Industrial Machine for
The Quality of LifeHARUO HAGIWARA
YUJI KAMIMURATOSHIKAZU HORIUCHI
HIROFUMI TAKAHASHI

Most products of the Industrial Machinery Division of Mitsubishi Heavy Industries, Ltd. (MHI) are industrial
machines for producing commodities necessary for living. MHI embarked on construction of film manufacturing
plants and food and packing plants in 1950 when the scars of war were still left, and entered upon the injection
molding machine business in 1961. In these three fields, it is required not only to improve the manufacturing speed
and accuracy, but also to remodel the products into human- and environment-friendly products. The major three
products on which the Industrial Machinery Division is engaged are introduced below.

chines, blown film machines, laminating machines, plastic corrugating machines, rubber extruders, oriented tapemanufacturing machines, pelletizers, T dies and otherperipheral devices, through joint development, technical cooperation and independent development. After this,while the distribution revolution was breaking out and
the Japanese economy was rapidly growing, the demand
and use for plastic film products were remarkably increasing and expanding. Then, MHI scaled up anddiversified the extruders and other products to meet therequirements of the times, enhancement of productivity,
energy conservation and environmental protection.

I. Extrusion machines of yesterday, today andtomorrow
1. Introduction
MHI began to construct rayon and cellophane manufacturing plants and manufacture spinning machines
through technical cooperation in 1950. Thus, MHI started
as a textile machine manufacturer supported by the boomof the textile industry. After this, as the customers, textile manufacturers, started plastic film production one
after another, MHI accumulated the plastic film production techniques. In 1959, MHI developed, fabricated andmarketed single screw extruders in cooperation with oneof MHI’s customers in Japan and entered the plastic film
manufacturing plant market.
At present, in the field of polypropylene film that is
the mainstream packaging film, MHI’s film manufacturing machines produce 80% or more of the film in Japanand 20% or more in other countries. For other plastic
materials, MHI’s extrusion machines are used widely to
produce films and sheets for industrial use, for example
food packaging and electronic device manufacturing.
These films and sheets assist us in realizing the ultimate convenience of life in the current consumer society.
The films and sheets including those that are unseen
are closely related to our life.

3. Extrusion machines of today
Recently, the convenience-store industry has grown
to change the life-style, and packaging materials havebeen diversified. Under these circumstances, MHI has
led the packaging material industry in the world as amanufacturer of polypropylene plastic, nylon and polystyrene plastic biaxially oriented film manufacturing
plants.
MHI’s polypropylene plastic biaxially oriented film
manufacturing plants realize a product film width of 8.3
m and an actual molding speed of 450 m/min. MHI supplies plants that have the highest performance in theworld. To win the competition for high molding speedwith a competitive German manufacturer, MHI has improved these plants developing and combining a functionthat enables control of thickness of 8.3-m-long and 19Figs. 1 and 2 ),μ-thick films with an accuracy of 1 to 2% (Figs.
extruder techniques, orientation techniques and urgent
breakage preventive measures. MHI intends to improvethe molding speed, stability, operability and maintainability to develop products that will gain technicalpredominance over other competitors’ products including those in foreign markets.
The scope of application of MHI’s technologies has ex-

2. Extrusion machines of yesterday
After 1955, as the result of postwar development of
the petrochemical industry and expansion of use of plastic products, most of textile manufacturers that were
MHI’s customers started to manufacture plastic film
products. To meet their demands for film manufacturing machines made in Japan, MHI supplied various
products, such as biaxially oriented film manufacturing
plants, cast film production machines, sheeting ma-

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.1 (Feb. 2003)

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Tandem extruder
T dieCasting machine
Longitudinal stretching machine
Control panel

Control panel

Transverse stretching machine

Fig. 2 Non-oriented film production line
Take-off unit
Surface treatment machine
WinderFig. 1 Outline of biaxially oriented film manufacturing plantFig. 3 Examples of oriented film products

Fig. 4 Bird's-eye view of synthetic paper plant

panded to construction of synthetic paper plants andpolyester biaxially oriented film manufacturing plants
for X-ray films through the biaxial orientation technique.
At present, MHI produces molding machines applicable to non-oriented film manufacturing plants for
special films, such as LCD films.
Facing industrial globalization, customers in Japanin a state of deflation intend to continue the film product business by heightening the added value anddiscriminating their products from others against reduction in demand for films. MHI meets their requirements
through its long-term experience in film plant construction and high-performance test equipment including theworld’s only high-speed biaxially oriented film manufacFig. 3
turing test plant (Fig.
3).

