At K 2025, Oerlikon HRSflow unveiled its patented STARgate HRS® hot runner technology, featuring a completely redesigned gate unit. Unlike conventional systems with axially moving needles, the new technology uses a diaphragm-like element in the gate plane to manage melt flow into the cavity, eliminating the need for needles and offering multiple processing and cost advantages.
The diaphragmatic concept enables optimal cooling performance, resulting in a significant reduction in cycle time and improved productivity. The absence of needle-guiding and movement components simplifies manufacturing, assembly, and maintenance operations.
The design also removes the need for actuator installation space typically required in conventional systems, allowing for thinner back plates. Additionally, the pinless configuration enables smaller nozzle diameters and reduced mold pocket sizes, making STARgate HRS® a highly compact solution.
The combination of smooth plastic flow and a reduced stagnation area enables faster color changes, lower scrap quantities, and lower pressure losses. Additionally, the easily replaceable gate insert
reduces maintenance costs. The external position of the actuator contributes to lower energy
consumption because it does not require cooling.
Experience at the Oerlikon HRSflow R&D Technical Center shows that the new STARgate HRS®
technology is ideal for injection molding medium-to-large parts with reduced holding and cycle
times. For these types of applications, the cycle time can be up to 20% shorter than with
conventional gate systems.
Massimo Rossi, R&D Director at Oerlikon HRSflow, comments: “A new era in valve gate solutions has
begun. The needle-free STARgate HRS hot runner technology, which is expected to be available by
mid-2026, is a true game changer, because it will radically transform the processing of amorphous
thermoplastics. Ongoing developments aim to expand its range of applications. We are proud of this
achievement by our development team, which includes employees from across the company.”
STARgate HRS® was demonstrated live at K 2025 during the production of a 6-litre bucket with a 1.1
mm wall thickness at the booth of the Italian injection molding machine manufacturer BMB. Project
partners included the Dutch plastics processor Dijkstra Plastics, R&D Plastics, Oerlikon Balzers, and
Piovan.
