AHEAD NEW MX SFT MOLD CARRIER A HEAVYWEIGHT FOR THE LIGHTWEIGHT CONSTRUCTION TECHCENTER LIVE DEMONSTRATIONS AT FAKUMA 2017 FROM FLAWLESS TO HIGH GLOSS

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1 AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue NEW MX SFT MOLD CARRIER A HEAVYWEIGHT FOR THE LIGHTWEIGHT CONSTRUCTION TECHCENTER LIVE DEMONSTRATIONS AT FAKUMA 2017 FROM FLAWLESS TO HIGH GLOSS

2 EDITORIAL CONTENTS COVER STORY 4 Innovative procedure for the reaction technology of today and tomorrow 5 A heavyweight for the Lightweight Construction TechCenter of KraussMaffei 6 The machine pool PROCESSES & PRODUCTS Dear readers, Thinking outside the box is the best way to achieve efficient, creative solutions in company management. Those who tread new paths in both thought and action have an opportunity to take advantage of the possibilities of new ideas and technologies. Therefore, in this issue of AHEAD, we are introducing options that could carry your company forward in a sustainable manner. One of them is our TechCenter for injection molding and reaction process machinery, which is the only one of its kind in the world. The TechCenter offers you the opportunity to optimize your product and its optimal manufacturing under real-life conditions and with assistance from experts. The ipul technology was also developed here. This pultrusion process is an outstandingly efficient response to the current demand for lightweight and cost-effective materials. We are demonstrating developments with profit potential live at Fakuma. The injection molding series PX, CX and ELION produce current applications. And the visitors can experience MaXecution, our new Manufacturing Execution System (MES) for smart production management, in action. Using this system means fewer rejects, better utilization and higher overall equipment effectiveness. We are thus contributing a fundamental element to the world of Plastics 4.0. Consistent quality is a basic pillar of industrial manufacturing. Using APC plus (Adaptive Process Control) for our injection molding machines allows you to attain shot weight consistency under fluctuating ambient conditions, shot by shot. The cavity is always filled optimally, cascade injection molding and thin-walled parts as well as a high proportions of recyclate achieve their profit potential. Roth Werkzeugbau in Auma-Weidatal, Thuringia, is treading new paths. This innovative company is showing tremendous commitment to establishing itself in the packaging segment as well. 8 A thermoset plastic in the injection molding machine 10 From flawless to high gloss 13 On the way to zero-defect production 14 Quite a crowd at the first Competence Day Pultrusion 16 New materials for efficient construction PARTNERS & PROJECTS 18 Everything packaged perfectly 20 Good cooling pays dividends 22 KraussMaffei now using the HoloLens for training KRAUSSMAFFEI GROUP 23 Social responsibility and sustainability count 24 Expertise determines success 25 Netstal: co-injection process for coffee capsules 25 KraussMaffei Berstorff: twin-screw extruder for PO recompounds 25 Trade show calendar 25 Imprint We are now using the Microsoft HoloLens, the latest mixed-reality technology, to train your employees. For you, this means higher efficiency and sustainability for the training seminars. Discover more interesting topics and ideas for thinking outside the box while leafing through the new AHEAD! With best regards, Nicolas Beyl President of the Reaction Process Machinery segment

3 KraussMaffei Contents 3 4 One of a kind In the KraussMaffei TechCenter in Munich, plastic experts can test and optimize components, processes and molds for manufacturing prototypes and series production Full flexibility Live demonstrations of the all-electric PX and the hydraulic CX series at the 2017 Fakuma trade show. Revolution in the construction industry Rebars made of fiber-reinforced plastics offer a wide range of advantages over the conventional rebar steel.

4 4 Cover story THE TECHCENTER FOR REACTION PROCESS MACHINERY AND FIBER COMPOSITES PRODUCTION INNOVATIVE PROCEDURE FOR THE REACTION TECHNOLOGY OF TODAY AND TOMORROW Our customers hold the TechCenter in high esteem as a one-of-a-kind option for testing and optimizing components, processes and molds manufacturing prototypes and series production, says Sebastian Schmidhuber, Head of the RPM Research and Development department at KraussMaffei. The TechCenter for reaction process machinery in Munich offers plastics companies everything necessary for the development of state-of-the-art composite and PUR foam com ponents: experts, experience and equipment for handling large and small components. TEXT: PETRA REHMET, GERHARD KONRAD PHOTOS: KRAUSSMAFFEI SEBASTIAN SCHMIDHUBER Head of RPM Research and Development, KraussMaffei Munich. KraussMaffei a competent development partner RTM with thermoplastic matrix, processing of recycled fibers, flooding with PUR paint and much more: As a development partner, KraussMaffei has the expertise to develop the perfect process steps and/or production processes for any project. We support customers throughout planning. Trials in real production environments make a critical contribution here, says Schmidhuber. ipul faster, more sustainable, more versatile In doing so, we are also paving the way for the development of new technologies, explains Schmidhuber. For example, here we developed the pultrusion process further in order to meet the latest requirements, and that is how the ipul technology was created. We recently presented this technology to the professional public. Not only is ipul significantly faster than the older pultrusion process with an impregnating bath, the new process and new materials also expand the range of applications for pultruded products significantly. Furthermore, we will be operating a second ipul system in the TechCenter by the end of the year, adds Stefan Ehrlicher, head of the TechCenter. Then we will be able to optimize different applications at the same time. The most versatile TechCenter in the world The KraussMaffei TechCenter in Munich combines reaction process machinery systems and technologies unlike any other facility in the world. On an area of more than 2,000 square meters, more than ten systems and machines are ready for in-house experiments and for customers to test, opti mize and further develop their processes under real-life conditions using experimental machinery or initial prototype components. A leader in lightweight construction KraussMaffei continues to be a leader in development, particularly in the area of fiberreinforced lightweight construction. In terms of reaction process machinery, this includes the wide array of RTM processes, pultrusion and the LFI process (long fiber injection). Perfect surfaces The KraussMaffei TechCenter also offers demonstrations of a wide array of surface technologies, including the ColorForm process or CCM (clear coat molding). Even traditional RIM (reaction injection molding) or R-RIM (reinforced reaction injection molding) foaming technologies can be run in the TechCenter. The whole range of reaction process machinery With far more than 20 processes, KraussMaffei provides a reliable picture of the entire range of processes covered by reaction process machinery. The range of products and services offered extends from processing methods for manufacturing composites and state-of-theart surface technologies all the way to solutions for foaming of polyurethane systems and numerous special processes. Our portfolio is rounded out by certified expertise in environmental simulation. Integrated processes Thanks to this bundled expertise, customers receive all services along the process chain from the system provider, this means from a single source. Thus, components with added value are created. And our customers are fit for upcoming tasks, explains Schmidhuber. Due to the stringent special requirements for the component being created, our experts provide consultation on an individual basis to work out the best possible process for you and your product.