including peripheral techniques, such as a technique todiminish the time after the start of operation until production stabilizes. From the viewpoint of customers, MHI
intends to establish techniques to comprehensively improve the productivity and quality through enhancementof safety, operability, maintainability and recovery from
Fig. 4
nonconformance (Fig.
4).
For global environmental protection, MHI is positively
promoting prevention of emission of dioxin and elimination of environmental endocrine disrupters. Usedpackaging films are normally treated as trash and incinerated. Unlike polyvinyl films that cause the problem
of emission of dioxin, polyolefin plastic films including
polypropylene films that MHI has handled mainly for along time do not affect the environment when they areburnt. MHI proposes appropriate equipment forpolyolefin plastic films to customers that will switch thefilm material from polyvinyl to polyolefin. Thus, it contributes toward promoting the environmental
maintenance activities. In addition, since biodegradable
plastics that naturally decompose and return to the soil
after they are discarded are supplied to the worldwide
market, MHI that is a plastic molding machine supplierdesigns the optimum film production systems to assist

4. Extrusion machines of tomorrow
To enhance the competitiveness of plastic films to be
used as packaging materials while globalization of thepetrochemical product market is being accelerated, customers in the world including Japanese customers will
demand for improvement of productivity of plastic film
manufacturing plants. To meet their needs, MHI will
promote establishment of high-speed molding techniques

Mitsubishi Heavy Industries, Ltd.
Technical Review Vol.40 No.1 (Feb. 2003)2

the spread of use of the plastics.
For environmental protection, MHI will develop lateral orientation machine cleaning equipment thatremoves volatile organic substances generated in the film
manufacturing process and develop expanded sheet machines to reduce the weight of sheets to be used for plastic
food containers. MHI will contribute toward supplying
environment-friendly machines.
MHI has embarked on investigation to meet the demand for plastic films that are environment friendly andeasy to use. Films having high barrier properties against
air, gas and water can be manufactured at a low cost by
improving the technique to laminate various plastic layers during film molding. The technique enables toprevent deterioration of food and extend storage life, diminish the conventional manufacturing process andreduce manufacturing cost, and reduce film thickness,thereby decreasing the amount of films to be discarded.
This laminating technique can be finally commercialized
as molding machines through analysis of the fluidity
characteristics of molten plastics in the flow channels
and junctures and prediction and verification of optimum
molding conditions. MHI continues to supply the mostadvanced manufacturing machines to stay in the forefront of development of applications of plastic materials
and films, and actively develops the laminating techniques.

MHI supplies large injection molding machines that
produce bumpers and interior parts of vehicles to many
auto manufacturers and occupies the highest share in thisfield.

2. Injection molding machines of yesterday
The history of MHI started in 1961 in which MHI
entered into a technical tie-up with National Automatic Tool Co., Inc. In the next year, MHI introduced
medium and large injection molding machines thatwere provided with a variable displacement piston
pump and had a mold clamping force of 300 to 1450
ton (TypeI).
In 1984, MHI marketed for the first time small injection molding machines having a high injection power for
precision molding at a mold clamping force of 220 ton orless. Thus, the full line-up from small to ultra-large injection molding machines, was prepared.
Then, MHI has supplied a series of injection molding
machines since 1986. Small sized injection molding mac h i n e s “ M SII ” a n d “ M S III ” s e r i e s u s i n g v a r i a b l e
displacement piston pumps to save energy were introduced. After medium sized injection molding machines“MF series” were introduced, “MG,” “MGII” and “MGIII”

Year

5. Conclusion'60 '61 '62 '63 '64 '65 '66 '67 '68 '69 '70 '71 '72 '73

Needs

As a global plastic film manufacturing plant manufacturer, MHI will improve the convenience of films for
consumers in the world who use plastic films in theirlife. MHI will make every effort to develop new techniques and products from the viewpoint of global
environmental maintenance and contribute to the development of the society through manufacturing highquality plants.

Large size

High speed
Automation

Use of plastic large automobile parts(radiator grilles)
Start of in-plant production
by auto manufacturers

MarkettrendsPeak of demand for large machines
Markets to which
MHI machines are supplied

II. Injection molding machines of yesterday, today
and tomorrow

Golden age of container molding

300,400,600,800,1200,1600,2 700,3 300
225,350,450 to 850
MV225,350,

1. Introduction

MH
450,

Nowadays, plastics are quality-of-life materials andused for daily necessities, cars, home electric appliances,
etc. in all fields of food, clothing and housing. Recently,
plastic parts have been used particularly for IT-related
products, such as DVD players and cell phones. Most of
the products are manufactured with injection molding
machines. In an injection molding machine, a molten
plastic resin is cast into a mold at a high speed and themolding is taken out after the resin cools.
Mitsubishi injection molding machines have been continually updated to meet the diversified customers’ needs
and apply constantly developed plastic resins.

