth operation • Lubrication points and whether the system works automatically and consistently Ask to measure the parallelism of the platens — misalignment can damage moulds and affect part quality. 4. INSPECT THE INJECTION UNIT This is the heart of the machine, and small issues here can become costly. Check: • Screw and barrel for wear (look for signs of abrasion, corrosion, or low compression) • Nozzle condition and proper heating • Heaters and thermocouples for consistent temperature control • Check valve function and seal • Plasticizing capacity — is it still within acceptable performance range? If possible, ask to perform a screw recovery or injection cycle and watch for inconsistencies. 5. EVALUATE THE HYDRAULIC AND ELECTRICAL SYSTEMS These systems are complex and should be tested thoroughly. Hydraulic system: • Look for fluid leaks, hose wear, and pump noise • Check pressure settings and response times • Inspect cooling system and filters Electrical system: • Test the control unit (often a brand’s proprietary system like Arburg Selogica or Engel CC300) • Check for fault messages, sensor feedback, and interface responsiveness • Ensure all safety interlocks and emergency stop functions are working properly 6. CONTROL SYSTEM AND SOFTWARE The PLC control is the brain of the machine. An outdated or failing control system can lead to serious operational issues. Check for: • Boot-up times and system responsiveness • Touchscreen or keypad functionality • Backup and restore options for machine settings • Availability of software updates or support from the OEM Older controls may still be functional but harder to service or source parts for. 7. RUN THE MACHINE IF POSSIBLE If the machine is still connected, request a test run under real or simulated production conditions. Watch for: • Startup sequence and cycle time • Pressure and temperature consistency • Alarms, vibrations, or abnormal sounds • Part quality (if mould and material are available) A live test gives you the clearest picture of machine health. 8. ASK FOR A THIRD-PARTY OR DEALER INSPECTION If you’re not experienced in machine assessment, consider hiring an independent technician or request a dealer inspection report. At BASTA Machines, we thoroughly inspect and document every machine before listing it for sale — including photos, videos, and condition reports. 9. CONSIDER SPARE PARTS AND OEM SUPPORT Check: • Is the machine from a major brand (e.g. Arburg, Engel, Demag, Haitian)? • Are spare parts readily available? • Is technical support still offered by the manufacturer? Machines from well-known brands usually offer longer service life thanks to easier sourcing of components. Final Thoughts Inspecting a used injection moulding machine doesn’t require advanced tools — just a sharp eye, a checklist, and a bit of knowledge. With a proper inspection, you reduce risk, increase confidence, and get more value from your investment. Want to see an example inspection? Check out our helpful videos on YouTube or see our machines working: • Injection moulding test run [https://www.youtube.com/shorts/943vMdId4Ys] Or get in touch with us at www.bastamachines.com [http://www.bastamachines.com] — our team is happy to help you choose and inspect the right machine for your needs.
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How to Read Injection Moulding Machine Model Numbers: A Beginner’s Guide
Apr 14, 2025
Ing. Andrea Balajová
If you’re browsing used injection moulding machines, you’ve probably come across listings with model numbers like ENGEL Victory 330/80 Tech, Arburg Allrounder 470C 1000-290, or Demag Ergotech 500-2000 System. While these combinations of numbers and letters might seem cryptic at first, they actually follow specific naming conventions that provide valuable information about the machine’s capabilities. In this beginner’s guide, we’ll show you how to decode injection moulding machine model numbers so you can make more informed decisions when buying. 1. WHY MODEL NUMBERS MATTER Model numbers aren’t random. They typically include data about: • Clamping force • Screw diameter • Machine series or generation • Optional features or technologies Understanding what each part of the model number represents helps you quickly identify whether the machine matches your production needs — without diving deep into full technical specs. 2. BREAKING DOWN COMMON MODEL NUMBER FORMATS BY BRAND Let’s look at how some of the most popular brands format their model numbers: ARBURG EXAMPLE: ALLROUNDER 470C 1000-290 • 470C – Refers to the distance between tie bars or size of the clamping unit (470 mm) • 1000 – The clamping force in kilonewtons → 1000 kN = 100 tons • 290 – The injection unit size (Arburg’s internal code — usually corresponds to a screw diameter of approx. 30 mm - this affects the shot volume and plasticizing capacity of the machine) So this machine has a 100-ton clamping force. ENGEL EXAMPLE: VICTORY 330/80 TECH • 330 – The screw diameter or shot size (depending on series) • 80 – The clamping force in tons • Victory – Refers to the machine series (toggle-free clamping system) • Tech – Indicates a special version or control system Note: ENGEL’s naming may vary depending on regional markets and series, but clamping force and shot size are almost always present. DEMAG EXAMPLE: ERGOTECH 500-2000 SYSTEM • 500 – The clamping force in kN → 500 kN = 50 tons • 2000 – The screw injection pressure unit or size of the injection unit • System – Indicates control system or configuration Demag machines are typically labeled with the clamping unit first, then the injection unit. 3. OTHER IMPORTANT ABBREVIATIONS AND TERMS Many brands use additional abbreviations or suffixes that reflect machine features: • U – Universal or multi-purpose • T – Tie-barless design • H – Hydraulic • E – Electric • V – Vertical (clamping or injection) • C – Compact or classic design • S – Servo-driven • 2K – Multicomponent Example: Arburg 420S 800-350 V → Vertical version, 80 tons clamping force, 35 mm screw 4. WHY THIS MATTERS WHEN BUYING USED MACHINES Used injection moulding machines are often listed only by model name and year. Knowing how to read the model number helps you: • Filter out machines that don’t meet your tonnage or size requirements • Avoid overpaying for a machine that’s too powerful for your product • Communicate clearly with sellers and brokers • Choose the right combination of clamping and injection units At BASTA Machines, we always provide full model names and technical specifications, but understanding how to decode them gives you an edge as a buyer. 5. NEED HELP MATCHING THE RIGHT MACHINE? If you’re unsure how to interpret a specific model or want advice on selecting the right injection moulding machine for your application, our team is here to help. With years of experience in the used machinery market, we can guide you toward the most efficient and cost-effective solution. Contact us at www.bastamachines.com [http://www.bastamachines.com] — and let us help you find the right machine, not just any machine.
