Upload
others
View
0
Download
0
Embed Size (px)
Citation preview
�������
������������������������������������������
��������
����������������������������� �
�������������������������
�������������
���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������
���������������������������������������
����������������������������
��������������������������������������������������������������������
��������������������������������������������
��������������������������������������������������������������
�������������������������������������������������������������
����������������������������������
�������
����������������������������������������
����������������������������������������
�����������������������������������
��������������������������������������
���������������������������������
���������������������������������������
�������������������������������������
���������������������������������������
���������������������������������������������������������������
������������������������������������������������������������������
����������������������������������������������������������
�����������������������
��������� �� ���������������������������������
���������������������������������������������������
������������������
�����������������
�������������������������������������
����������������������������������
�������������������������������
�����������������������������������������������������������
��������
�������������������������������������������������������������
��������������������
��������
�������
��������������
��������������
���������
���
���������
���
������
���
�������������
����������������������������
��������������������
����������������������
������������
�������
“Technology
advances mark the
way forward.”Dr. Dietmar Straub,
KraussMaffei CEO.
EDITORIAL
made by KraussMaffeiPublished by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, 80997 Munich, Germany Phone + 49/89/88 99-0, Fax + 49/89/88 99-2206, www.kraussmaffei.com Responsible: Matthias Andreesen Viegas
PUBLICATION DATA
EDITORIAL | NEWS
Editorial office: mk publishing GmbH, Döllgaststraße 7–9, 86199 Augsburg, Phone +49/821/3 44 57 0, Fax +49/821/3 44 57 19, www.mkpublishing.de Photo credits: Becker Kunststofftechnik, Bikkoplast/Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunst-stofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM
02 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Dear Readers,
Forcing down costs, increasing efficiency and boosting productivity – these
are key concerns right now throughout the plastics industry. It takes new-
generation machines and systems to gain a key competitive edge; technology
advances mark the way forward.
This holds true for KraussMaffei as much as for the rest of our industry. It’s
why we’ve recently invested a substantial amount to boost quality and
productivity in our main production plant in Munich. Our new Surface
Treatment Center opened just a few days ago, replacing our previous paint
shop. All in all, the new facility cost around four million euros – you
couldn’t ask for a stronger sign of our conviction that the economy can and
will recover. Experts tell us that you’d have to look a long way to find the
equal of our new facility anywhere in the world. For example, we now
move parts and modules weighing up to 32 tonnes through the paint line on
an overhead track system synchronized with the rest of the assembly line.
When the system is operating at full capacity, it is handling the equivalent
of the take-off weight of an Airbus. As you see, we never let up in our
pursuit of quality and productivity for our machines and processes. But
your vote is the decisive one – as our customer you have the final say in
whether we’re offering you the right solution at the right time!
If you’re among the customers who currently have no plans for major
investments, we can nonetheless show you affordable options for increasing
the efficiency of your production. Our retrofit packages and upgrades can
significantly improve the productivity and energy efficiency of your installed
machines. You might opt for a higher level of automation with a robot from
our expanded portfolio, or for reduced energy consumption with one of our
efficiency packs. Especially in recent years, KraussMaffei has taken up the
theme of energy efficiency; today “BluePower” stands for the products and
upgrades we offer to help you reduce energy consumption. To add even
more momentum to this strategy, KraussMaffei has now launched the
BluePower Award, which will honour energy- and resource-efficient
production solutions. We’ll be announcing the winners during the world’s
biggest plastics show, the K2010, at the end of October. We’re looking
forward with great interest to your competition entries.
With best regards,
Dr. Dietmar Straub
BluePower is the
concept that bundles
our continuing
endeavours to
promote the
development
of energy- and
resource-efficient
production
solutions. As part
of this effort, KraussMaffei has now launched
the BluePower Award inviting entries from all
the innovative plastics processors among our
customers.
We’re looking for new developments that deliver
a significant increase in energy- and resource-
efficiency. They can be anything from individual
applications and processes to complete concepts
– and they can come from any area of the plastics
processing industry. We’re especially interested in
processes that make sustainable use of synergies
through intelligent combinations of different
technologies, such as injection moulding, reaction
moulding and extrusion. The entries will be
evaluated and the winner selected by an independent
jury panel made up of high-ranking representatives
from science and industry. KraussMaffei employees
will not be eligible to vote on this panel. The winner
of the BluePower Award 2010 will be announced on
October 28, during the world’s biggest plastics show,
the K2010 in Düsseldorf, Germany. Closing date for
entries, which must be in writing, is May 31, 2010.
More information and details of how to enter are
contained in a questionnaire that you can request by
email. p
KraussMaffei sets up a prize for efficiency!
BLUEPOWER AWARD 2010
CONTACT
Dr. Reinhard SchiffersPredevelopment/EnergyPhone +49/89/[email protected]
KraussMaffei Berstorff is now offering complete
systems for continuous production of PU-
insulated pipes. One, or two, plastic media pipes
is encapsulated in an insulating polyurethane
layer plus a protective polyethylene sheath.
The insulated pipes can transport either hot or
cold media. With this single-vendor production
solution, the company, a world leader in
plastics and rubber processing machinery,
once again demonstrates its multitechnology
competence – in this case in pipe extrusion and PU processing – built on
many decades of engineering excellence. This unique know-how enables
us to develop complete production solutions by skilfully integrating
modules from different technologies. p
NEWS
Events through to autumn 2010
TRADE SHOWS
19. – 22.04. Chinaplas Shanghai, China
19. – 23.04. Expoplast Algiers, Algeria
11. – 14.05. RusChem Moscow, Russia
11. – 15.05. Technics Belgrade, Serbia
13. – 16.05. Plastex Cairo, Egypt
25. – 28.05. Plastpol Kielce, Poland
26. – 28.05. PU China Shenzhen, China
14. – 16.09. Composites Essen, Europe Germany
27.10. – 03.11. K 2010 Düsseldorf, Germany
COVER
03
�������
������������������������������������������
��������
����������������������������
� �
�������������������������
Perfectly paired off:pipe plus insulation
Bavarian Economics Minister
Martin Zeil (right) and
Dr. Dietmar Straub,
KraussMaffei CEO, at the
opening of the new Surface
Treatment Center.