Transitionof
products

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series employing a direct clamping system were developed. “MM,” “MMII” and “MMIII” series that were themost compact medium sized injection molding machines
in the world using a 2-platen clamping mechanism werealso put on the market.
Large sized injection molding machines at which MHI
excels were developed as “MM series.” They were themost compact large sized injection molding machines,
using the same clamping system as that of the medium
sized machines. They were highly appreciated in Japanbecause Japanese factories did not have enough space.

injection molding machines “MMG” series and continually marketed ultra-large sized injection molding
machines “MMIII” series.
In these years, the market of injection molding machine has been at an important juncture to switch fromhydraulic machines to electric machines.
About 70% of small injection molding machines
shipped by Japanese manufacturers are electric machines. To expand the share in this market, MHI produces
Mitsubishi-Fanuc injection molding machines for Japanese customers based on the alliance with Fanuc Ltd.
and exports MEt machines supplied by Toyo Machinery& Metal Co., Ltd. on an OEM basis.
For medium injection molding machines, motorization
has been accelerated. In 2000, MHI introduced “ME series” that show a high injection rate using a toggle
Fig. 5clamping mechanism and Fanuc servo motor. (Fig.
5)
This enabled MHI to remarkably expand the share in
the automobile and home electric appliance fields in Japan. There is a greater demand for electric injection
molding machines also in other countries. So that, it isexpected that MHI will receive more orders.
MHI developed large electric injection molding machines “em” series that were the most compact large

3. Injection molding machines of today
From 1998 to 2002, MHI have supplied midium sized
injection molding machines “MSG” series and large sized

Fig. 5 Appearance of 450EM'74 '75 '76 '77 '78 '79 '80 '81 '82 '83 '84 '85 '86 '87 '88 '89 '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01 '02
Small and precision molding machines Ultra-precision molding machines Transition to electric Injection Molding Machine(cheap and Dichotomization
expensive machines)
Energy conservation and recycling
Energy and resource conservation
Tendency to
Ultra-large machines
High-mix low-volume
heighten added value
Downsizing of machines
FMS
production system
Collective management
Use of plastic automobile bumpers(Toyota and Honda)
Expansion of in-plant production
Weight reduction (expansion of use of plastic parts
and thickness reduction)
Use of incombustible materials
Large-size TVs
for TVs for export

Use of plastic door trims
Increase of use of PET bottles
Spread of personal computers and cell phones
Low pressure molding of large automobile parts

Shift of production of home electric appliances to overseas bases

C/D V/D
Expansion of in-plant production
by home electric appliance
Expansion of use of plastic parts for business and office machines
manufacturers
VTR cassette molding

Increase in demand for LCD panels

Ultra-small MSS (hybrid)

MSS (motor-driven cone screws)

15, 30, 50

15, 30, 50

MS (T)
75,100,150, 220

MRMSV
75, 100, 150, 220

200

80,100,130,160, 240, 290
MSH
MSP
80 to 290450

80,100,130,160, 240, 290

MM

PET

350, 450, 550, 650, 850

1 250

100,130,160, 240, 290

MD350, 550MSG

350 to 850

350, 450

350, 450, 550, 650, 850,1 450

MG550, 650, 850

MMG

350, 450, 550, 650, 850,1 050MF

350 to 850

550, 650, 850,1 050

350,450, 550, 650, 850,1 250,1600

Ultra-large MM

350, 450, 550, 650, 850,1 050

1 300 to 5 000
1 300 to 4 000

em (2-platen electric machines)
650, 850,1 050,1 450

ME (electric machines)

350, 450, 550

Fig. 7 Transition of injection molding machine series

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Technical Review Vol.40 No.1 (Feb. 2003)4

ers becomes a critical issue. MHI will endeavor to develop user support systems using Information
Technologies and expert systems.

5. Conclusion
In the future, transition from metallic products toplastic products will be more increasingly accelerated,and medium and large sized injection molding machines
will be rapidly switched from hydraulic machines to electric machines. As a result, orders for medium and large
sized injection molding machines “ME” and “em” series
will be increased in Japan and other countries.
To survive in the current molding industry, it is necessary to realize high cycle time and energy saving aswell as to improve the product accuracy to win the costcompetition. Under these circumstances, the demand forelectric injection molding machines is growing, and expectations on MHI’s electric machines discriminated fromother manufacturers’ machines are increasing.
In the auto industry in which large sized hydraulicinjection molding machines “MMIII” series, are highly
appreciated, MHI introduced 1450 em (mold clamping
force of 1 450 ton), large sized electric molding machines,
last year. MHI intends to become the world’s top electric
injection molding machine manufacturer in this field.

