Ciject® Injection Equipment Ciject™ Two

CIJECT™ Two- RTM/VRTM Injection Machine

The most sophisticated machine in the range, the Ciject Two is based around a powerful modular touch-screen PLC enabling the addition of a wide range of options and control functions.

The Ciject Two features an unrivalled level of control with simplicity of operation.

Features include:

  • Fully enclosed cabinet with full operator control
  • Mixed output from 0.1Kg up to 10Kg per min (dependant on resin viscosity)
  • Available with mix ratios to suit polyester/vinylester, epoxy or phenolic systems (see options list)
  • Full PID Electronic Pressure Control from –1 bar to 10 bar
  • In-mould pressure sensors (IMPS) can be connected to the machine to enable pressure control based on internal mould pressures
  • Fully automatic open/close mixing head
  • Low volume/high velocity mixing head flush system to ensure simple and quick cleaning with minimum solvent use
  • 20 Litre non-pressurised solvent tank
  • Storage area for original catalyst/hardener container
  • Adjustable umbilical support boom
  • Stainless steel resin drum platform optimised for easy loading of standard resin barrels
  • In-line resin and catalyst filters to allow cleaning without removing loading hose from material
  • Purpose designed resin and 316 Stainless Steel catalyst/hardener pumps for high reliability and simple maintenance. Modular for easy removal
  • Seals designed and tested for service life in excess of 250,000 Kg of resin.
Control System:
  • 110-240V Industrial Omron Microelectronic Modular PLC.
  • 7” Colour HMI touch screen 480x320 resolution with adjustable brightness/contrast.
  • Compact Flash (Type II) slot for data logging in CSV format
  • Intelligent machine program - prevents operator error (e.g. flushing while injecting)
  • 30 Recipes for operator programmes (Unless RFID option 2 specified which has unlimited recipe capacity)
  • Password protection for configuration and programming screens
  • Programmes enable input of injection volume, injection pressure, start and end catalyst/hardener percentages
  • Machine Operation Log Screen records machine actions
  • Average flow rates displayed during injection
  • Automatic recirculation feature with user programmable timers
  • Automated flush sequence
  • Adjustable flush alarm to warn operator if flush has not been carried out
  • Adjustable machine stall warning/alarm
CIJECT™ Two Machine Options
Solvent Level Sensor
  • Non Intrusive Solvent Level Sensor. Detects if level is insufficient for operation. Prevents start-up and warns operator if level is low.
  • Catalyst Level Sensor (Polyester/Vinylester version only)
  • Non-Intrusive capacitive sensor. Detect if level is insufficient in operation.
  • Prevents start-up and warns operator if level is low.
  • Catalyst/Hardener Monitoring System
  • Unique system to monitor catalyst/hardener flow.
  • Alarms to warn of catalyst/hardener over/under pressure with user adjustable setting to warn of irregular flow during recirculation or injection.
  • Catalyst/Hardener and Resin Flow Measurement System
  • A more sophisticated flow sensing system based on gear-type flow meters.
  • Sensors available for both resin and catalyst/hardener pump out-puts.
  • Output displayed graphically and numerically on operator screen.
  • Outputs can be data-logged (if SCADA system is specified). *sensors to be specified to suit required mix ratio and output range.
  • Motorised Catalyst/Hardener Ratio System (MCR)
  • Automatic motorized servo control of catalyst level; linked to recipes.
  • Progressive catalyst injection for automatic control during injection of large components. Allows injection to start at one ratio and progressively increase during the injection to finish at a second ratio.
  • System uses high quality Omron AC servo motor system with digital rotary encoder for continual position monitoring and origin detection.
  • Auto origin function on machine start-up.
  • Radio Frequency Identification (RFID)
  • RFID mould recognition system enables supervisor to program tag attached to mould. Operator scans tag which sets machine injection parameters. Allows unlimited number of moulds to be identified by the machine. Prevents incorrect injection settings.
  • Tags can be attached to mould, are self powered and are highly resistant to damage.
  • This system removes the requirement for an operator to select the correct recipe and allows unlimited numbers of moulds to be instantly recognised by the injection machine.
  • Pre-Injection Vacuum Level Test Facility
  • In-mould pressure monitoring via sequenced injection valve operation. Automatically measures mould vacuum level and provide Pass/Fail feed-back prior to injection.