KraussMaffei has recently completed a future-oriented project in our main
production plant in Munich. Guest of honour at the opening of the new Surface
Treatment Center (STC), on March 5, 2010, was Bavarian Economics Minister
Martin Zeil. The new facility replaces our previous paint shop. In his address,
Martin Zeil commented, “The German plastics machinery sector has been
especially hard hit by the turbulence of the economic crisis. This is why I’m
absolutely delighted with every Bavarian company that has taken the crisis
as a spur to look ahead, modernize and invest. With its new and innovative
paint facility, KraussMaffei is among the leaders in this area too.” Despite the
economic crisis, KraussMaffei invested around four million euros in building and
equipping the STC. As Dr. Dietmar Straub, CEO of KraussMaffei AG, pointed
out, “With the new Surface Treatment Center we’re improving the transparency
of our entire assembly process; it will enable us to work more efficiently and
cut our turnaround times – our customers will benefit significantly.” The STC
was planned and built in a close collaboration between KraussMaffei and
Rippert Anlagentechnik GmbH & Co. KG, from Herzebrock-Clarholz/North
Rhine-Westphalia. Rippert, a systems engineering company with around 300
employees, has almost 40 years’ experience in planning and installing painting
and filtering systems and industrial ventilation units. Complex coating systems
are among its core competences. p
MULTI-MILLION INVESTMENT
New Surface Treatment Center opened
04 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Cleanroom Competence Center in Rosenheim,
opened on January 29, 2010, provides an excellent
environment for researching this field,” emphasizes
Martin Würtele, Manager Predevelopment New
Technologies at KraussMaffei. Under the aegis of
Prof. Peter Karlinger, researchers in Rosenheim
are working on a complex production cell based
on a KraussMaffei all-electric EX 80/380. “Our
cooperation with the university in Rosenheim has
already generated a large number of successful
projects and graduate theses across all three key
technologies – injection moulding, extrusion and
reaction moulding,” says Martin Würtele. Much
of this research is aligned with KraussMaffei’s
“Technology to the Power of Three” strategy. With
the opening of the competence center, Rosenheim
University became part of the PRIMUS Network
for Innovation set up by KraussMaffei (responsible
for the focus area “Life Sciences”).
Focus on energy efficiency
The University of Duisburg-Essen (UDE) is
also a member of the PRIMUS Network. Since
January 15, 2010, there’s been a cooperation
agreement between the university’s Faculty of
KNOW-HOW SHARING DRIVES DEVELOPMENT
Development engineers in mechanical engineering companies are not the only people working on solutions to tough challenges in plastics processing – there’s a lot of academic research going on too. In Germany alone, KraussMaffei supports over 20 universities and other research institutions with machinery and know-how. Life sciences, lightweight structures and energy efficiency are among the key research topics.
One strong trend in
plastics research is
the increased focus on
the life sciences sector
– medical technology,
pharmaceuticals and
cosmetics. There’s
a long-standing
cooperation in
this area between
KraussMaffei and
Munich’s University
of Technology (TU), with ordinarius professor
for medical technology, Prof. Dr. Dr. Erich
Wintermantel. TU researchers and students have
two injection moulding machines, including an
EX 50/55, and a compounder at their disposal for
experiments.
Relatively new, by contrast, is the cooperation
agreement between KraussMaffei and Rosenheim
University of Applied Sciences. It’s also focused
on the life sciences field and especially on
cleanroom technology. “One of the main concerns
in this sector is to develop processes that make
post-mould sterilization unnecessary. The new
FOCUS
Industry and research hand-in-hand
Celebrating another
recent cooperation
agreement: Prof. Dr.
Dieter Schramm and
Prof. Dr. Johannes
Wortberg from the
University of Duisburg-
Essen with Dr. Karlheinz
Bourdon and Georg
Holzinger, from
KraussMaffei (l. to r.).
05
Engineering and KraussMaffei with the specific
goal of improving the energy efficiency of plastics
processing machinery. The strategic cooperation
partner on the university side is the chair of
Engineering and Plastics Machinery headed by
Prof. Dr.-Ing. Johannes Wortberg. The cooperation
partners have agreed on regular information
exchange and supporting engineering students and
researchers. One specific area of cooperation will
be developing and optimizing alternative drive
technologies for plastics processing machinery. The
remit for this project includes energy consumption,
energy recovery, precision and efficiency.
KraussMaffei is mainly concerned with developing
and optimizing components, in particular with the
practical implementation and with application-
related process engineering.
Combined process for function-integrated
lightweight systems
The cooperation between KraussMaffei and the
Institute for Lightweight Structures and Plastics
Technology at Dresden University of Technology,
headed by Prof. Dr. Werner Hufenbach, dates
back to 2008. One important area of research
here is fiber-composite lightweight elements and
the development of new resource-efficient process
chains for manufacturing them. The researchers
in Dresden have at their disposal an innovative
LFI (Long Fiber Injection) system, including a
shuttle mould carrier, supplied by KraussMaffei’s
Reaction Process Machinery division. The research
encompasses multitechnology and multiprocess
solutions.
The Center for Integrative Lightweight
Technologies (ZIL) at the Chemnitz University
of Technology is working in related fields. For
example on the development of a new combined
process for reinforcing plastics with long fiber
materials and fabric intermediates in injection
moulding. These types of lightweight composites
are used in making anything from aircraft to
rolling stock and road vehicles, because their
lighter weight reduces fuel consumption and
carbon dioxide emissions. The ZIL, headed
by Prof. Dr. Lothar Kroll, operates a total
of six KraussMaffei machines, including a
multicomponent spin-platen machine, a RIM
polyurethane system and an IMC injection
moulding compounder. A new addition to the
center’s machine park is a ZE 40 A x 50 D UTXi
twin-screw extruder from KraussMaffei Berstorff
engineered for high-performance compounding
tasks. “Basic research is very important for us
as a mechanical engineering company, because
it paves the way for adapting our extruders
to market requirements and to continuously
developing them,” points out Prof. Dr. Bernd
Poltersdorf, head of Foam, Film and Sheet
Extrusion at KraussMaffei Berstorff. p
FOCUS
CONTACT
Martin WürteleManager PredevelopmentNew Technologies/Process EngineeringPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Prof. Dr. Bernd PoltersdorfManager Foam, Film and Sheet ExtrusionPhone +49/511/[email protected]
Prof. Dr. Lothar Kroll,
Dr. Wolfgang Kempt and
Dr. Wolfgang Nendel
(from left) of the TU
Chemnitz with the ZE
40 A x 50 D UTXi twin-
screw extruder from
KraussMaffei Berstorff,
Hanover, which offers
new scope for research.