5 KraussMaffei Cover story 5 NEW MX SFT MOLD CARRIER IN OPERATION A HEAVYWEIGHT FOR THE LIGHTWEIGHT CONSTRUCTION TECHCENTER OF KRAUSSMAFFEI KraussMaffei Reaction Process Machinery has enhanced its TechCenter for lightweight components and fiber composite technology at the Munich location by adding an MX SFT mold carrier. The mold carrier features a clamping force of 8,000 kn and stands out for its very high locking force in combination with fast travel times. Customers and processors benefit from high precision and flexibility when using a wide variety of materials and processes, especially fiber-reinforced plastics. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI STEFAN EHRLICHER Head of the RPM TechCenter, KraussMaffei Munich. High demand Demand for new fiber-reinforced composites is unhindered. The addition of the new mold carrier to our TechCenter provides our customers with optimum prerequisites for developing and testing processes and solutions tailored to series production, says Stefan Ehrlicher, Head of the RPM ( reaction process machinery) TechCenter at KraussMaffei. For example, the new MX SFT mold carrier is ideal for the entire range of RTM processes (resin transfer molding), such as high-pressure RTM (HP-RTM), compression RTM (C-RTM), surface RTM (S-RTM), thermoplastic RTM (T-RTM) and even wet molding. Even OEMs and tier-1 suppliers outside of the automotive industry utilize the unique options for prototype development and validation in our TechCenter, adds Ehrlicher. Thanks to easy-to-use metering machines, the new mold carrier can be combined with almost all of the available metering machines in the KraussMaffei TechCenter. An epoxy RTM machine is permanently installed in combination with a release agent unit and an industrial robot for open injection (wet molding). Four-column concept for extremely heavy molds The high positioning accuracy and bending stiffness provided by the four-column concept makes it possible to use molds suitable for series production to manufacture structural or surface parts in single cavities or multiple cavities. This considerable holding force in the mold carrier system is made possible thanks to hydraulic locking cylinders over the entire press stroke. The use of differential cylinders ensures extremely short cycle times and very high speeds. At the same time, the SFT design concept from KraussMaffei guarantees a perfect power flow and a high level of stiffness (FEM-optimized). EXPERIENCE THE TECHCENTER IN FLIGHT

6 6 Cover story AHEAD Issue THE MACHINE POOL OF THE TECHCENTER 1 WHAT DOES THE TECHCENTER OFFER? Field tests with development setups/ prototypes Customer trials Commissioning and v alidation of molds Processing trials of chemi c al systems and semi finished products Processing fillers and fibers Manufacturing prototypes and pilot series

7 Cover story For surface finishing CCM process cell RimStar Compact 4/8 CC Mold carrier with 80 tonnes of clamping force 2 For RIM / automotive flexible foam applications RimStar Compact 40/40 Metering piston for KD80-15 filler system Mold carrier with 80 tonnes of clamping force 3 For HP-RTM and wetmolding Process cell for HP-RTM and wet molding Processing epoxy resin, polyurethane and caprolactam Wet molding: robot-assisted material application Infiltration of dry, 2D or 3D-preformed semifinished fiber products Mold carrier with 800 tonnes of clamping force Clamping area of 2.50 m 1.50 m RimStar Thermo 8/4 metering machine 4 For HP-RTM Process cell for HP-RTM Processing epoxy resin, polyurethane and caprolactam Infiltration of dry, 2D or 3D-preformed semifinished fiber products CFT mold carrier with 380 tonnes of clamping force Clamping area of 1.30 m 1.30 m 5 For LFI, FCS and SCS Process cell for LFI and SCS/FCS Robot-assisted injection of glassfiber-reinforced polyurethane Robot-assisted injection of release agent or IMP/coating Processing fillers Mold carrier with 300 tonnes of clamping force E-tandem Hybrid 15/40 metering machine

8 8 Processes & Products AHEAD Issue Processes & Products POLYSET TECHNOLOGY FOR MANUFACTURING AUTOMOTIVE REFLECTORS A THERMOSET PLASTIC IN THE INJECTION MOLDING MACHINE Whether halogen headlamps or LEDs, the reflector behind the lamp ensures that the headlight lights up the road at night. The renowned lamp manufacturer ELBA has a plant in Romania, producing for Renault, Dacia and Škoda using the PolySet technology from KraussMaffei. This makes it possible to process thermoset plastics in the injection molding process. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI, ELBA, ISTOCKPHOTO C ar headlights have to be able to tolerate extreme temperature fluctuations ranging from minus 40 degrees in the Canadian winter to the blistering heat of the desert sun. Only thermoset plastics provide the necessary warping resistance. They cross-link in a chemical reaction and are substantially more dimensionally stable compared to the aliphatic-structured thermo plastics. ELBA uses BMC (bulk molded compound) for manu facturing reflectors. Today, 95 percent of all reflectors are manu factured using BMC. A proven material that can absorb up to 80 percent of mineral fillers is used in this process to achieve the desired mechani cal properties. In the case of reflectors, glass fibers that are four to six millimeters long are added. Due to the fact that BMC is not free-flowing, it places special demands on the machine equipment, especially on the material feed. Consistent repeatability fewer rejects For this reason, ELBA opted for a total package from Munich, which included a CX injection molding machine with 420 tonnes of clamping force, an AZ 100 automatic feed unit and the PolyLift material lift that makes it possible to load the BMC without physical exertion and without cycle interruption. It was important for us to ensure that all components are compatible with each other and for us to only have one contact person. Compared to the earlier BMC machines, we are now experiencing more uniform levels of repeatability and lower scrap rates, emphasizes Nicolae Motateanu, Director of the Automotive Division at ELBA. The AZ 100 automatic feed unit contributes to this as well. It breaks up the tough molded material in a hopper with pins without