  • In-line Resin Heater
  • Stainless steel in-line fluid heater with 2KW thermostatically controlled cartridge type elements.
  • Solid State Relay switching reliable operation.
  • Connection to injection machine ‘pump run’ signal to prevent overheating.
  • PID temperature control with over-temperature alarm, adjustable from ambient temperature to 60°C.
  • Dual display output showing actual and pre-set temperature.
  • Note: Machine is rated for maximum material temperature of 80°C
  • Catalyst Return Isolation
  • Actuated isolation valve provides additional security in the event of a mix-head valve failure and prevents catalyst bypass
  • High-Flow Head Option
  • Injection mix-head designed to optimise material flow
  • Robust actuated ball-valve recirculation valves
  • High-Flow Hose Option
  • For use to maximise machine output. Particularly useful when using higher viscosity resins.
  • Large bore resin inlet and feed hoses with suitable filter
  • Standard configuration for connection to IBC (other configurations available on request)
  • Fixed Catalyst Tank
  • Rigidly mounted 10 litre catalyst tank (positioned on rear of machine cabinet)
  • Includes replaceable in-line filter
  • Provides gravity feed to catalyst pump
  • IMPS Input Module - 4 Inputs
  • Additional PLC Module to enable monitoring of and control from 4 additional IMPS sensors
  • On-screen display with graphs
  • Can be recorded and monitored if SCADA option is specified Note: IMPS sensors to be specified and ordered separately
  •  Thermocouple Input Module - 6 Inputs
  • Additional PLC Module to enable monitoring of up to 6 K type thermocouples
  • On-screen display with graphs
  • Temperatures an be recorded and monitored if SCADA option if specified Thermocouple sensors not included with this option. Please contact Composite Integration Ltd for more details.
  • SCADA Data Monitoring Option
  • Citect’ SCADA system to capture and store process data from Ciject machine and present it in PC readable format.
  • Custom interface designed for use with Ciject equipment
  • Graphical process visualisation
  • Historical and real-time trending
  • Alarm management and monitoring
  • Built-in reporting
  • Powerful analysis tools
  • System includes software licence, Ethernet card and all bespoke programming etc.
  • Software/hardware can be configured to suit customer specification including additional input/outputs e.g. thermocouples, pressure sensors etc
  • Please Note: Customer to supply suitable PC with Windows 7 or above (If required, Composite Integration can provide a quotation for a laptop. Please contact Composite Integration Ltd for more details) To facilitate setup the customer will also need to supply a Fixed IP Address and Netmask and Gateway Key
  • Conversion Kits
  • To convert a machine originally configured for use with one resin system to work with another
  • All parts necessary to convert for use with an alternative resin system (available to convert to polyester, epoxy or phenolic)
  • Includes appropriate catalyst/hardener pump
  • Includes alternative resin pump if necessary
  • Includes all necessary instructions pipe-work and connectors
  • Spares Kit
  • Spares Kit containing all necessary service replacement seals for pumps and injection head
  •  Automatic Injection Valve
  • Allows clean and efficient connection between the injection machine and the mould.
  • Can include all necessary hoses, control valve and quick-couple connections (see separate data sheet)
  • IBC Connection Kit
  • Parts kit to connect Ciject Injection machine to IBC resin container
  • Includes male/female Camlock connector, in-line Y filter and connections to fit standard 1” resin feed hose
  • IBC Heater
  • 240 volt flexible heated jacket with quick release buckles to heat 1000L Intermediate Bulk Container.
  • 1000mm x 4400mm (3900mm Heated Length)
  • Switchable upper and lower heat zones (1000 watt each zone)
  • Performance: Water temperature with insulation lid 15 - 80°C in 56 hours
  • Note: Machine is rated for maximum material temperature of 80°C
  • Barrel Heater
  • 240 volt flexible jacket to heat 200 litres barrel to a maximum of 80°C.
  • Silicone insulated heating element with PU covered Polyamide cover.
  • IP 40 Protection and 5 metre connection cable.
  • Note: Machine is rated for maximum material temperature of 80°C
  • Material Holding and degassing tanks
    A range of material holding/ degassing tanks that can be used with Ciject injection equipment (See separate data sheet) The range includes:
  • Resin holding tanks
  • Hardener holding tanks
  • Optional vacuum rated degassing tanks
  • Heating options
  • Stirrer options
  • How to specify / order