06 MADE BY KRAUSSMAFFEI 1 ¦ 2010 FEATURE
– adding up to around 14 in total. “Thanks to our
joint project with Evonik, we can now offer our
customers a far more cost-effective process,” says
Dr. Karlheinz Bourdon, head of KraussMaffei’s
Injection Moulding Machinery division. And Josef
Renkl, R&D Manager for the company’s Reaction
Process Machinery division adds, “Thanks to our
multitechnology know-how – in this case injection
moulding and PU processing – we’ve been able to
develop the process to market readiness. It will
dramatically shorten the process chain. The new
CoverForm process has just four steps: incoming
check, injection moulding and coating in the same
mould, quality control, final assembly. All these
steps are performed in one and the same machine.
The process saves time, costs and production space.
In addition, the surfaces produced in this way are
often more scratch-resistant than those that are
COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK
Display panels in mobile phones, appliances,
consumer electronics and automotive instrument
panels are made of transparent polymers.
The displays must remain transparent despite
exposure to mechanical and chemical impact, for
example, through cleaning agents or handcreams,
otherwise they are not fit for purpose. The
material most used for these applications is
polymethyl methacrylate (PMMA) often known
by the tradename Plexiglass. The PMMA must
be specially coated to protect the surface from
scratches and chemical damage. In conventional
production, this coating is applied in a post-
mould paint process.
A far shorter process chain
A conventional process comprises multiple steps
including quality controls, storage and transport
Joint project in surface treatment technology
Dr. Karlheinz
Bourdon, member of
KraussMaffei’s Board of
Management (left) and
Gregor Hetzke, head of
Performance Polymers
at Evonik, at the opening
of the CoverForm
Competence Center.
The CoverForm process, developed by KraussMaffei, as machine supplier, and Evonik, as material supplier, substantially shortens the process chain for the production of transparent, scratch- and chemical-resistant parts. Processors save transport effort, time and production floor space – in the last analysis they save costs. The quality is often better than can be achieved in a conventional painting process.
COVERFORM PROCESS STEPS Inl ine scratch-resistant coating of PMMA
Inject PMMA
Compression/cooling
Open cavity & inject coating
Compression & heating 100%
Compression & cooling
Compression & start heating
FEATURE 07
conventionally painted. It couldn’t be simpler. This
is how CoverForm works – after injection of the
special PMMA, a mould stroke forms the surface
to be coated. The part cools in the mould. The
cavity is then enlarged slightly, creating a space for
the surface coating layer. This gap is flooded with
a liquid reactive system, ideally matched to the
PMMA material, and the mould closes in a second
compression stroke. The high-performance Dynamic
Temperature Control (DTC) ensures that the
temperature profile in the mould, required for the
different process stages, is exactly repeated in each
cycle. The only post-mould process is UV curing
which takes place immediately after demoulding.
The parts are then ready for assembly.
Competence center
for award-winning process
In November 2009, a CoverForm Competence
Center was opened at the Evonik plant in
Darmstadt – it’s the ideal
place to demonstrate
the new process. The
center was opened by
Gregor Hetzke, head of
Performance Polymers at
Evonik and Dr. Karlheinz
Bourdon. Evonik is using
the new center both for demonstrations and for
further development of reactive systems. Among
the possible candidates are new anti-reflective or
electrically conducting coatings. In addition, the
center is the ideal training environment for the
technicians in Evonik’s worldwide service teams.
despite its relatively short time on the market,
CoverForm has already won an award. At the
Materialica trade show, last autumn in Munich,
it won “Best of” award in the category Surface
and Technology. In its review, the jury noted
that CoverForm is a forward-looking,
market-ready process which is the
result of productive interaction between
materials, engineering expertise and design.
CoverForm is a system solution available
exclusively from the joint partners Evonik
and KraussMaffei. It’s yet another example
of the sustained increase in productivity
that can be achieved by joining up
processing technologies, as advocated by
KraussMaffei’s “Technology to the Power
of Three” strategy. p
KraussMaffei injection
moulding machines are
at the heart of CoverForm
production cells.
CONTACT
Marco GruberManager Application Engineering,Process Development IMMPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Sven Schröbel, Evonik
Industries, Martin
Eichlseder, KraussMaffei,
and Arne Schmidt, Evonik
Industries (from left),
showing off the “Best of”
award at the Materialica.
Demoulding Final curing (UV curing)
08 MADE BY KRAUSSMAFFEI 1 ¦ 2010FEATURE
LIFE CYCLE SERVICE
Technologies change over time. Part of KraussMaffei’s full-service offering is our commitment to maintaining and upgrading plastics processing machinery over the whole life cycle, so that it is always fit for purpose in fast-changing markets.
Multitechnology processes – such as CoverForm
(see page 6/7), nanoskin (see page 9) or inline
compounding – are an important way forward
for plastics processors. Production cells for these
processes are all based on a KraussMaffei injection
moulding machine. Our customers know they can
count on our many decades of experience with
injection moulding machines, which are one of
our core businesses. Our expertise goes beyond
developing and supplying highly productive ma-
chines; we also have the engineering skills to make
sure they stay that way over long service lives and
in the face of changing products and markets. “A
processor buying a machine today generally has
only the vaguest idea of what he’ll be producing in
five or ten years’ time. He would be well advised
to invest in KraussMaffei machinery, because we
can make sure that his production solution will
grow with his changing applications – even for
decades ahead,” says Josef Hammerschmid from
Service Marketing at KraussMaffei.
