On the occasion of Plast 2023, the most important Italian event of the sector, Moretto will participate with a stand of 400 sqm at the edition scheduled from 5 to 8 September in Milan. The fair will give the opportunity to know the evolution in the world of plastics processing, a sector that is facing a phase of radical change due to new technologies, renewed consumer trends and the needs of an ever-evolving market.
ENERGY EFFICIENCY SUCH AS A ENGINE DEVELOPMENT
One of Moretto’s strategic development drivers is energy efficiency guaranteed through its products. A long journey in which the awareness of customer needs, the company’s commitment and the development of the necessary technology have combined perfectly to create a virtuous path that has led to innovative solutions, in line with the needs of the current economic context. The manufacturing industry sector has among its highest costs the electricity, and equipping itself with solutions capable of significantly reducing these costs is an indispensable competitive advantage.
The OTX hopper is the result of sophisticated mathematical simulations that allows the analysis of the geometry, fluid dynamics, thermodynamics and material flow of the plastic granule with the support of the super computer Leonardo, an exceptional computer capable of 22 trillion operations per second. OTX ensures a regular material flow, guaranteeing correct drying of each individual granule being processed. In addition, the optimisation of the process parameters has enabled the hopper size, technological airflow and treatment time to be reduced by 40% for the same hourly output. The reduction of hopper size has been possible by the energy efficiency of OTX, which improved by 66% at the same production capacity. Because OTX is not a simple hopper but a concentrate of 7 patents that ensures a perfect execution of the drying process with full control of all working parameters. OTX can be considered a ‘Hopper Machine’ in its own right by virtue of its features.
But the advantages don’t finish here. The use of a smaller hopper allows the application of a smaller dryer. Moretto has developed the HYPER FLOW turbo project capable of generating up to 2,400 mc/h of technological air with the aim of creating a machine capable of using as little energy as possible. As an example, the HYPER FLOW version, available on 17 models, is a revolution of dryer project on the 800 series and the entire X Dryer 20 series range. A 1,200 mc/h generator with side channel pumps in continuous operation consumes 16.5 kW/h. A HYPER FLOW turbocompressor for the same performance consumes 4.8 kW/h, guaranteeing energy savings of 11.7 kW/h and economic savings of € 35,800 per year. This is just the last part of a project development and innovation that have covered over 32 years which can be summed up as following:
- X Technology
- No water for cooling
- Electrical movememt of the exchange valves
- Total energy recovery
- OTX Hopper
- Moisture Meter
- Hyper Flow Turbocompressor
Leonardo Cluster has contributed to this energy efficiency challenge by enabling us to offer customers’ solutions that are indispensable for all companies. Tangible energy efficiency that frees up significant resources for development and growth.
THE HUMAN AT THE CENTRE
Following the signals of the market, Moretto, leader in the research and development of new technologies for plastic processing, has oriented its business model, investing in the Human-Machine relationship, one of the most important levers to be always competitive and innovative. This has allowed the Veneto-based company to consider the centrality of man within its reality for the transition towards the so-called ‘Industry 5.0’. With the previous model of ‘Industry 4.0′, the focus was on digitalization and the interconnection of systems, while now the focus is on the development of technologies that simplify the interaction between human and machine. Humans improve their skills and the effectiveness of their actions by technology, reducing the repetitiveness of operations and improving the user experience. The human being maintains an essential role in planning, organizing and managing production activities with the support of automated machinery and state-of-the-art robots. The full integration of human talent and technology enables the company to produce innovative, state-of-the-art products that meet customers’ needs in terms of quality and reliability.
The central role of human is at the base of Moretto’s philosophy, which for years has endowed its most technologically advanced products with the ethical OMS&P trademark, whose symbol is represented by Leonardo da Vinci’s Vitruvian man, an expression of the values of creativity and genius that also characterize the activity of the Massanzago-based company. These values guided Moretto towards the development of an offer that enhances the creativity and intelligence of human capital, which has always been the driving force behind the company’s innovation and success.
 THE DIGITALIZATION THAT IMPROVES THE AFTER-SALES SERVICE
In addition to the central role of man, the digitalization of processes and services is another cornerstone of Moretto’s business strategy. The continuous evolutions of the modern world, combined with the need to provide customers with a quick response, have accelerated the need to possess digital tools to further improve the service. The after-sales service is a real commitment to customers for Moretto and this is why the company guarantees it worldwide, through trained technicians and specialists. A high level of service is also guaranteed by the use of automated warehouses, management software and online platforms that allow a real-time resolution of ongoing issues.