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7 Reasons to Buy a Used Injection Moulding Machine
Apr 7, 2025
Ing. Andrea Balajová
In the world of plastic manufacturing, injection moulding machines are the backbone of efficient and precise production. These powerful systems are responsible for creating everything from automotive parts and packaging components to electronics housings and medical devices. When investing in a machine, many businesses face a key question: Should we buy a new injection moulding machine or opt for a used one? At BASTA Machines, we specialize in high-quality used injection moulding machines, and we believe the answer often leans in favor of going second-hand — especially when done right. Here’s why. 1. SIGNIFICANT COST SAVINGS The most obvious reason? Price. A used injection moulding machine can cost up to 50–70% less than a new one, depending on the age, condition, and brand. These savings can be redirected into molds, automation, or raw materials — all of which directly affect your production capacity and profitability. 2. IMMEDIATE AVAILABILITY New machines often come with lead times ranging from several weeks to even months, depending on the manufacturer. In contrast, used machines are usually in stock and ready to ship. This means less downtime and faster scaling of your production line. 3. TRUSTED BRANDS AND PROVEN PERFORMANCE When buying used, you’re often purchasing equipment from well-known manufacturers like Arburg, Engel, Demag, Haitian, Krauss Maffei, or Wittmann Battenfeld. These machines are built to last — and a unit with a strong service history can still deliver years of reliable output. Plus, many used machines come from European factories with regular maintenance logs and service records, giving you additional peace of mind. 4. FLEXIBILITY FOR STARTUPS AND EXPANDING BUSINESSES Used machines offer a lower barrier to entry, making them ideal for: • New businesses entering the plastics industry • Companies expanding their capabilities with limited capital • Specialized runs or short-term contracts where new investment isn’t justified They also allow you to test production ideas or molds before committing to full-scale, high-cost solutions. 5. ECO-FRIENDLY MANUFACTURING CHOICE Purchasing second-hand equipment is a sustainable decision. By extending the life of existing machinery, you help reduce industrial waste and the environmental impact associated with new machine manufacturing. In industries under increasing pressure to meet environmental targets, this is a smart and responsible move. 6. EASY UPGRADE AND COMPONENT REPLACEMENT Modern injection moulding machines — even older models — are often modular and upgradable. You can easily: • Replace control units with newer PLCs • Add robots or conveyors • Retrofit energy-saving features • Replace wear parts like screws, barrels, and heaters This gives you the performance of a newer machine at a fraction of the cost. 7. PROFESSIONAL GUIDANCE AND SUPPORT FROM SPECIALISTS Buying used doesn’t mean buying blindly. At BASTA Machines, we: • Inspect and clean every machine before listing • Provide detailed technical specs and photos • Help you match the right model to your production needs • Support you with logistics and export documentation With the right partner, buying a used injection moulding machine becomes a strategic business decision, not a compromise. FINAL THOUGHTS While new machines may offer the latest tech and factory warranties, used injection moulding machines offer speed, savings, and flexibility — without sacrificing quality when sourced properly. Whether you’re starting out, expanding your line, or just optimizing budget and output, used machinery can be the key to faster growth. Looking for a reliable, ready-to-run machine? 👉 Explore our stock of used injection moulding machines here [https://www.bastamachines.com/en/machines/c/plastic-machines-2000/s/injection-moulding-2001?sorting=latestAdditions&page=1] or get in touch with our team [https://bastamachines.com/contact].
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