Retrofit, overhaul, move
A production cell may undergo many changes over
the years. The experts in our Service teams can
help our customers cope with them all. A pro-
cessor might come to us with a request to adapt
an existing machine for a new application, perhaps
with a MuCell package for physical foaming at low
unit cost. Or he might want to expand into multi-
component moulding. This upgrade can be achieved
relatively simply with a bolt-on unit. Hydraulic and
electric bolt-on units are completely self-sufficient,
so only minor changes, if any, need be made to the
machine.
Combining an upgrade with a planned machine
move saves production time. “We’re professionals in
moving and transporting machines – we do it all the
time,” points out Josef Hammerschmid. “Our com-
mitment to our customers is to move any machine
any distance, on time and within budget. And to see
the job through from start to finish.” Occasionally,
the machines make a detour to the KraussMaffei
plant in Munich for a general overhaul. We also op-
erate a practical trade in used machines. In our skilled
hands machines get a new lease on life. p
CONTACT
Josef HammerschmidService SalesPhone +49/89/[email protected]
Always fit for purpose
KraussMaffei Service
professionals have
the expertise to make
a complete success of
any task, however big.
LIFE CYCLE
SERVICE FROM
KRAUSSMAFFEI
• Plasticizing units
• Refurbishing
• Functionality upgrades
Moving machinery •
Technology upgrades •
Consulting and advice •
Bolt-on units are a
fast, sure route into
multicomponent
moulding.
Teleservice •
• Robots, handling systems, automation
09FEATURE
NANOSKIN PROCESS
Integrated multitechnology processes are often the answer to the challenge of producing polymer parts with durable, functional surfaces at a competitive cost. The new CoverForm process (see page 6/7) is an example of this type of integrated process. Another new process – nanoskin – is approaching market readiness. Again teaming injection moulding with PU processing, the nanoskin process is being developed by KraussMaffei and a number of project partners.
Functionalizing materials by generating a finely
structured surface – a nanostructure – is among the
dominant trends in process engineering. There are
well-known examples of nanostructures with useful
properties in nature, like the self-cleaning leaves of
the lotus flower or the anti-reflective surface layer
of moths’ eyes. The quest is on to develop a process
for transferring the moth’s-eye effect to transparent
polymer parts so as to make them inherently anti-
reflective – in other words to eliminate the need
for a post-mould anti-reflective coating. The part
would also need to be resistant to mechanical and
chemical damage. Possible applications include
covers for dashboard instruments and displays.
The nanoskin process supplies the answer.
Injection moulding and RIM
The nanoskin project partners set themselves
the task of developing a cost-effective technical
solution for a one-step multicomponent moulding
process which would combine thermoplastic and
chemically crosslinking polymer materials. The
core of the part can be produced in a conventional
injection moulding process. Only the nanostruc-
ture surface is generated in a parallel RIM process,
using a chemically crosslinking polymer which also
guarantees the necessary mechanical and chemical
resistance. The nanoskin research and development
project received funding from the German Federal
Ministry of Economics
and Technology as part
of the government’s
InnoNet concept, which
aims to promote and
support networks for
innovation. It was carried
out with organizational
and technical support
from the project sponsor,
the VDI/VDE. “Now,
well ahead of the planned
project end in autumn
2010, we can already say
that KraussMaffei and
our partners are writing
the first chapter of a suc-
cess story. Together we
have taken the nanoskin
process to a point where we’ll be able to offer it to
our customers for concrete production applications,”
says Martin Eichlseder, who is leading KraussMaffei’s
contribution to the nanoskin project. p
CONTACT
Martin EichlsederProcess DevelopmentSystems & SolutionsPhone +49/89/[email protected]
Finely structured
The nanoskin process
generates transparent
parts with finely
structured surfaces.
NANOSKIN PARTNERS
• Plasmatreat GmbH and Fraunhofer IWM:
Regenerative hybrid layer systems and process-
integrated atmospheric plasma treatment
• Hochschule Heilbronn: Process integration
• Mast Kunststoffe GmbH & Co KG:
Durable, functional components, tested under
production conditions
• FHR Anlagenbau GmbH:
Mould coating and surface structuring
• Krallmann Holding & Verwaltungs GmbH:
Moulds with highest precision and rigidity
• RÜHL PUROMER GmbH and KraussMaffei:
Tough, transparent polyurethane systems
for surface functionalization and technology
development – flow moulding
One of the stations for the VBM’s mobile information
center was the KraussMaffei plant in Munich-Allach
(March 10-16, 2010). School classes and teenage
children of KraussMaffei employees were keen to
find out what’s on offer in the way of vocational
training for careers in the metal processing and
electrical industries. The truck was fitted out to bring
the world of technology closer to the young people
and to provide a window onto all sorts of interesting
fields – from physics to CNC machining. At the same
time, we also offered the visitors a chance to find out
more about an apprenticeship at KraussMaffei. Our
in-house trainers and some of our current apprentices
were on hand to talk individually with the young
people. Richard Schmidt, Director of Vocational and
Advanced Training and Personnel Development at
KraussMaffei, pointed out, “In the 2009 training
year, 40 young people began an apprenticeship or
a sandwich degree in our Munich plant. We offer
training in various trades and in commercial fields. We
take a proactive role in ensuring that we can draw on
a pool of well-trained candidates for future jobs.” p
10 KEYNOTE | NEWS INJECTION
“With KraussMaffei
you cut your operating
costs and increase your
productivity.”
Dr. Karlheinz Bourdon,
General Manager,
Injection Moulding Machinery.