Part of the process of digital evolution and service improvement is QR Code project, which aims to provide customers with some useful information by supporting them from the very first stages of their purchase. Its functioning is simple and intuitive: using the mobile phone and framing the QR Code on the machine, the user can access a series of services with high added value, such as useful information on the machine, tutorial videos, the list of recommended spare parts and much more.
SUSTAINABILITY AS A STRATEGIC DRIVER OF DEVELOPMENT
The adoption of a production approach based on circular economy principles has steered the activities of the Moretto group over the years. Sustainability and energy saving are an established part of the company philosophy and are developed through technologies that take into account the needs of customers, but also the environment and the community in which we live.
With the aim of reduce its environmental impact, the company has chosen to use only energy from renewable sources in its plants, as evidenced by its participation in Dolomiti Energia’s ‘100% clean energy’ project.
The growing interest around these issues has led Governments and Institutions around the world to rethink the use of plastics, promoting practices and regulations that allow their reuse within a new production process. The plastics sector is making important steps forward on this issue, and Moretto also makes its contribution every day by trying to provide solutions that reduce the use of raw materials from exhaustible resources. The development of equipments suitable for recycling is not only a duty for plastics processors, but also a necessity for customers who demand solutions suitable for both virgin materials and those with high percentages of recycled material.
SOME OF OUR INNOVATIONS AT PLAST
The Plast exhibition will be an opportunity to showcase some of the most innovative solutions dedicated to plastics processing in the world.
Dehumidification is one of Moretto’s strategic segments, thanks to solutions that over the years have satisfied the most demanding customers by combining high technical performance with low energy consumption.
These requirements find their maximum expression in X COMB, the latest addition to the range of dehumidifiers that immediately met the needs of processors thanks to its compact dimensions, which make it suitable for treating small quantities of highly hygroscopic technical polymers. A highly energy-efficient product that is the ideal solution for production-intensive sectors such as medical, optics and electronics.
Very often small details can determine the success of a dehumidification process, where even a small amount of no-dried polymer can compromise the quality of the final moulding. Moisture Meter was created with the intention to completely eliminate this problem, thanks to its ability to detect the percentage of residual moisture in the polymer without the need for off-line sampling. Moisture Meter is able to provide the operator in real time with the moisture value of the plastic granule after drying, allowing the operator to fix the situation if the resin has not been properly treated, “saving” the transformation process. Different versions are available depending on the type of installation and the hourly output of the polymer to be treated.
Another process that requires great precision to achieve a quality product from a technical and aesthetic point of view is dosing.
Moretto has a wide and comprehensive range of blenders, including the DGM Gravix 20, the new gravimetric batch blender developed specifically for high-precision dosing of small percentages of material. The 20 series is built on the model of the Gravix series, but features a renewed design that improves granule flow.
Configurable through a easy touch view and equipped with Modbus RS485, USB and Ethernet connections, it mantains the technical features that have distinguished the Gravix line.
Raw material procurement is a crucial step in plastics processing, which is why storage solutions will play a prominent role on the Plast stand.
Oktobag meets the requirements of processors who want an automatic system for emptying octabins and big bags. The bag is attached by means of 4 gravity grippers which, with a wave-like movement, bring the plastic granule to the centre where a suction probe will take it.
The storage line also includes SILCONTROL, the system designed and developed to control the loading of plastic granules into storage silos. The material, identified via a special barcode reader, is matched to the correct silo by interrogating the database. Thanks to this procedure, SILCONTROL aims to avoid errors, even human errors, in the material loading phase.
The interconnection of machines and the management of large amount of data generated within the plants prompted Moretto to develop MOWIS, the software platform developed in-house for the control and management of processes within the production plant. A modular and self-configurable tool, usable on-site or remotely, which via OPC UA protocol achieves total connectivity between machines, processes, departments and plants and allows the management of highly complex in an optimized and intuitive manner.
Moretto will address many themes at the next edition of Plast, from innovations which aim to enhance the value of man and his work to a digitalization process that has involved all branches of the company, improving the efficiency and response times of customer service.
The solutions shown at the exhibition will embrace all the company’s product lines, from conveying to drying, from dosing to grinding, from thermoregulation and refrigeration to storage. Solutions that must combine customer needs on the one hand, and sustainability goals on the other, which are fundamental for reducing production costs and safeguarding the environment in which we live.
We look forward to seeing you at Stand A81/B82 in Hall 22.
Moretto S.p.A.
Since 1980 Moretto designs and manufactures auxiliary equipment for the plastics industry. Leader in the industrial automation field, Moretto offers solutions for feeding & conveying, dosing, drying, granulation, temperature control, process cooling, storage, integrated system supervision & management of the plastics material. The company has 5 production sites, 8 sales subsidiaries in Germany, Poland, Turkey, Brazil, United States, India, Russia, and China serving customers in more than 70 countries worldwide.