9 KraussMaffei Processes & Products 9 EFFICIENT: THE POLYSET TECHNOLOGY Around 95 percent of all reflectors are today made of BMC (bulk molded compound). Due to the fact that BMC is not free-flowing, it places special demands on the machine equipment, especially on the material feed. damaging the fiber and has an important design advantage compared to the conventional piston stuffers on the market. Its screw feeder pulls the BMC downward and makes it possible for the air inside to escape from the back at the same time. In other models, however, the air remains inside of the material as soon as it is sealed at the top. This air is trapped and, under certain circum stances, passes into the mold, which results in fault patterns. To date, ELBA has been struggling with this, especially in visible parts. The AZ 100 has a filling volume of 100 liters and is fitted automatically by the PolyLift. The user loads the new BMC batch easily into a window at waist level. From there, it is brought upwards, the AZ 100 cover opens automatically and its hopper receives the replenishment. We now experience more consistent repeatability and lower reject rates. NICOLAE MOTATEANU, DIRECTOR OF THE AUTOMOTIVE DIVISION OF ELBA The plasticizing unit, the core element of the machine, was developed specifically for this procedure. The screw also ensures a long service life under the abrasive conditions of high filler content levels in the material and has been consistently optimized to conserve fibers. A mechanical anti-rotation device ensures that the screw position is held precisely and a non-return valve designed specifically for BMC prevents unwanted material backflow. The overall result is an extremely stable shot weight. In their automotive area, which accounts for nearly 60 percent of its business volume, ELBA specializes in headlights and tail lights. The company carries out all manufacturing steps it needs to be able to ship a complete light module to its customers in-house. This includes all steps from the component design and optimization to mold making, to the production of reflectors and colored multicomponent disks made out of PC and PMMA final assembly. ELBA also provides the reflector s aluminum coating itself, which requires an immaculate surface. For BMC, which is fibrous, this is achieved by compacting the material. Higher level of user-friendliness than before To ensure the large selection of different compression molding and ventilation steps and mold functions remains clearly arranged and user-friendly, the multi-touch MC6 machine control system has a 24-inch touch screen with a rugged glass surface and the Process- Designer software program. This ensures the mold setters can see all ongoing process steps, including the vacuum pump, AZ 100 and handling in a graphic display. Furthermore, they can move icons for dragging ejectors (for example) via drag and drop, and are thus able to control the entire sequence intuitively. For Motateanu, it was the right decision because it has given us significantly higher levels of user-friendliness than we ever had before. KraussMaffei uses its full range of expertise in the area of plastics processing and offers a complete package of material feed, preparation and processing for a technically challenging procedure like PolySet. Motateanu says, We are extremely satisfied with the GOOD COLLABORATION The engineers of ELBA and KraussMaffei in front of the CX 420 PolySet. product quality and service. For these reasons, KraussMaffei is our preferred partner when it comes to injection molding machines. ELBA wants to grow rapidly in the area of electromobility with new products. It is safe to say that both partners will continue to collaborate successfully in the future. YOUR CONTACT: Cordula Wieland Product Management PolySet, DuroSet, SilcoSet cordula.wieland@kraussmaffei.com

10 10 Processes & Products AHEAD Issue NUMEROUS LIVE DEMONSTRATIONS AT FAKUMA 2017 FROM FLAWLESS TO HIGH GLOSS Plastics processing involves a great deal of variation, from the packaging product, in which speed and precision are most important, to special processes such as silicone processing or the design of highend surfaces. By displaying exhibits in the clamping force sizes from 500 through 2,000 kn at Fakuma, KraussMaffei is demonstrating how flexibly the all-electric PX and the hydraulic CX series adapt to their respective requirements. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI T he success of the new all-electric PX series introduced to the market at K 2016 is impressive. Our customers appreciate the great variety and flexibility, not only in the configuration of the right machine, for example, thanks to a wide selection of clamping unit and injection unit combinations, but also in production or retrofitting, says Dr. Hans Ulrich Golz, President of the Injection Molding Machinery segment of the KraussMaffei Group and Managing Director of KraussMaffei. Demand is enormous, particularly from German customers, but also from those in the United States and China. Visitors at Fakuma will get the chance to see select exhibits in live operation at the KraussMaffei booth. These exhibits are selected as examples for demonstrating the unique combination of maximum precision and maximum flexibility on an all-electric injection molding machine. Flawless Fresnel lenses made of silicone Manufacturing transparent diffusion lenses, or what are called Fresnel lenses, from silicone is challenging because the material, which is called LSR (liquid silicone rubber), is extremely low viscosity and requires extremely high precision during the injection. Furthermore, the faceting on the surfaces of the flat lenses has no visible structures. The lenses are flawless, so to speak. It is in this application where the modular concept of the new PX series from KraussMaffei truly stands out. At Fakuma, the PX SilcoSet will combine hydraulic nozzle contact force with an electric injection unit in an unparalleled way. The result is extremely high precision. The molds hold tight and the production is free from leakages. APC plus for constant part weight The APC plus function assumes a special task in this application. It compensates for the batch fluctuations commonly encountered in LSR processing. As the process progresses, APC plus monitors the viscosity of the material and corrects the filling volume even in the shot. The process as a whole is made even more precise; the part weight remains constant. Even potential cross-linking of the silicone can be safely compensated. Producing thin-walled screw-cap closures at a higher rate Thin-walled parts need power during injection. The PX , the machine on which flip-tops of the Fontane type are being