KEYNOTE
Dear Readers,
We’re now some way into 2010 and I hope that you too are
noticing more positive economic signals than were evident a
year ago. For us at KraussMaffei, the turning point was the very
encouraging reaction at the Fakuma 2009. Since then we’ve seen
a slow upward trend. And even when the economy enters a
stronger recovery phase – we’re definitely talking about the
future here – I’m certain that one trend is irreversible. This is
the accelerating pace of technological change. Around the
world, plastics processors are looking to counter intense
pressure on prices with efficiency gains. They need to see fast
returns on every investment. The return you get on new
production machinery depends on two factors – operating costs
and productivity. Processors installing injection moulding
machinery from KraussMaffei score on both points – especially
if they chose a complete production cell with integrated
automation. One very important advantage of these integrated
production cells concerns the changed safety requirements
contained in the new European Machinery Directive – which
came into force without a transition period at the end of
December. Every KraussMaffei machine satisfies these
requirements. We supply complete solutions that meet all
standards, where the customer has absolutely no documentation
or certification effort. And lastly, even with the lower investment
in new machinery, KraussMaffei is still strongly focused on
optimizing your operating costs and productivity. Our
automation retrofit programme is just one striking example.
You can find out more between the covers of made by
KraussMaffei. I trust you enjoy reading this edition of our
company magazine!
Dr. Karlheinz Bourdon,
General Manager,
Injection Moulding Machinery
Technology roadshow: KraussMaffei and the VBM
Info-truck provided information for young people about
careers in the metal processing and electrical industries.
MADE BY KRAUSSMAFFEI 1 ¦ 2010
TRAINING AT KRAUSSMAFFEI
A truckload of information
KraussMaffei has always put the highest priority on in-
company training for our future technicians and on giving
young people a good start on the career ladder through
first class vocational training. We’re far from alone in this
endeavour; the Association of the Bavarian Metal and
Electrical Industry (VBM) operates an “Info-truck” to
give young people an insight into their career options.
11
INTERPLASTICA IN MOSCOW
NEWS INJECTION
KraussMaffei’s specialized teams build switching
cabinets not only for plastics machinery. The
cabinets are engineered and manufactured to
international, European and German standards
– and now they are UL-certified for the North
American market.
KraussMaffei is world market leader in machines
and systems for plastics and rubber processing. We
also supply specific high-tech production solutions
– such as switching cabinets – to other mechanical
engineering companies. Our specialized electrical
engineering teams are experts in the whole task
spectrum, from integrating small automation
PRODUCTS AND SERVICES FOR INDUSTRY
Switching cabinets with UL certification
modules to the highly
complex connection
of large machines.
Their intensive daily
experience means
they’re familiar with the
statutory requirements
and conditions in all parts of the world.
KraussMaffei engineering and manufacturing
meets international and regional standards.
Our production is certified to DIN ISO 9001,
DIN EN ISO/IEC 17025/2005 and VDMA 24470.
We recently qualified for the Underwriters
Laboratories (UL) certification essential for
selling our switching cabinets into the US market.
Our engineering and manufacturing operations
are now certified to UL 508A (Safety Standard
for Industrial Control Panels) and NFPA 79
(Industrial Standard for Electrical Machinery). p
Focus on standard applications
At the Interplastica in Moscow (January 26 to
29, 2010), KraussMaffei’s Injection Moulding
Machinery division demonstrated what it takes
to make a successful production cell for standard
applications – highest energy efficiency and
repeatability, plus very short cycle times.
The Russian market for plastics processing
machinery has not been untouched by the
economic crisis. But it
is still a market where
KraussMaffei has a
strong presence. This is
important, because the
market is changing. The
Russian economy used
to be dominated by the
export of raw materials,
while large quantities
of consumer goods
KraussMaffei’s switching
cabinet manufacture now
has the UL certification
essential for selling into
the US market.
Engineering “Made in
Germany” as cost-effi-
cient standard solutions
for the Russian market –
this was KraussMaffei’s
focus at the Interplastica
in Moscow.
were imported. Now more and more consumer
goods are being produced in Russia. And
Russian processors are increasingly demanding
premium quality and efficiency for their
machine park. KraussMaffei’s booth at the
Interplastica demonstrated how competently
we respond to these expectations. The booth
showcased an all-electric AX 100-380 injection
moulding machine. It was in action producing
grip shells for mobile phones with a cycle time
of 8.5 seconds. The innovative production cell
was completed by an integrated parts removal
robot. The all-electric AX series machines
generally slash electricity consumption by
over 50%, often by as much as 60%. Water
consumption is cut by up to 70% compared
with hydraulic machines. Highly dynamic drive
systems and servo motors contribute to faster
cycles, while precision controlled machine
movements ensure high repeatability. p
MADE BY KRAUSSMAFFEI 1 ¦ 2010
IML packaging made in
a single-step, injection
moulding process is
spreading throughout
the food industry.
Packaging is a very
attractive field for plastics
processors, especially
since this market has
so far proved to be
relatively immune to the
crisis. IK, the German
Industrial Association
for Plastics Packaging
and Films, announced
in December that its
member companies had
suffered a 14% drop in
sales in the first three
quarters of 2009, but that fall was relatively low
compared with 21% drop experienced by German
industry as a whole. The reason is obvious: the bulk of
plastic packaging is accounted for by food, beverages
and other basic necessities – such as detergents and
personal care products – where consumers are loath
to make economies, even as they cut back in other
areas. Plastic is still the most widespread packaging
material, according to the Joint Committee of German
Packaging Manufacturers (GADV). And the industry
processes more plastics to make packaging than to
make products for the construction or automotive
sectors.
IML for dynamic results
In-mould labelling (IML) is a packaging solution
which typifies how several process steps can be
combined on a single injection moulding machine.
It is the method by which thin-wall polypropylene
tubs for margarine, salads and many other foods are
made. The decor film label, which will eventually
be visible on the outside of the packaging, is placed
in the mould and the container is injection moulded
behind it. No post-mould printing or labelling is
necessary. KraussMaffei’s EX series of all-electric
injection moulding machines are ideal for this type
of application. A production cell comprising an
Ultra-injection unit and an SR side-entry robot
makes a very dynamic system. Fast injection coupled
with rapid robotic label insertion and tub removal
cut cycle times to under four seconds. Engineered
for the production of food packaging, all EX drives
and the robot are encapsulated, thereby ensuring
clean production. A dry-air system prevents moisture
condensing in the mould, helping to create the
constant ambient conditions that boost the reliability
of the label insertion process.
