Companies like Ypsomed that make products to promote healing and good health in people place very high standards on their production. This is why Ypsomed adopted the intelligent fluid management system FLUIDLYNX from MOTOREX a year ago – and ever since has consumed far fewer resources, thereby saving a lot of money.

Ypsomed AG, based in the Swiss town of Burgdorf, is the global leader in developing and manufacturing injection and infusions systems for self-medication and, with almost 40 years’ experience, a proven specialist in diabetes. The company’s name reflects its corporate mission: “ipso” means “self” in Latin, and “med” stands for “medication”. Ypsomed offers products and services that enable patients to administer their own medication in safe and simple ways. The injection and infusion systems and associated services from Ypsomed benefit and improve the lives of millions of people, most of them suffering from diabetes mellitus. The firm’s product portfolio ranges from simple preloaded insulin pens to pens with variably adjustable dosage and an electronic display and to highly complex injectors with multifunction electronics.

The company has been growing rapidly. Over 50 injection molding and assembly systems are now housed in the Burgdorf production building alone. Worldwide, the company employs a workforce numbering over 2,200, and has a global network of production locations, subsidiaries and sales partners. Ypsomed pursues a long-term corporate strategy and, as a company oriented to sustainability, embraces an obligating sense of responsibility towards society. The firm strives to play a pioneering role in its industry in terms of sustainability. With an eye to this goal, Ypsomed meticulously analyzes all of its processes to continuously leverage opportunities for optimizing every detail. A year ago, these efforts led them to take a closer look at fluid management in their in-house tool and mold making operations.

UNITING SUSTAINABILITY WITH INCREASED PRODUCTIVITY

Sustainability plays a decisive role in today’s production industry. So, Martin Held, team leader for soft tooling in Ypsomed’s tool and mold making department, asked himself: “How can we reduce the resources we use in production without forfeiting efficiency?” In his department, injection molds and assembly equipment are manufactured on twelve state-of-the art CNC milling centers. These machined molds and tools are generally made from high-alloy stainless steel, which is very difficult to cut. In addition to machine performance and choosing the right tools, utilizing the best-suited cutting fluid also plays a crucial role in this work. The right cutting fluid can improve product surface quality, extend tool service life, enhance productivity and quality, and lower costs. Achieving these benefits, however, requires keeping the cutting fluid in constant balance and maintaining a constant specified pH value. Up until a year ago, the machine operator on duty thus had to measure the pH value at more or less regular intervals – and then add water or concentrate to the cutting fluid as required. Each intervention took around 20 minutes and, like any human activity, was a potential source of human error. On average, about five cubic meters of used emulsion had to be disposed of every year. If the measuring intervals were too long, requiring addition of a larger quantity of water, the machine lost its thermal balance and, as a result, produced a number of parts that had to be scrapped. Ypsomed, wanting to improve this situation, found the best solution to be the FLUIDLYNX[1] system from MOTOREX.

STEPPING INTO THE DIGITAL AGE

Digitalization is blazing the trail for sustainable production. Thus, smart software monitors all processes in real time, synchronizing and analyzing data. But FLUIDLYNX from MOTOREX takes things one step further: the system regulates and controls itself. Martin Held therefore succeeded in quickly convincing his coworkers and line managers to install this system. The first step was to procure two COOLANTLYNX and connect five milling machines to one of them, and six to the other. One major advantage of the system is that it can be installed in existing machinery with any great effort. It doesn't take up a lot of space, and requires only one power, water, and compressed air connection. Ypsomed opted for connections comprised of fixed piping and flexible hoses. The system measures the concentration, water temperature, pH value and filling level, and independently controls compliance with each of the specified values. This automatic adjustment enhances process reliability, economy, availability, productivity, and quality. The automated operation has enabled Ypsomed to save on cutting fluid concentrate and cut operating costs – and thereby eliminate some five cubic meters of used emulsion. What’s more, these improvements extend the emulsion service life, which directly reduces disposal costs. The working conditions for personnel have likewise also improved as a result of this system. They no longer have to take charge of ensuring the quality of the cutting fluid, and instead enjoy the certainty that optimum quality is provided. What’s more, it’s filtered, aerated, temperature-controlled and free of leakage oil.

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