11 KraussMaffei Processes & Products 11 PRECISE AND FREE FROM LEAKAGE AT THE SAME TIME The PX SilcoSet proves its worth when processing the challenging LSR material. CLICK HERE FOR THE VIDEO manu factured during Fakuma, thus has a boosted injection speed of 270 mm/s. The sealing caps, made of polypropylene, have a diameter of 28 millimeters and are designed with the short thread 1881 making this a classic packaging application. The high output quantities in this area require particularly short cycle times. Therefore, the PX 160 is equipped with speed options: faster injection, faster ejection, increased torque and faster nozzle movement. The compact automation system with the small LRX 100 linear robot of the new KraussMaffei generation removes the covers from the mold and places them into an integrated automation unit in which they are closed. The bottom line is that this saves time and space compared to familiar solutions on the market such as in-mold closing and separate covering process. Great freedom in design thanks to inductive mold heat balancing For its demonstration at Fakuma, KraussMaffei will collaborate with its partner Roctool (HD plastics). The demonstration will show how impressive surface effects can be achieved without additional post-mold finishing. For example, this is how 16 various surfaces, and thus 16 design variants, of a plastic game MORE TRANSPARENCY IN PRODUCTION: THE ENEW MAXECUTION Better utilization, fewer rejects and higher overall equipment effectiveness these are the target requirements of MaXecution, the new Manufacturing Execution System (MES) from KraussMaffei, which is celebrating its premiere at Fakuma. The MaXecution offers comprehensive integration and analysis of data and has been specifically tailored to the demands of small and medium-sized injection molding companies. This is because the new software creates more transparency and thus efficiency in production by means of key performance indicators, for example regarding the overall equipment effectiveness (OEE), the management of molds and resources, and the statistics on machines and rejects. MaXecution has a modular design and can thus be precisely adapted to the requirements of the respective customer. KraussMaffei is thus adding another fundamental element to its portfolio of Plastics 4.0 solutions. Premiere at Fakuma

12 12 Processes & Products AHEAD Issue POWER DURING INJECTION The PX produces fliptops of the Fontane type and operates at an injection speed of 270 mm/s at Fakuma. Demand for the PX is enormous, particularly from German customers, but also from those in the United States and China. DR. HANS ULRICH GOLZ, PRESIDENT OF THE INJECTION MOLD- ING MACHINERY SEGMENT OF THE KRAUSSMAFFEI GROUP AND MANAGING DIRECTOR OF KRAUSSMAFFEI LRX SMALL ROBOT console housing are created on a CX 200 in a 16-cavity mold. The design options in the technology are immense. Whether it is shades of colors, hologram, glossy or matte effects, every thing can be done in the one-shot process without additional postmold processing such as film decoration or (secondary) painting. The CX 200 from KraussMaffei scores points in this application with its outstanding performance as an extremely cost-effective and precise two-platen machine. These options include, for example, the drive concept in accordance with the state-of-the-art technology (IE3 types) and the energy-efficient BluePower servo drive. An active accumulator management system completes the BluePower overall concept. As a two-platen machine, the CX series requires a smaller installation area than longer three-platen models. Under the clamping unit, it provides space for peripheral devices and inside the clamping unit all kinds of demolding systems. During Fakuma, an LRX 150 of the new generation of linear robots will demold the components. In the next step, the component and the sprue are separated. Finally, the bagging and packaging are carried out. Thanks to the compact design, all this is possible within the safety housing. Which, in turn, reduces the footprint. YOUR CONTACT: PREMIERE AT FAKUMA The new LRX small robot generation from KraussMaffei proves its value through a progressive design and high flexibility. Jochen Mitzler Head of Market Intelligence and Product Management IMM jochen.mitzler@kraussmaffei.com

13 KraussMaffei Processes & Products 13 APC PLUS FOR UNIFORM QUALITY ON THE WAY TO ZERO-DEFECT PRODUCTION Thanks to intensive research and many years of experience, KraussMaffei has taken another successful step toward perfect consistency with respect to component quality. The adaptive APC plus process control ensures consistent molded part filling under any conditions. TEXT: GERHARD KONRAD GRAPHIC AND PHOTO: KRAUSSMAFFEI CLICK HERE FOR THE VIDEO In the start-up sequence as well as in cascade injection molding or with varying recyclate mixtures or simply if the door of the hall is open and a draft is generated, the patented APC plus technology (Patent DE B3) analyzes and regulates the injection molding process dynamically and can be used for all thermoplastic series. The system makes sense both in theory and practice. Over 50 percent of all new injection molding machines by KraussMaffei are equipped with APC plus. Consistently high component quality The APC plus system analyzes the current process status and compares it continuously with the learned target curve (reference curve). The changeover point and the holding pressure profile are adapted according to the viscosity and the material-specific melt compressibility. APC plus makes the necessary corrections in each individual shot directly and automatically. All disruptive influencing variables are compensated for in real time. With each shot, the mold is filled completely. The rejection rate is approaching zero. Fast start-up and stable processes Interruptions in the production process and the compensation of fluctuations necessitated by them are an ideal application area for APC plus. For example, in the series production of premium-quality interior components in in-mold labeling, the rejection rates can be reduced significantly. Frequent cleaning of the mold is a mandatory requirement in this process because of the specific glass-like surface of the inserted foil. Thanks to APC plus, after restarting, optimal product quality can be attained without delay. Increased proportion of recyclate saves expenses APC plus makes it possible to consistently process premium-quality components from difficult batches and an increased percentage of recyclate. Viscosity fluctuations occur due to bulk density, grain size and the properties of the respective batch. APC plus automatically intervenes in the production process in such a way that even when the material viscosity changes, the component weight remains consistent. YOUR CONTACT: REJECTS Unfilled spot on a cover. WITH APC PLUS Perfectly filled mold with every shot. Dr. Stefan Kruppa Head of Machine Technology stefan.kruppa@kraussmaffei.com

14 14 Processes & Products AHEAD Issue SUCCESSFUL LIVE DEMONSTRATION OF THE NEW IPUL SYSTEM QUITE A CROWD AT THE FIRST COMPETENCE DAY PULTRUSION CLICK HERE FOR THE VIDEO When guests from the United States, China and Japan are making a special trip to Munich just to see a new technological development, then you know the time has come for this technology. At Competence Day Pultrusion on June 28, KraussMaffei presented ipul, the first complete system for continuous pultrusion. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI I t is the easiest way to produce profiles, there are hardly any turnkey offers and it is a growth sector. In addition, we are knowledgeable about fibers, metering technology and extrusion. That is how Nicolas Beyl, President of the Reaction Process Machinery business area of the KraussMaffei Group, described the motivation of KraussMaffei to enter the pultrusion sector when he welcomed the guests. Already at the JEC trade show in Paris, the new ipul complete system had aroused great interest, and at the Competence Day, approx. 220 visitors took the chance of experiencing it live. Presentations by development partners and raw material manufacturers and a speed dating event between experts and prospective customers rounded out the program. The easiest way to produce profiles In pultrusion, continuous fibers usually of glass, carbon or aramid are infiltrated with a reactive plastic matrix and formed to the desired profile in a heated mold. Grippers pull the cured profile continuously and feed it to a sawing unit. The new ipul system from KraussMaffei encompasses this entire sequence. It takes a technology that has been common for a long time and revolutionizes it in two respects. It encapsulates the soaking of the fibers, which has mostly taken place in open vessels thus far, in an injection box, which permits the use of fast-reacting systems (epoxy, polyurethane, polyamide 6). And it increases the production speed from the usual 0.5 to 1.5 meters per minute to approximately 3 meters per minute. With this, efficiency approaches the extrusion of PVC, which opens entirely new markets to this technology.