Solutions along the supply chain
The beverage industry benefits widely from plastic
packaging. Here, again, injection moulding
demonstrates its versatility in producing the full
range from PET bottle preforms, to closures, bottle
crates and pallets. KraussMaffei supplies machinery
and production cells for almost the entire supply
chain, from CX series machines in PET preform
production cells, through to the large MX machines,
delivering the high shot weights needed for making
12 FOCUS INJECTION
SOLUTIONS FOR THE PACKAGING INDUSTRY
No other sector processes as much plastic as the packaging industry. KraussMaffei’s injection moulding division offers powerful production solutions– especially our in-mould labelling process and PETForm production cells – for this market, which is proving to be particularly resilient in the current economic crisis.
Innovative in packaging
13FOCUS INJECTION
require any regular mould overhauls. They’ve easily
chalked up some 15 million production cycles and
they’re still going strong. Compared with competing
systems, they deliver substantial savings on mould
maintenance costs for years on end. And this in turn
reduces manufacturing costs. p
PETForm systems
produce quality
preforms for the
beverage industry.
CONTACT
Markus Betsche Product and Marketing ManagerPhone +49/89/[email protected]
bottle crates, and the IMC injection moulding
compounders for producing pallets. We’ve got the
beverage industry’s logistics chain almost completely
bottled up.
Every PET bottle starts life as a preform. With hotfill
preforms, the threaded section of the future bottle is
crystallized in a separate downstream step. Because
shrinkage occurs during crystallizing, very narrow
tolerances are applied to the threaded section, this
puts huge demands on the production process.
The tried-and-tested PETForm system devised by
KraussMaffei for preform production features
a vertical clamp that produces perfect preforms
without the need for complex temperature control,
even running moulds with a high cavity count.
Extremely long mould life and dependable preform
production to narrow tolerances are assured, thanks
to excellent platen parallelism. PETForm systems that
dispense with separate needle-valve control have long
been successfully used in hotfill applications. Thanks
to high-precision clamp movements, they don’t
MADE BY KRAUSSMAFFEI 1 ¦ 201014 FEATURE
MULTINJECT PROCESS
In this particular application, plastic has two clear
advantages over metal. On the one hand there is
greater design scope, on the other hand there is the
optimal combination of stiffness with a premium
surface and lighter weight. The multipart handles are
made in a four-cavity mould.
Bikkoplast’s Multinject system runs an absolutely
stable, smoothly efficient process thanks to high-
performance engineering and a package deal from
KraussMaffei and Hofmann, one of the leading
suppliers of sophisticated mould technology.
Bikkoplast, founded in 1983, today employs around
90 people under the management of Katarzyna
Wnek. Bikkoplast has installed 18 KraussMaffei
machines, using them mainly for its core business,
which is components for the white goods industry.
The precision of the machines’ settings and their
high repeatability deliver the highest possible part
quality. This consistent quality was a decisive factor
in Bikkoplast’s decision to invest in KraussMaffei
machinery. Managing director Katarzyna Wnek
also welcomes the expert advice and fast service she
gets from Dopak, KraussMaffei’s channel partner
in Poland. Dopak, also based in Wroclaw, is one of
oldest and most successful sales and service partners
of KraussMaffei’s Injection Moulding Machinery
division. p
Today, multicomponent injection
moulding is as popular as ever.
KraussMaffei has almost 50 years’
experience in the development
of system solutions to produce a
huge diversity of composite parts
using thermoplasts, polyurethanes
or elastomers. The comprehensive
portfolio includes package solutions
– with tooling technology and
process know-how – and a complete
spectrum of system combinations.
KraussMaffei will also engineer space-saving
solutions with the injection units optimally
positioned with regard to space constraints,
mould technology and existing infrastructure.
Far better than metal
One of the many plastics processing enterprises
using Multinject technology for large-volume
orders is Bikkoplast, located in Wroclaw in
western Poland. Bikkoplast manufactures around
150,000 refrigerator handles a year on a 2C
system configured on KraussMaffei’s CX modular
platform, mounting a mould with indexing
technology. The first component, glassfiber-
reinforced ABS, is injected from the main
processing unit. The reinforced material gives the
inner handle element the stiffness it needs. The
second component, injected from the co-injection
unit, is non-reinforced ABS which forms the
handle’s outer layer. ABS is the material of choice
for these refrigerator handles, because it combines
excellent optics with outstanding wear resistance.
Multicomponent technology – always up-to-date
Production with
KraussMaffei machines
at Bikkoplast in
Wroclaw.
“Multinject” stands for KraussMaffei’s almost inexhaustible range of solutions for multicomponent injection moulding. Customers – like Bikkoplast in Poland – profit from the company’s extensive know-how, built up over decades of experience.
CONTACT
Andreas HandschkeTechnology Manager Multinject/ SpinForm/TwinForm/MuCellPhone +49/89/[email protected]
Hans Arnold GmbH specializes in 2K and 3K moulding. This second-generation, family-run business always insists on KraussMaffei machines, not only because of our engineering competence but also for our customer service.
Experts in multicomponent injection moulding
15
In Germany, where production costs are relatively
high, any family-run SME seeking to survive in the
plastics processing business must first identify a
niche for itself and then strive to become the
undisputed expert in that field. Hans Arnold
quickly realized this when he founded his company
in Mühlhausen im Täle, Baden-Wurttemberg, some
35 years ago. He decided to concentrate on
multicomponent injection moulding. Now, the
company has 30 employees and an impressive – and
highly automated – machine park. In fact, the ratio
of employees to machines is more or less one to
one. The parts produced range in weight from 0.5
to 850 grams. Central to this production operation,
and representing the top end of the clamp force
range, are four machines which are fully-equipped
for multicomponent injection moulding. Each one
has been sourced exclusively from KraussMaffei,
including the top model from the CX range, a 650-
tonne Multinject machine.
Short distances are crucial
Among the products which Hans Arnold GmbH
can manufacture with the multicomponent
technology at its disposal are power-tool housings
comprising up to three thermoplastic components,
automotive gear sticks and automotive aftermarket
parts. Not only must the component materials
have different properties, but they are often
combined in various colours to meet design
specifications. This presents a challenge for
mould makers and machine technology alike.