Fig. 6 Appearance of 1050em

Fig. 6
injection molding machines (Fig.
6) in cooperation withvarious laboratories, such as Nagasaki Research & Development Center. MHI applied for the first time in theindustry a clamping mechanism (2-platen clamping
mechanism) discriminated from the toggle clamping
mechanisms that all competitors employed, and receives
more orders from customers mainly in the auto industry.

4. Injection molding machines of tomorrow
Environment-friendly electric injection molding machines can save 60% or more of energy as compared toconventional hydraulic machines. As a result, the production cost can be reduced, and the defect rate can be
improved remarkably. In the field of ultra-large injection molding machines having a capacity of 1 000 tons or
more, there is an increasing demand for development ofelectric injection molding machines.
To meet this demand, MHI has embarked on development of ultra-large electric injection molding machinesthat occupy as little space as possible. These models areprogressive next-generation electric injection molding
machines developed based on the 2-platen clamping
mechanism highly appreciated in the auto industry and
MHI’s wide-range techniques, for example the power electronics techniques and tribology techniques. MHI ismaking every effort at developing the world’s largest
2000 ton class electric injection molding machines usinglarge-capacity, high-performance servo motors and MHI’s
unique drive control technique to place the machines on
the market in 2003.
Since there is a tendency toward plastic products inthe auto industry, module products attract attention as
substitutes for metallic parts to reduce the weight fordevelopment of electric cars in the future.
In this respect, MHI is promoting development of thesurface reforming technique in plastic foaming for weightsaving and the plasticizing technique for plastics containing continuous glass fibers that are the major
materials of module parts. MHI is not only a hardware
manufacturer of injection molding machines, but also amanufacturer engaged in development of new molding
techniques to meet the customers’ demands.
As production bases of injection moldings are moving
abroad, transmission of operation know-how to custom-

III. Food and packaging machinery of yesterday,
today and tomorrow
1. Introduction
MHI’s food and packaging machinery includes various machines, such as machines that fill and package
beer, juice and alcoholic drinks in bottles, cans and PET
bottles, machines that fill pharmaceutical products, coffee flesh, jam and seasonings in bags and cups formed
from film, and beer storage and fermentation tanks.
MHI supplies machines for filling and packaging various products, such as automobile oil and liquid detergent.
As stated above, most of products created by MHI’s
food and packaging machinery are consumed directly bygeneral consumers. These machines can be regarded as
quality-of-life machines, and have the potential to fill
and pack various foods and liquids in various containers. Application possibilities are limitless.

2. Food and packaging machinery of yesterday
The history of MHI’s food and packaging machinery
originated from delivery of the initial bottle filler for soda
pop in 1950. After this, the consumption of beer and softdrinks increased rapidly, and customers’ needs for highefficiency filling machines increased. MHI positively
introduced techniques from overseas manufacturers, promoted development of its original machines anddeveloped a bottle filler having the world’s highest
Mitsubishi Heavy Industries, Ltd.
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Bottle conveyor

PalletloaderLabeler

Bottle cooler (warmer)
Weight checker

Bottle inspection machine

Case sealer

CIP equipment
Pallet unloader

Case packer
Case conveyor
Filler and capper
Bottle cleaner

Fig. 8 Flow meter type PET bottle fillingmachine (1 000 bottles/min)

Unpacker
Fig. 9 Example of manufacturing line constructed by MHI (outline)

throughput of 800 bottles per minute in 1966. After two
years, it increased the filling speed to 1 200 bottles/min.
Since then, it has improved its technical capability tolead the industry and has created products that meetthe market needs.
In the 1970’s, bottles were replaced with cans. In 1970,
MHI developed can filling machines. In 1987, it developed a high-capacity machine having a throughput of
1 500 cans per min. To meet the needs for high speed
and high capacity keeping the high-accuracy filling rate,
it developed a unique measuring system that measured
the filling rate with a flow meter and put a filling machine having the world’s highest throughput of 2 000 cansper min on the market in 1997. Thus, MHI has led in
the filling and packaging technology.
It entered the toiletry field making the best use of its
liquid filling and packaging technology in 1986 and thepharmaceutical field in 1992 to expand the market.

together with the filling machines in cooperation with
Mitsubishi Materials Corporation (named Shinryo Aluminum Can Sales Company Ltd. in 1993 when the joint
development was done) that is a container and cap manufacturer and Alcoa Closure Systems Japan Ltd. (named
Shibasaki-seisakusho in 2000 when the joint development was done), so that the reliability and quality of theFig. 9whole plants can be improved (Fig.
9).
Due to the various needs in the market and environmental concerns, in different shapes of containers, suchas bags, cups and bottle shaped cans are introduced. With
50 years of experience in the filling and packaging, ourcompany has been leading the market by adopting theseexperience to always meet the requirments. The fillingmachine has been proven to be efficient and 1 000 units
are delivered in the market in total.

