KraussMaffei sets up a prize for efficiency!

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2 Dr. Dietmar Straub, KraussMaffei CEO. Dear Readers, EDITORIAL Technology advances mark the way forward. Forcing down costs, increasing efficiency and boosting productivity these are key concerns right now throughout the plastics industry. It takes newgeneration 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 AWARD 2010 KraussMaffei sets up a prize for efficiency! 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 resourceefficiency. 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, More information and details of how to enter are contained in a questionnaire that you can request by . p PUBLICATION DATA made by KraussMaffei Published by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, Munich, Germany Phone + 49/89/ , Fax + 49/89/ , Responsible: Matthias Andreesen Viegas Editorial office: mk publishing GmbH, Döllgaststraße 7 9, Augsburg, Phone +49/821/ , Fax +49/821/ , Photo credits: Becker Kunststofftechnik, Bikkoplast/ Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunststofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM Dr. Reinhard Schiffers Predevelopment/Energy Phone +49/89/ EDITORIAL NEWS MADE BY KRAUSSMAFFEI

3 COVER Perfectly paired off: pipe plus insulation TRADE SHOWS Events through to autumn 2010 KraussMaffei Berstorff is now offering complete systems for continuous production of PUinsulated 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 Chinaplas Shanghai, China Expoplast Algiers, Algeria RusChem Moscow, Russia Technics Belgrade, Serbia Plastex Cairo, Egypt Plastpol Kielce, Poland PU China Shenzhen, China Composites Essen, Europe Germany K 2010 Düsseldorf, Germany MULTI-MILLION INVESTMENT New Surface Treatment Center opened 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 Bavarian Economics Minister Martin Zeil (right) and Dr. Dietmar Straub, KraussMaffei CEO, at the opening of the new Surface Treatment Center. NEWS 03

4 KNOW-HOW SHARING DRIVES DEVELOPMENT Industry and research hand-in-hand 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. 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.). 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 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 04 FOCUS MADE BY KRAUSSMAFFEI

5 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 applicationrelated 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 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 Martin Würtele Manager Predevelopment New Technologies/Process Engineering Phone +49/89/ Josef Renkl Manager Research and Development RPM Phone +49/ 89/ Prof. Dr. Lothar Kroll, Prof. Dr. Bernd Poltersdorf Manager Foam, Film and Sheet Extrusion Phone +49/511/ Dr. Wolfgang Kempt and Dr. Wolfgang Nendel (from left) of the TU Chemnitz with the ZE 40 A x 50 D UTXi twinscrew extruder from KraussMaffei Berstorff, Hanover, which offers new scope for research. FOCUS 05

6 COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK Joint project in surface treatment technology 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. 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. 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 postmould paint process. A far shorter process chain A conventional process comprises multiple steps including quality controls, storage and transport 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 STEPS Inline scratch-resistant coating of PMMA Inject PMMA Compression/ cooling Open cavity & inject coating Compression & start heating Compression & heating 100% Compression & cooling 06 FEATURE MADE BY KRAUSSMAFFEI

7 KraussMaffei injection moulding machines are at the heart of CoverForm production cells. 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 Demoulding Final curing (UV curing) 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 Sven Schröbel, Evonik Industries, Martin Eichlseder, KraussMaffei, and Arne Schmidt, Evonik Industries (from left), showing off the Best of award at the Materialica. Marco Gruber Manager Application Engineering, Process Development IMM Phone +49/89/ Josef Renkl Manager Research and Development RPM Phone +49/ 89/ FEATURE 07

8 LIFE CYCLE SERVICE Always fit for purpose Consulting and advice Moving machinery Teleservice Technology upgrades LIFE CYCLE SERVICE FROM KRAUSSMAFFEI Plasticizing units Refurbishing Functionality upgrades 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. Robots, handling systems, automation KraussMaffei Service professionals have the expertise to make a complete success of any task, however big. 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 machines; 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. 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 multicomponent 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 commitment 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 operate a practical trade in used machines. In our skilled hands machines get a new lease on life. p Bolt-on units are a fast, sure route into multicomponent moulding. 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 processor might come to us with a request to adapt Josef Hammerschmid Service Sales Phone +49/89/ FEATURE MADE BY KRAUSSMAFFEI