15 KraussMaffei Processes & Products 15 CLICK HERE FOR THE VIDEO READY FOR THE VISITORS Final touches to the ipul system for the Competence Day Pultrusion at KraussMaffei. The widespread interest was mirrored by the composition of the attendees. Four of the ten largest practitioners of pultrusion in the world came to Munich, as did manufacturers of sporting goods and windows and automakers. Exciting papers bolster growth potential Wolfgang Hinz and Daniel Lachhammer, the pultrusion experts at KraussMaffei, recollected in their presentation the development of the ipul system over the past one and a half years, and they also explained its name: The i in ipul stands for injected, innovative, integrated and industrialized, which are the core features of out system. The subsequent presentations by development partners shed light on interesting partial aspects of pultrusion. For instance, Dr. Klaus Jansen of Thomas Technik discussed manufacturing curved and irregularly formed profiles. Here, it became obvious why the two companies complement each other so well. The pleasure of developing perfect solutions even for niche applications meets industrial competency, orientation toward efficiency, and worldwide marketing. Renato Bezerra from Fraunhofer IGCV presented the research capabilities of his institute in Augsburg, and Stephan Constantino from Huntsman even went airborne with pultrusion. The company collaborates with KraussMaffei in solutions for wind power plants. Wladimir Richter from Evonik explained examples from the construction industry. In a sandwich pane facade, the use of pultruded glass reinforcements (as opposed to steel) saved a lot of concrete because the concrete layer could be kept significantly thinner (10 to 15 mm) than was prescribed by the standards for corroding reinforcements (40 mm). Benedikt Kilian of Covestro explained in his presentation the advantages of polyurethane compared to earlier matrix materials such as polyester (inferior mechanical properties) and competing processes such as extruded aluminum (lower insulation capabilities and geometric stability). Face to face with experts Prior to the following live demonstration of the ipul system, Nicolas Beyl, Wolfgang Hinz, Daniel Lachhammer and retiring development director Josef Renkl, who after more than 40 years at KraussMaffei experienced his last working day, cut the ribbon. A face-to-face Q&A session was added to the program and then completely booked shortly thereafter. Interested parties were able to pose questions directly to the specialists of KraussMaffei and its partners. A guided tour through the plant and a get-together in the evening concluded the first, successful Competence Day Pultrusion. YOUR CONTACT: Wolfgang Hinz Business Development and Sales Management Pultrusion wolfgang.hinz@kraussmaffei.com WE HAVE STRUCK A CHORD IN THE MARKET WITH THE RELEASE OF OUR NEW IPUL COMPLETE SYSTEM Daniel Lachhammer, Nicolas Beyl, Josef Renkl and Wolfgang Hinz (left to right).

16 16 Processes & Products AHEAD Issue PULTRUDED REBARS PLASTIC REVOLUTIONIZES THE CONSTRUCTION INDUSTRY NEW MATERIALS FOR EFFICIENT CONSTRUCTION Concrete designs owe a significant part of their properties to the non-visible reinforcement on the inside. From now on, the pultrusion process on ipul systems from KraussMaffei can be used to produce the fiber-reinforced plastic rebars used as reinforcement in concrete designs. TEXT: GERHARD KONRAD PHOTOS: EVONIK, FOTOLIA

17 KraussMaffei Processes & Products 17 PULTRUDED REBARS Corrosion-resistant, lightweight, costeffective. the reinforcing steel, coating it with epoxy resin or, especially if intensive road salting or maritime air are involved, using stainless steels. All these options, however, are very cost-intensive. In contrast, rebars of fiber-reinforced plastic offer a host of advantages: high corrosion resistance, high tensile strength, no In coast protection, reinforcements of composite profiles ensure concrete bodies of high dura bility, since plastic rebars are resistant to saltwater. This corrosion-resistant material is equally attractive for use in underground construction, e.g., for subway tunnels and road foundations, as it is for the construction of bridges, facade cladding and walls along roads. In these applications, designs with fiber-reinforced plastic reinforcement enjoy another added benefit: because the reinforcement does not have to be protected against corrosive substances, the surrounding concrete layer can be significantly thinner with no reduction in strength of the component. This means immense cost savings for both material and transport as well as increased time savings thanks to the smaller volume of concrete required. R einforcing bars or grids, usually made of steel these days, give concrete its flexibility and carrying capacity. Environmental influences such as moisture and salt impede the service life of concrete designs substantially. Steel reinforcement is prone to corrosion. Concrete fundamentally protects the steel through its alkaline milieu. Corrosion, however, can only be prevented if a relatively thick, and therefore expensive, concrete cover over the steel reinforcement is ensured. There is always the risk that, due to faults in the concrete cover (e.g., cracks or accumulations of gravel), permanent protection is not guaranteed. This results in corrosion, detachment of the concrete layer and, finally, very time-consuming restoration. Potential counter measures here include galvanizing electromagnetic conductivity, reduced thermal conductivity. Further advantages include the low weight and consequently cheaper transport, the far easier handling at the construction site and the fact that the fiber-reinforced rebars can be produced endlessly and wound onto drums or into coils at the end of the pultrusion system. The market for composites continues to develop very dynamically. Important drivers of innovation are automated processes that allow manufacturing that is ready for large series production. In light of this fact, we are continually optimizing our systems and processes while expanding our port folio, says Erich Fries, Head of the Composites/ Surfaces business unit with KraussMaffei. By creating ipul, KraussMaffei has given a new foundation to the manufacturing process for pultruded components. Several renowned partners are using the technology and developing corresponding applications. Even the thermal conductivity is low, which is an advantage if insulating components have to be produced and, for instance, thermal bridges have to be avoided. Elements made from porous concrete and reinforced by composite rebars are also viable because they reduce the weight and because they feature excellent temperature resistance and bending stiffness. YOUR CONTACT: Daniel Lachhammer Project Manager of Pultrusion daniel.lachhammer@kraussmaffei.com Wolfgang Hinz Business Development and Sales Management Pultrusion wolfgang.hinz@kraussmaffei.com