And for the latter, the company banks on
KraussMaffei’s engineering capability and service-
oriented approach. As Petra Arnold-Herpertz,
managing director and daughter of company
founder and current senior boss Hans Arnold,
puts it: “Quality products, fast response and a
‘can do’ company culture are what our customers
expect from us – and that is precisely what we get
from KraussMaffei. The machines are totally
dependable and have absolutely no problems
coping with complex processes. The company has
a local presence, not only physically in the form
of its distribution and service center in nearby
Zell unter Aichelberg, but also figuratively in that
its decision lines are short and we have direct
lines to all contacts.” p
HANS ARNOLD GMBH KUNSTSTOFFTECHNIK, MÜHLHAUSEN IM TÄLE
CONTACT
Jochen MitzlerDirector Product and Technology Management IMMPhone +49/89/[email protected]
Arnold uses four
KraussMaffei Multinject
machines for multicomponent
injection moulding.
PORTRAIT
The latest KraussMaffei
machine to be supplied
to Arnold was delivered
in summer 2008.
MADE BY KRAUSSMAFFEI 1 ¦ 201016 APPLICATION
KUNSTSTOFFTECHNIK WIESMAYER GMBH, NEUSTADT AN DER DONAU
Kunststofftechnik Wiesmayer GmbH does much more than make plastic components for the automotive industry – it supports its customers every step of the way, from planning through to delivery of the finished article. For its large parts, Wiesmayer relies on KraussMaffei MX and CX injection moulding machines.
Increased productivity
This specialist producer of plastic parts makes
small, medium and large production runs. For
example, the two 1,600-tonne MX machines are
currently producing nothing but inner carriers
for the doors of the Mercedes E Class. The
technologies employed – MuCell and the tandem
system – are both innovative and forward-
looking. “Because the MuCell process operates
without holding pressure, the parts we make are
less subject to warpage,” says Robert Gassner,
process engineer at Wiesmayer. “And the tandem
system has boosted productivity by a factor of
1.6, because while one part is cooling, the other is
already being moulded.” The two CX machines,
which were only commissioned this year, have
enabled Wiesmayer to move into the world of gas-
assisted injection moulding. This method achieves
substantial material and weight savings without
sacrificing stiffness, especially in the production of
thick-wall parts, such as map pockets. p
More than 30 automotive and electronics
customers use the services of Kunststofftechnik
Wiesmayer GmbH, which boasts 35 injection
moulding machines with clamping forces
ranging from 40 to 1,600 tonnes. Founded
in 1992, it is a direct supplier for some car
manufacturers such as Audi, while its other
products take a detour via subcontractors such
as Johnson Controls and Faurecia. “Some of
the parts we make in our shops are extremely
complex, others must have pristine surfaces,”
says Stephan Weber, Commercial Director at
Wiesmayer. “Our experts work closely with
customers, right from the development stage.
Not only that, but we also make majority of the
moulds used.” The company started using large
production machines in 1994 and has worked
closely with KraussMaffei ever since. Today,
Wiesmayer runs six KraussMaffei machines
– two 800-ton MX’s, two 1,600-ton MX’s and
two 650-ton CXs.
Always ready for new technologies
Wiesmayer relies
on heavy-tonnage
injection moulding
machines from
KraussMaffei to
produce large parts.
CONTACT
Christian RösslerSales Injection Moulding MachinesPhone +49/8031/[email protected]
A special tandem
mould has boosted
productivity of door
inner carriers by a
factor of 1.6.
17APPLICATION
Ready for the future
For many years, two trends in the automotive
industry have been accelerating rapidly. One is the
increasing use of plastics in automotive
components, the other is the increasing size of
individual plastic components. Where these large
parts are injection moulded, this trend is pushing
demand for higher clamp forces and shot weights.
Aware of these trends, Ford invested in a high-
performance injection moulding machine for its in-
house plastics processing operation in Saarlouis.
Since September 2009, a 4,000-tonne KraussMaffei
MX 4000-24500 injection moulding machine has
been installed in Ford’s plant in Saarlouis. The
machine is currently producing bumpers for the
passenger car models Focus, Focus ST and Kuga,
which by no means stretches its capacity reserves.
“In the foreseeable future, automotive components
are likely to become bigger and more complex
with every model generation,” explains Serjoscha
Skrabs, the manager responsible for the plastics
plant and bumper painting at Ford in Saarlouis.
“The big MX machine is an investment that will
continue to pay off in terms of future production
tasks,” he continues. Rainer Hoefner, zone
manager for the paint shop and plastics
production, adds, “Regular benchmarking shows
that running our own injection moulding
operation at the Saarlouis plant brings clear
efficiency gains. This was the basis for our decision
to expand our machine park with a big tonnage
machine.”
Perfect machine/robot pairing
There aren’t many manufacturers offering
injection moulding machines in the MX 4000
performance segment. Ford’s investment decision
was influenced by the machine’s convincing
performance in preseries acceptance trials, by
KraussMaffei’s many years of experience with big
machines and by the attractive price/performance
ratio. As often before, KraussMaffei supplied a
complete production cell. The system, painted to
customer specifications rather than in the
standard KraussMaffei colours, is paired with an
IR 2100-1000 S/K industrial robot (Kuka KR 210
L100 K). To match the large size of the machine,
the robot has a payload of 100 kg and a working
range of 3,900 mm. The robot places the plastic
parts on a 2-belt conveyor belt where they are
buffered for the 30-minute cooling period. The
complete package from KraussMaffei includes the
safety housing, and the platforms and ladders for
maintenance access to the injection unit and the
clamp. p
MX MACHINE IN FORD‘S SAARLOUIS PLANT
It’s no secret that not all the traffic lights in the automotive industry are set on green – especially in the USA and in Germany. Against this background, it’s remarkable that, in 2009, the Ford-Werke GmbH, based in Cologne, invested in a large, new KraussMaffei machine for in-house plastics processing at its production plant in Saarlouis, Germany.
CONTACT
Thomas HörlProduct Manager MX SeriesPhone +49/89/[email protected]
Impressive size: the MX
4000 installed with Ford
in Saarlouis, Germany.