9 NANOSKIN PROCESS Finely structured 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. The nanoskin process generates transparent parts with finely structured surfaces. 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 antireflective 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 nanostructure 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 success 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 NANOSKIN PARTNERS Plasmatreat GmbH and Fraunhofer IWM: Regenerative hybrid layer systems and processintegrated 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 Martin Eichlseder Process Development Systems & Solutions Phone +49/89/ FEATURE 09

10 Dr. Karlheinz Bourdon, General Manager, Injection Moulding Machinery. Dear Readers, KEYNOTE With KraussMaffei you cut your operating costs and increase your productivity. TRAINING AT KRAUSSMAFFEI A truckload of information KraussMaffei has always put the highest priority on incompany 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. 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 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. 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 MADE BY KRAUSSMAFFEI

11 PRODUCTS AND SERVICES FOR INDUSTRY Switching cabinets with UL certification 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 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 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 KraussMaffei s switching cabinet manufacture now has the UL certification essential for selling into the US market. INTERPLASTICA IN MOSCOW Focus on standard applications Engineering Made in Germany as cost-efficient standard solutions for the Russian market this was KraussMaffei s focus at the Interplastica in Moscow. 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 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 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 NEWS INJECTION 11

12 SOLUTIONS FOR THE PACKAGING INDUSTRY Innovative in packaging 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. 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 MADE BY KRAUSSMAFFEI

13 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 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. Markus Betsche Product and Marketing Manager Phone +49/89/ FOCUS INJECTION 13

14 MULTINJECT PROCESS Multicomponent technology always up-to-date 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. Production with KraussMaffei machines at Bikkoplast in Wroclaw. 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, glassfiberreinforced 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. 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 highperformance 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 Andreas Handschke Technology Manager Multinject/ SpinForm/TwinForm/MuCell Phone +49/89/ FEATURE MADE BY KRAUSSMAFFEI

15 HANS ARNOLD GMBH KUNSTSTOFFTECHNIK, MÜHLHAUSEN IM TÄLE Experts in multicomponent injection moulding 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. 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 serviceoriented 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 The latest KraussMaffei machine to be supplied to Arnold was delivered in summer Jochen Mitzler Director Product and Technology Management IMM Phone +49/89/ Arnold uses four KraussMaffei Multinject machines for multicomponent injection moulding. PORTRAIT 15

16 KUNSTSTOFFTECHNIK WIESMAYER GMBH, NEUSTADT AN DER DONAU Always ready for new technologies 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. Wiesmayer relies on heavy-tonnage injection moulding machines from KraussMaffei to produce large parts. 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. 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 forwardlooking. 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 gasassisted 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 A special tandem mould has boosted productivity of door inner carriers by a factor of 1.6. Christian Rössler Sales Injection Moulding Machines Phone +49/8031/ APPLICATION MADE BY KRAUSSMAFFEI

17 MX MACHINE IN FORD S SAARLOUIS PLANT Ready for the future 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. Impressive size: the MX 4000 installed with Ford in Saarlouis, Germany. 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 highperformance injection moulding machine for its inhouse plastics processing operation in Saarlouis. Since September 2009, a 4,000-tonne KraussMaffei MX 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 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 Thomas Hörl Product Manager MX Series Phone +49/89/ Machines from KraussMaffei s MX series are engineered for sizable tasks, for example, making automotive bumpers. APPLICATION 17

18 BECKER KUNSTSTOFFTECHNIK GMBH, HOHENTENGEN Service packages all along the supply chain Quality 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. In Hohentengen, Becker Kunststofftechnik injection moulds highend plastics parts on machinery made by KraussMaffei. 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. Partners creating customer loyalty Managing Director Alfred Becker founded the company in 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 Helmut Störk Sales Engineer Injection Moulding Machinery Phone +49/741/ PORTRAIT MADE BY KRAUSSMAFFEI

19 STANDARDIZED INDUSTRIAL ROBOTS Automated solutions keep machines on their toes There 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. 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 The current KraussMaffei retrofit programme provides robots on very favourable terms. Manuela Schmidbauer Product Management Automation Phone +49/89/ FEATURE 19

20 COST SAVINGS Switch and save with the new, low-energy, all-electric c AX from KraussMaffei 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 efficiency bonus. Profit from KraussMaffei experience, expertise and quality at a bargain value. Opt for the new, compact AX. KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei Technologies GmbH Phone