18 18 Partners & Projects AHEAD Issue Partners & Projects ROTH WERKZEUGBAU ENTERING THE PACKAGING SECTOR EVERYTHING PACKAGED PERFECTLY Together with KraussMaffei and Netstal, Roth Werkzeugbau hopes to conquer the packaging market. The official launch was Roth Packaging Day in Auma-Weidatal, Thuringia, Germany, in late May. More than 80 visitors accepted the invitation to the new, state-of-the-art technology center. TEXT: MICHAEL BIRCHLER, PETRA REHMET PHOTOS: ROTH WERKZEUGBAU, K-ZEITUNG SPACE FOR IDEAS The new, amply dimensioned technology center was abuzz with interest at the first Roth Packaging Day. Live demonstrations on the machines from KraussMaffei and Netstal highlighted the broad spectrum of packaging solutions offered. E ntering a market segment that is still new to the company, Roth Werkzeugbau is pursuing an ambitious objective and setting a high company standard for quality. Our motto is: Either we do it right, or we don't do it at all, declared Marco Roth at the beginning of the event, who is managing the family business in its second generation. So far, the company has had a strong presence in the auto motive industry, and now it wants to make a name for itself in the packaging industry as well, not least because many packaging manu facturers have their headquarters within 300 kilometers of Auma-Weidatal (in the Greiz district of Thuringia, Germany). According to Roth, the company has been studying the special properties of packaging tools intensively for around four years. It has already implemented its first project, and its employees had to learn a few things the hard way while doing so. By now, though, we have gained enough experience for the official launch. This launch means entering a new era for our company. Within the next five to ten years, we want to make about 50 percent of our sales volume in the packaging industry, says Roth. New, state-of-the-art technology center The newly built, amply dimensioned technology center plays a central role in the

19 KraussMaffei Partners & Projects 19 implemen tation of the packaging strategy. The customer nowadays wants more from us than merely the mold. We support the customer in its effort to make its injection molding processes more efficient. Our longtime partnership with the KraussMaffei Group has made a great deal of difference in this respect, explains Roth. The basic equipment includes four injection molding machines of the CX and MX series from KraussMaffei, which cover the clamping force range from 110 to 1,300 tonnes. All machines are equipped for three-component applications and with six-axis robotics from KraussMaffei. Previously, molds for auto motive applications have been validated on these systems. Now, these systems are also being used for packaging products with larger wall thicknesses, particularly for reusable and logistics containers. For extremely thin-walled packaging applications, Roth has also owned two fast EVOS injection molding machines from Netstal with 350 and 550 tonnes of clamping force since mid Between the two machines, there is a highly flexible six-axis robot for inserting in-mold labels (IML) and demolding the finished articles. To ensure its ability to make the validation process as efficient and precise as possible, Roth has developed a special handling solution in collaboration with KraussMaffei Automation. The solution fits the requirements in the test mode of a mold maker optimally and also permits short cycle times. The systems used at Roth s technology center have been designed specifically for flexible use in mold validation. All products from the world of packaging from a single source Packaging Day at the Roth technology center was something of a small milestone, even for the KraussMaffei Group. Here at the facility of our respected partner, Roth Werkzeugbau, we can give a live demonstration to show that our two brands KraussMaffei and Netstal make us the only manufacturer of injection molding machines in the world to cover the entire range of packaging applications with highly efficient solutions for any specific product, says Klaus Zeiler, Head of Global Business Development Either we do it right, or we don t do it at all. MARCO ROTH, MANAGING DIRECTOR OF ROTH WERKZEUGBAU at KraussMaffei. During the one-day event, live demonstrations were performed on a total of five injection molding machines. The range extended from the solenoids and stacking boxes used at the company s own plant, to the popular EMSA food storage containers with matching lids and patented TPE seal, to an IML decorated polypropylene cup with a wall thickness of only 0.4 millimeters. During the development of this extremely challenging application, the team at Roth Werkzeugbau was able to count on complete support from Netstal. Thanks to our decades of experience and our sophisti cated application knowledge for thinwalled packaging with and without in-mold labeling, we were able to provide optimal consultation to our partner, Roth Werkzeugbau, regarding wall thickness optimization, cycle time reduction and reproducibility. The result is a win-win situation for a packaging manufacturer, with consistently high quality and very low unit costs, explains Thorsten Just, Managing Director at Netstal Germany. Ambitious plans for the future Roth Werkzeugbau relies completely on innovation to achieve its ambitious goals. For instance, in order to further reduce the wall thickness of cups, the company will soon be taking a chance on the injection compression molding process that was further developed by Netstal. Given the company slogan We do it once and we do it right! one can imagine that the next Packaging Day will feature a series-ready injection compression molding application for interested industry professionals to admire. The next Packaging Day is being planned for YOUR CONTACT: Klaus Zeiler Head of Global Business Develpoment klaus.zeiler@kraussmaffei.com WE WANT TO TAKE OFF TOGETHER IN THE PACKAGING MARKET Klaus Zeiler (KraussMaffei), Marco Roth (Roth Werkzeugbau) and Thorsten Just (Netstal Germany) (left to right).

