Oerlikon HRSflow: Hot Runner Solutions for Packaging, Medical Technology and Automotive Applications

“Stargate HRS”: The innovative needle-free hot runner nozzle concept uses a novel mechanical system to open and close the nozzle - (Photo: Oerlikon HRSflow).

Oerlikon HRSflow will present several hot runner applications for the packaging, consumer goods, medical and automotive industries at Fakuma 2026. The focus will be on the mechanically actuated “Stargate HRS” system, the Xp nozzle series for thick-walled transparent cosmetic packaging, and “Glow HRS” for visible component surfaces. Further applications will be demonstrated in live injection molding production at the booths of several partner companies.

According to the supplier, “Stargate HRS” is suitable not only for processing PP and rPP, but also for plastics such as PMMA and ABS. This broadens its range of applications across various market segments - (Photo: Oerlikon HRSflow).

“Stargate HRS” for Different Polymer Classes
Introduced at K 2025, the “Stargate HRS” hot runner nozzle concept uses a mechanically actuated central shut-off and does not require a conventional valve pin. At Fakuma 2026, Oerlikon HRSflow will demonstrate the system not only for applications using polypropylene and recycled polypropylene, but also for processing PMMA and ABS.

The aim is to extend the system’s range of applications to additional market segments. According to the company, the design facilitates color changes and, thanks to targeted cooling, supports shorter cycle times.

Initial users of the system have achieved lower wall thicknesses and component weights as well as shorter cycle times, reports Matteo Badella, Global Sales Director for Packaging, Medical, Consumer Goods and Logistics at Oerlikon HRSflow.

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Xp Nozzle Series for Thick-Walled Cosmetic Jars
For the production of thick-walled, transparent cosmetic packaging, Oerlikon HRSflow is introducing the Xp series of valve gate nozzles. The series has been designed for components with high requirements in terms of transparency and surface quality.

A coordinated thermal control system and a newly developed end-ring design are intended to enable uniform processing at high wall thicknesses. The nozzles are designed for shot weights of up to 70 g and can be used with materials including PET, recycled PET and copolyesters such as PETG, PCTA and PCTG. According to the company, additional materials are currently being tested.

Several cosmetic jars with different geometries will be displayed at the booth. The components are made from Eastman’s Cristal One Renew IM812 copolyester and have wall thicknesses of up to 12 mm. According to the material manufacturer, the recycled content determined using the mass-balance approach can be as high as 100 percent.

In addition to Oerlikon HRSflow, moldmaker Cromes and packaging manufacturer Technicaps were involved in the development.

Direct-Gated Luer-Lock Components
Another application involves the production of a Luer-lock component for medical technology. The precision part is direct-gated and manufactured from LNP ELCRIN W1000JiQ. The PBT offered by Sabic is based on chemically recycled PET and is produced by Guztec Polymers. Alternatively, the component can be manufactured from PEEK for applications with higher thermal or mechanical requirements.

The multi-cavity mold is equipped with “Techflow HRS” valve gate nozzles. External end rings are intended to reduce wear, particularly when processing abrasive, reinforced or flame-retardant thermoplastics. These materials often require high processing temperatures and narrow process windows.

A uniform temperature profile in the hot runner system is intended to support process stability and component dimensional accuracy. It is also designed to facilitate a controlled machine restart following production interruptions.

The mold was supplied by C.P. Stampi. An automatic unscrewing system from Moulding Devup handles demolding of the internal Luer-lock threads.

Visible Parts without Additional Surface Finishing
For visible components made from amorphous thermoplastics, Oerlikon HRSflow will present the compact “Glow HRS” gating solution. The system is designed for direct gating onto high-quality surfaces and is intended to prevent visible halo marks around the gate area.

The objective is to reduce the need for additional finishing steps after injection molding. The technology is aimed, among other things, at automotive interior and exterior applications in which gate locations are situated on visible surfaces.

A scratch-resistant bumper will also be presented, produced using a combined process incorporating a polyurethane coating and a decorative film. Compared with a separate two-stage process, this approach is intended to reduce production time and equipment requirements.

The hot runner system used in the application features nine conical valve gate nozzles and has been adapted to the combination of the two surface technologies. Project partners include Borealis, Cannon, DNP, Engel, Inevo and the Inabata Group.

Applications at Partner Booths
In addition to the exhibits at its own booth, several Oerlikon HRSflow hot runner applications will be shown in live operation at partner companies’ booths.

Fanuc: Cable Holders Made from Glass-Fiber-Reinforced Polyamide
At the Fanuc booth in Hall A7, Booth 7304, cable holders made from PA6.6-GF30 will be produced. The technical small parts have a shot weight of 1.2 g.

The 16-cavity mold is equipped with “Techflow HRS” valve gate technology and Sa-series nozzles. This configuration is designed for processing glass-fiber-reinforced thermoplastics.

A monitoring system records the filling behavior of the individual cavities during the process. Based on this data, process parameters can be adjusted to achieve the most uniform possible mold filling. Cavity Eye, a supplier of cavity pressure measurement technology, is also involved in the application.

Haitian: Transparent Trunk Lighting Strip
A transparent lighting strip for a vehicle trunk will be produced on a Haitian injection molding machine in Hall B1, Booth 1205.

The application uses the servo-electrically driven “Flexflow HRS” valve gate technology. Individual control of the valve pins makes it possible to influence melt flow during mold filling. This is intended to support uniform filling and limit component warpage, particularly in transparent and distortion-sensitive parts.

Wittmann: Closure Cap for an Autoinjector Pen
At the Wittmann booth in Hall B1, Booth 1204, a polypropylene closure cap for an autoinjector pen will be produced.

The application is based on an eight-cavity mold featuring “Multiflow HRS” technology. V-series nozzles with torpedo tips are used. The system is designed to provide uniform melt distribution and a stable production process for medical components manufactured in series.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall A1, Stand 1211

More information: www.oerlikon.com/hrsflow

Oerlikon HRSflow, San Polo di Piave, Italy

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