PlugOne
Advanced development and manufacturing of an innovative integral plunger for the glass industry
Challenge
The main challenges associated with the narrowneck plunger are related to the proper definition of design, conception, and manufacturing strategies, in order to ensure that, in an industrial environment, the cooling of the plunger is as efficient as possible without compromising its mechanical integrity. Currently, the solution consists of introducing cooling tubes inside the plunger, which are cooled by compressed air. However, the fragility of these metallic tubes frequently leads to failure of the molding component during service. In addition to technical issues, material waste and the high production time/costs are also undesirable consequences for the manufacturers of this component.
Solution
The overall objective of PlungOne is to redesign the cooling system of the narrowneck plunger, used in the glass industry, taking into account the implementation of additive manufacturing technologies (for metals) in the production chain of the new plunger, as well as the development of new materials/coatings for its manufacture. The proposed strategy includes conceptual, mechanical, and thermal aspects, with the aim of producing an integral plunger and eliminating the need for cooling tubes, supported by numerical models that accurately simulate the thermal behavior of plungers under real operating conditions.
Objectives, Activities and Results expected / achieved
The work program is structured into eight integrated activities to achieve the project’s objectives. Initially (Activity 1), a global analysis of the glass packaging production process is carried out and strategies for materials, coatings, and manufacturing are defined. This is followed by the development of the case study concept (Activity 2), including sizing, geometries, materials, and processes. Activity 3 focuses on numerical simulations of thermal behavior, which are fundamental for the following phases. In Activity 4, additive manufacturing parameters are defined and tested, and base materials are selected. Activity 5 is dedicated to the development and characterization of coatings (PVD and HVOF). Activity 6 involves the production and testing of prototypes in real service, also assessing the economic impact. Finally, Activities 7 and 8 cover dissemination of results, valorization, project management, and exploitation of intellectual property.
Project Reference
CENTRO2030-FEDER-01464100Funding
Intervention Region
PortugalTotal Investment
1.125.949,60IPN Investment
243.760,00Total Eligible
1.125.949,60IPN Eligible
243.760,00EC Funding – Total
820.196,61EC Funding – IPN
207.196,00Duration
36 MonthsStart Date
2025-01-01End Date
2027-12-31Approval Date
2025-01-02Consortium
INTERMOLDE - Moldes Vidreiros Internacionais, LdaInstituto Pedro Nunes
Instituto Politécnico de Leiria
DRT - Moldes E Plásticos Lda
Associação Para o Desenvolvimento da Aerodinâmica Industrial
Keywords
Thin coatings;Surface engineering;
Additive manufacturing
Glass industry;
Thermal cycles;
Temperature control;
Glass packaging;
Numerical simulation;
Cooling.