    Machine Item/Option NotesPart/option Number
    Ciject Two Injection Machine
    Polyester version 0.5% - 3.5% ratio rangeXE-2000-01
    Epoxy version 2:1 100:12.5 - 100:50 ratio range XE-2000-02
    Epoxy version 1:1100:25– 100:100 ratio rangeXE-2000-03
    Phenolic Version1% - 8% ratio range XE-2000-04
    OPTIONS
    Solvent Level Sensor 05
    Catalyst Level Sensor
    Polyester/vinylester version
    06
    Catalyst Monitor07
    Hardener Monitor
    Epoxy version
    08
    Resin and Catalyst flow metersPolyester/Vinylester version
    09
    Resin and Hardener flow meters
    Epoxy Version
    10
    Motorised Catalyst System (MCR)
    11
    RFID
    12
    Pre-Injection Vacuum Test
    13
    Inline PID Resin Heater
    14
    Inline PID Hardener Heater
    Epoxy version
    15
    Catalyst Return Isolation
    16
    High-flow Head option17
    High-flow Hose option IBC Type 18
    Fixed Catalyst Tank
    Polyester/Vinylester version19
    IMPS input module - 3 input
    20
    Thermocouple monitoring module - 6 input
    21
    SCADA data monitoring
    22
    Conversion KitsKits available to convert machines to process alternative resin types–
    specification and prices on request.
    Options Conversion Kit—Polyester to Epoxy 100:50 XE-2000-CK-01
    Conversion Kit—Epoxy 100:50 to Polyester XE-2000-CK-02
    Conversion Kit—Polyester to Phenolic XE-2000-CK-03
    Conversion Kit– Phenolic to Polyester
    XE-2000-CK-04
    Conversion Kit– Epoxy 100:100 to Polyester
    XE-2000-CK-05
    Conversion Kit– Epoxy 100:50 to Epoxy 100:100
    XE-2000-CK-06
    Conversion Kit– Epoxy 100:100 to 100:50
    XE-2000-CK-07
    Ciject Two Spares KitsPolyester option 0.5% - 3.5% ratio range XE-2000-SK-01
    Epoxy option 100:12.5 - 100:50 ratio rangeXE-2000-SK-02
    Epoxy option 100:25– 100:100 ratio rangeXE-2000-SK-03
    Phenolic option 1%-8% ratio range XE-22000-SK-04
    Automatic Injection Valve See Injection Valve data sheet for full list of configuration options and part numbers
    IBC Connection Kit Resin feed XA-1094
    IBC Heater OptionEpoxy Hardener feedXA-1094-01
    Barrel HeaterXA-1097
    Material holding/degassing Tanks
    See Tank data sheet for full list of configuration options and part numbers

    To specify a machine configuration use the machine part number followed by the required option numbers separated by a hyphen.

    e.g. XE-2000-01-06-11 & XE-20000-SK-01 specifies a Ciject Two Polyester with Catalyst Monitor option and MCR plus the appropriate spares kit.