4. Food and packaging machinery of tomorrow
Environmental problems top the list of our world’s
most pressing issues today. Also in the food industry,
there is a rapid move toward 3R (reduce, reuse and recycle) and energy saving to reduce the influence on the
global environment. MHI develops and supplies products for the recycling-oriented society as measures torealize the philosophy of the customers.
First, MHI develops methods of manufacturing containers for maintaining the product quality and reducing
the weight. Second, it develops new methods of sterilizing and cleaning containers without using conventional
cleaning water and chemicals. Third, it promotes chemical recycling of used PET bottles increasing in number.
For these methods, MHI makes full use of the most advanced plastic technology, electronic technology andprocess technology. It has started the development ofthese methods to realize them in the near future.
Consumers pursue safety, convenience and high quality. To meet these demands, it is required to takemeasures to increase the productivity and reduce thequality cost. Under these circumstances of the market,

3. Food and packaging machinery of today
The PET bottles were introduced into the soft drink
field for the first time in 1982. As the use of small PET
bottles was permitted in 1996, containers were rapidly
switched from cans to PET bottles, and it has been required to increase the kinds of applicable liquids andimprove the productivity and quality of filling machines.
In 1996, MHI developed a volumetric PET bottle aseptic
filling line including an inline PET bottle molding forthe first time in the industry to reduce the running cost.
In 1997, it introduced a high-speed and high-accuracy
PET bottle filling machine having the Japan’s highest
throughput of 1 000 bottles per min. to meet the needs ofFig. 8the industry (Fig.
8).
At present, mainly cans are used for beer, and mainly
PET bottles are used for soft drinks. To more appropriately meet the needs for stable production and highquality of these products, MHI has improved filling machines and developed key devices in the production
process, such as can seamers and cappers, that are used

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Year

1 940

1 950

1 960

1 970

Technical cooperation with Meyer
in U.S.A.

1 980

1 990

Technical cooperation with H & K
in West Germany

2 000

2 010

FCS Series

2 030

Development ofservo capper

FmCm Series

Bottle fillers
PET fillers

2 020

FF Series

New
seriesFHR
SeriesExpansion to peripheral devices(High-performance barrier container
manufacturing machines, PET bottle
chemical recycling, etc.)

New sterilizing and cleaning systems
FGR
New
Seriesseries
Aseptic filling machines
Development of can seamers
FK Series

Can fillers

2 000 CPM Can fillers/seamers

FKH Series
FKM
SeriesNew
series2000 CPM can line
Bag making andfilling machines

Hyper servo capper

New field
High value-added products

Bag making and fillingmachines for pharmaceutical products

Packagingmachines

Application
to flexible
containers

Pouch filling machines

High quality products

Filling machines
for detergent

Pouch filling machines with spout

Fig. 10 History of major products

environment.
MHI is expanding the product line of food and packaging machinery mainly based on the liquid filling andpackaging technology. It intends to improve and developthese products and develop filling and packaging systems that enable to supply safe and high-quality foods,
anticipating what the aging society will demand for(safety, convenience and high quality). It is marking afirst step toward a total plant supplier.
MHI intends to further improve the food and packaging machinery which have the limitless possibilities, andsupport the customers under the slogan of “exciting prodFig. 1
1 ).
ucts” and “active service” (Fig.
11
Fig. 11 Examples of products produced by MHI's food andpacking machinery

Industrial Machinery Division
Deputy General Manager,
Industrial Machinery Division

machine manufacturers must examine how to fill various containers with various kinds of products and how
to improve the maintenance efficiency. To solve theseissues, it is necessary to introduce an operation knowledge system and establish a 24-hour service system toFig. 10reconstruct the quick service system. (Fig.
10)

Haruo Hagiwara

5. Conclusion
It is said that the world’s food packaging industry has
a 50-year history. The food packaging market is developing with changes in consumers’ needs and social

Yuji Kamimura

Toshikazu Horiuchi

Hirofumi Takahashi

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