KOMPAKTE ZWEIPLATTENTECHNIK FÜR GROSSE AUFGABEN
Spritzgießmaschinen der MX-Baureihe
Machines from
KraussMaffei’s MX series
are engineered for sizable
tasks, for example, making
automotive bumpers.
MADE BY KRAUSSMAFFEI 1 ¦ 2010
No less than 16 KraussMaffei injection moulding
machines populate the production floor of Becker
Kunststofftechnik GmbH in Hohentengen,
Germany. With clamp forces from 30 to 1,600
tonnes, these machines mirror the full performance
range of the hydraulic CX series, and include the
jumbo machines – the MXs. The star of the fleet,
the 1,600-tonner, is used for producing visible
automotive interior trim. This type of product
imposes two tough requirements: high shot weight
and perfect looks. Aside from the automotive
sector, Becker has customers across many other
industries, including sanitation, medicine,
horticulture and water engineering. It has a
particularly strong foothold in components for
white goods. This is one area where Becker not
only operates as an injection moulder, but also
covers a good part of the supply chain: 2K injection
moulding, pad printing and assembly are key steps
in production of operating panels for fully
automatic washing machines prior to shipment to
the manufacturer.
18 PORTRAIT
BECKER KUNSTSTOFFTECHNIK GMBH, HOHENTENGEN
Partners creating customer loyalty
Managing Director Alfred Becker founded the
company in 1997. Today, there are roughly 75
employees working at the Hohentengen site.
Becker prides itself on the production of high-end,
moulded technical components. A focus on
quality, rather than the production of cheap
plastic parts, has always been the company’s
recipe for success. And, as everyone knows,
quality has many aspects. At Becker, it extends to
regular staff training, comprehensive service
packages for customers – including design and
mould making – and, of course, the right
machines for the job. “We have the injection
moulding capability, for example, to implement
complex 2K solutions. Not everybody can do
that. We view our machine supplier as a partner
who helps us generate customer loyalty,”
summarizes Alfred Becker, who sources the
company’s machines exclusively from
KraussMaffei. p
Service packages all along the supply chainQuality in the end product and in all upstream steps – that’s been the motto of Becker Kunststofftechnik GmbH for 13 years. KraussMaffei was one of its machine suppliers back in its start-up days, and has since taken on this role exclusively. It’s a solid partnership, which over the years has helped Becker to build a customer base across a large number of industries.
CONTACT
Helmut StörkSales Engineer Injection Moulding MachineryPhone +49/741/94 24 [email protected]
In Hohentengen, Becker
Kunststofftechnik
injection moulds high-
end plastics parts on
machinery made by
KraussMaffei.
19FEATURE
KraussMaffei injection moulding machines
are rock-solid technology and, when regularly
professionally serviced and modularly upgraded
as needed, nothing stops them from operating for
decades – in fact such a lifespan is not uncommon,
especially for large machines. It’s often relatively
simple to boost the performance of existing
injection moulding machines. “Our retrofit
programme helps plastics processors achieve just
that,” says Manuela Schmidbauer from product
management at KraussMaffei Automation. This
company has been equipping injection moulding
machines with industrial robots (IR) for almost
on two decades. As part of the current retrofit
programme, KraussMaffei experts will devise
automation solutions on extremely attractive
terms. KraussMaffei is also offering application
engineering and service packages – including
optimized plasticizing units – supplied on demand
and as needed.
The aim is to optimize production processes and
to ultimately reduce the cost per output. “This
is where our standardized IR series comes in. We
launched it in autumn 2009 as an automation
solution for all new and existing machines,”
explains Thomas Marufke, Sales Manager
at KraussMaffei Automation. “The lower
maintenance and operating costs are of enormous
benefit to the user. And, if it’s a new investment, he
gets a production cell where the robot is controlled
directly via the operator panel of the injection
machine.” In the current retrofit program,
KraussMaffei customers are benefiting from
the exclusive partner
programme which the
KraussMaffei set up with
Kuka.”
Every size catered for
The industrial robots
come in 11 sizes, and
their payloads cover
the entire spectrum
– from 6 to 210 kg – of
KraussMaffei injection
moulding machines,
whether hydraulic or
all-electric. The series
includes floor- and console-mounted robots as
well as models that integrate into the safety guard.
As always, for new investments, KraussMaffei
supplies complete, CE-compliant production cells.
And we’ll replace existing handling systems and
retrofit injection moulding machines made by
KraussMaffei or other manufacturers. p
STANDARDIZED INDUSTRIAL ROBOTS
Automated solutions keep machines on their toesThere’s no time like the present for plastics processors to secure crucial production advantages by making a modest investment in upgrading existing machinery. KraussMaffei offers a highly standardized range of industrial robots for automating new and existing machines.
The current
KraussMaffei retrofit
programme provides
robots on very
favourable terms.
CONTACT
Manuela SchmidbauerProduct Management AutomationPhone +49/89/[email protected]
Switch and save – with the new, low-energy, all-electric AX from KraussMaffei
SAVINGSCOST
Clever, clean, precise and economical – meet the AX series! It’s our new all-electric injection molding machine that saves energy in a big way. With energy prices spiralling, the AX is a prudent investment. Flexible design and an automation solution contained inside the safety housing add space savings to energy savings – a production cell for an extra effi ciency bonus. Profi t from KraussMaffei experience, expertise and quality at a bargain value. Opt for the new, compact AX.
KraussMaffei Technologies GmbH ··· Phone +49 89 [email protected] ··· www.kraussmaffei.com
KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide.
Switch and save – with the new, low-energy, all-electric AX from KraussMaffei
SAVINGS
Clever, clean, precise and economical – meet the AX series! It’s our new all-electric injection molding machine that saves energy in a big way. With energy prices spiralling, the AX is a prudent investment. Flexible design and an automation solution contained inside the safety
KraussMaffei is a premium partner for the plastics and rubber
Switch and save – with the new, low-energy, all-electric AX from KraussMaffei
Switch and save – with the new, low-energy, all-electric AX from KraussMaffei
Anz_intern_AX_GB.indd 1 23.03.09 09:30