20 20 Partners & Projects AHEAD Issue CRIOTEC TRUSTS IN THE PUR FOAM TECHNOLOGY FROM KRAUSSMAFFEI GOOD COOLING PAYS DIVIDENDS By investing in a state-of-the-art, automated housing foaming system from KraussMaffei, Criotec S. A. has more than doubled its production capacity at its headquarters in Santa Catarina, Mexico. In three-shift operation, 1,800 refrigerator housings per day are foamed with an insulating layer of polyurethane and shipped. TEXT: PETRA REHMET PHOTOS: CRIOTEC a RimStar Compact 40/40 mixing and metering system with mobile mixing head, an automated loading and unloading shuttle, six stationary fixtures and six adjustable foam molds for cabinet foaming, a preheating oven with two different cabinet positions, and a pentane monitoring system. R efrigerators must be well insulated if cooling capacity and energy efficiency are to remain stable. Criotec is one of the leading manufacturers of refrigerators and freezers in the Americas and has specialized mostly in products for industrial use such as refrigerators for beverages, refrigerated display cases or insulated boxes. Especially in these large-volume cooling units, insulation is critical to ensure an optimal trade-off between cooling capacity and cost-efficiency in the end. This task is handled by a layer of foamed polyurethane (PUR) produced on the new housing foaming system from KraussMaffei Reaction Process Machinery. KraussMaffei has convinced us over the long term as a system supplier. Thanks to the high degree of automation of the new housing foaming system, we have been able to significantly increase productivity and thus cost-efficiency, says Felipe Nuñez, Manufacturing Manager at Criotec. The scope of supply for the entire line includes High quality and dimensional stability In addition to the high degree of automation, it is the consistently excellent quality and dimensional stability of the produced foam products that we benefit from, Nuñez continues. One decisive factor for the high product quality is the RimStar Compact 40/40 mixing and metering system, which impresses with its particularly stable process and temperature control of the components, and thus ensures a permanently constant temperature. The mobile ULP 12/18 transfer mixing head can be conveyed on a manipulator and supplies the individual fixtures. The entire process is fully automated. KraussMaffei has earned a longterm partnership with us as our system supplier. FELIPE NUÑEZ, MANUFACTURING MANAGER AT CRIOTEC A STRONG TEAM (LEFT TO RIGHT) Gerardo Manrique (Operations Director, Criotec), Angel Gonzalez (Reaction Process Machinery Manager, KraussMaffei, Mexico) and Felipe Nuñez (Manufacturing Manager, Criotec).

21 KraussMaffei Partners & Projects 21 SYSTEM SOLUTION FROM A SINGLE SOURCE The new KraussMaffei cabinet foaming line at Criotec in Santa Catarina, Mexico, stands out for its high degree of automation and for its consistently high foam product quality and dimensional stability. CLICK HERE FOR THE VIDEO Flexibly positioned for new markets However, speed, precision and top quality are not the only requirements that must be met at Criotec. The cabinet foaming line is at present foaming up to seven different sizes and models from the current Criotec portfolio. In this flexibility, we see a further strength of the new cabinet foaming line. Thanks to this line, we are perfectly prepared not only for the current Criotec products but also for future developments and markets, concludes Nuñez. For example, the six hydraulically driven fixtures can be individually adjusted to the cabinet dimensions. The precise temperature control is a state-of-the-art energy-saving system. In addition, fast and easy mold changing is poss ible due to the partly automated changeover devices of the fixtures, increasing the flexibility and availability of the system. During configuration, delivery and commissioning of the new Criotec system, the three KraussMaffei locations Munich, Abbiategrasso (Italy) and Queretaro (Mexico) worked in collaboration with each other. The mixing and metering system, including the tried-andtested mixing head, came from the original plant in Munich, as usual, while the robust and simultaneously precise foaming system including the pentane monitoring system came from the Major Appliances Competence Center in Abbiategrasso. The customer receives prompt and professional service and local support from the KraussMaffei employees in Mexico. Production capacity doubles and foaming efficiency increases: In the end, it is not just Criotec who benefits from the new housing foaming system, but the end customers as well, who get to enjoy a perfectly insulated, and therefore energy-efficient, cooling unit. YOUR CONTACT: Gabriele Amodeo Head of KraussMaffei Italiana S.r.l. gabriele.amodeo@kraussmaffei.com

22 22 Partners & Projects AHEAD Issue SUSTAINABLE LEARNING IN MIXED REALITY KRAUSSMAFFEI NOW USING THE HOLOLENS FOR TRAINING KraussMaffei is one of the first companies in the world to use a real-time simulation in a mixed-reality world to train operators of injection molding machines. The program developed by KraussMaffei is visualized realistically by Microsoft HoloLens. TEXT: GERHARD KONRAD PHOTOS: KRAUSSMAFFEI Training with Microsoft HoloLens Programming core-pulling units is an import ant operating step in injection molding, says Rupert Gruber, leader of the training program. That is why we have implemented this procedure as the first 3D simulation in the mixedreality technology. Using HoloLens, we can prepare the participants in our seminars for their jobs even more intensively. And learning with the data glasses is a fun solution that is viable in the long term. Sustainability and fun factor Training in a 3D world in combination with real-world experience makes learning easier and ensures sustainable success in learning, states Michael Zawrel from Microsoft. Users especially like the intuitive operability. Universities in the United States, the United Kingdom and Switzerland are the pioneers in applying the mixed-reality technology using HoloLens. Courses in anatomy for future surgeons are being carried out efficiently and under optimal conditions thanks to support from HoloLens technology. Even in machine building, mixed reality is seeing increased use as a training instrument and in maintenance work. KraussMaffei is also a pioneer in this respect. Simulation in real time With the HoloLens, students can immediately experience the functional core-pulling sequence that they have programmed on the physical simulator in real time using a virtual mold. The virtual representation also allows the user to take a glance beneath the surface, i.e., at processes that usually happen hidden inside the machine. We are one of the first companies to let a physical control system communicate with a virtual tool simulation in real time, explains Günther Grimm, Department Head of Software and Control Technology and initiator of the project. Full view A person wearing the mixed-reality glasses can see through the components virtually and look at the assemblies of a machine from all sides. Furthermore, the user can even manipu late the virtual reality directly and program the desired processes on a physical MC6 control system. The outcomes of the entered parameters on the 3D reality are shown immediately, whether they are positive or negative. Learning from experience In this case, however, incorrect programming does not destroy the mold or the machine. Correction is always possible in the virtual environment/world. Thus, learning from mistakes becomes possible without outrageous expenses or damaged assemblies. YOUR CONTACT: MIXED REALITY Learning for real applications in virtual spaces. Rupert Gruber Head of Training, Injection Molding Machines rupert.gruber@kraussmaffei.com

23 KraussMaffei KraussMaffei Group 23 KraussMaffei Group THE NEW CSR WEBSITE IS ONLINE SOCIAL RESPONSIBILITY AND SUSTAINABILITY COUNT The KraussMaffei Group pledges to uphold sustainability and, for the first time, is publishing non-financial information about its social responsibility on a dedicated website. CSR (corporate social responsibility) is a general term used to describe a companyʼs responsibility for sustainable management in economical, ecological and social terms. This year, CSR reporting became mandatory for large capital market-oriented companies as a result of a new EU directive. Although the KraussMaffei Group is not directly affected by the directive, it is in keeping with our mission to report about CSR topics proactively and with transparency. This so-called nonfinancial information regarding topics such as respect for human rights, environmental protection and social aspects is an increasingly important part of our corporate culture. Moreover, the information requirements from customers, representatives of public interests and potential employees concerning these topics are growing. The strategy of the KraussMaffei Group is focused on long-term corporate success and includes five areas of sustainability: COMMITMENT TO SOCIAL CAUSES AND SUSTAINABILITY The CSR website of the KraussMaffei Group provides information about current projects and measures. Sustainable company management Our employees Product management Corporate environmental protection Social involvement The current CSR projects include the use of environmentally friendly technologies and donations to non-profit organizations as well as professional development programs and development measures for employees. Of course, our sustainable compliance system also makes an effective contribution to the social responsibility of the KraussMaffei Group. For more information, refer to our new CSR website: Check it out!

24 24 KraussMaffei Group AHEAD Issue TRAINING PROGRAMS EXPERTISE DETERMINES SUCCESS Employees with sufficient training are a critical success factor in plastics processing. For this reason, the KraussMaffei Group offers the users of its systems a sophisticated, modular seminar program. The courses deal with practical aspects of machine operation and configuration as well as the theoretical basics of the work with all types of plastics. Qualified instructors share their knowledge of mechanical and hydraulic systems, machine control systems, servicing and maintenance of machines, and fault manage ment. New employees recognize opportunities to improve their performance and to implement the correct measures where necessary. Experienced machine operators can help them refresh their knowledge and learn to use new technical developments optimally. Specific course offers The seminars are each specifically tailored to the special features of products from the KraussMaffei, KraussMaffei Berstorff and Netstal brands, and to the needs of the target groups. The courses are held at all locations by request or at a customerʼs facility. We have developed a special selection of qualification courses for our customers in Mexico and South America. You can obtain information on the websites of the KraussMaffei Group brands, or contact your service contact or our sales and service partners. FIRSTHAND EXPERTISE Experts convey knowledge about the technology and process.

25 KraussMaffei Imprint 25 OUTSTANDINGLY EFFECTIVE AROMA PROTECTION CO-INJECTION PROCESS FOR COFFEE CAPSULES The Netstal product brand is internationally known for first-class, high-performance and high-precision injection molding machinery and system solutions. At Fakuma 2017, Netstal produces three-layer coffee capsules using the precise co-injection process. An all-electric two-component injection molding machine of the Elion series with 1,200 kn of clamping force is used. Through sandwich pane injection molding, IML-labeled plastic capsules and many other packaging products can be manufactured with outstanding efficiency and a reliable barrier effect. THE DECISIVE FACTOR FOR COST-EFFECTIVENESS TWIN-SCREW EXTRUDER FOR PO RECOMPOUNDS At the Fakuma trade show, KraussMaffei Berstorff is presenting concepts for a processing system built in a cascade design. Customized compounds can be manufactured entirely or in part from recyclates. They feature similar characteristics to those of virgin materials, but at a significantly more attractive price. Compatible processing units are required in order to create customized recompounds. Extrusion technology plays an increasingly important role here. IMPRINT Publisher: KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Germany Phone Fax Person responsible: Simone Werner (responsible for content according to German media law) Editor-in-chief: Gerhard Konrad Editorial team: Michael Birchler, Dr. Sabine Kob, Gerhard Konrad, Petra Rehmet Photo credits: Criotec, ELBA, Evonik, Fotolia, istockphoto, KraussMaffei, K-Zeitung, Roth Werkzeugbau Concept and design: Kirchhoff Consult AG, Hamburg Printed by: omb2 Print GmbH, Munich In order to make the magazine easier to read, we have mostly dispensed with gender-related double designations (e.g. male and female readers this is more relevant for the German text) for mixed groups of persons. The male gender form is used as a collective term. TRADE SHOW CALENDAR JANUARY 2018 JUNE 2018 India Rubber Expo, Chennai, India KraussMaffei Berstorff Lightweight Technology, Tokyo, Japan KraussMaffei Saudi Plas, Riyadh, Saudi Arabia KraussMaffei, KraussMaffei Berstorff Interplastica, Moscow, Russia KraussMaffei Group MD&M West. Anaheim, CA, United States KraussMaffei Iran Plast, Tehran, Iran KraussMaffei, KraussMaffei Berstorff Plast India, Gandhinagar, India KraussMaffei Berstorff Gulfood, Dubai, United Arab Emirates Netstal Tire Technology Expo, Hanover, Germany KraussMaffei Berstorff Polyurethanex, Moscow, Russia KraussMaffei Foam Expo, Novi, Michigan, United States KraussMaffei JEC World, Paris, France KraussMaffei Plast Alger, Algiers, Algeria KraussMaffei Plastics in Automotive Engineering, Mannheim, Germany KraussMaffei Medtec, Stuttgart, Germany KraussMaffei ReTEC, Essen, Germany KraussMaffei, Netstal Tires & Rubber, Moscow, Russia KraussMaffei Berstorff Chinaplas, Shanghai, China KraussMaffei Group NPE, Orlando, Florida, United States KraussMaffei Group Elmia Polymer, Jönköping, Sweden KraussMaffei Utech Europe, Maastricht, The Netherlands KraussMaffei Plastpol, Kielce, Poland KraussMaffei, Netstal Plast Milano, Milan, Italy KraussMaffei Group The customer magazine is published twice a year in German and English. The magazine may only be reprinted with the written permission of the publisher.

26 Lightweight construction/ Composites Auto moti ve inte rior s Su rfac es Insu la ti on/ white goodod s Spec ecia ial so lu tions, you r KraussMaff affei expert for lightweight construction/ on/composites Leading experts for leading solutions Rethinking lightweight construction/ composites Welcome to KraussMaffei the world s leading provider of reaction process machinery. Fiberreinforced plastics combine a low weight and a high degree of stability. KraussMaffei provides you with all of the services required along the composites technology process chain and for the entire planning process all from a single source. We are a global leader thanks to the many technologies we use, such as long fiber injection molding or high pressure resin transfer molding. Engineering Passion