Innovative, multifaceted talents Leading the way with

Transcription

1 Ahead The CUSTOMER Magazine of KraussMaffei Issue Innovative, multifaceted talents Leading the way with technological expertise Wind energy Solar energy Utility vehicles Construction materials Automotive

2 Editorial CONTENTS Cover story 4 Leading the way with technological expertise 7 interview: Developing the cutting edge further Brand & markets Dear Customers and Readers, Many athletes have produced inspiring peak performances at the Olympic Games in London. In addition to being impressed by the athletes wanting to give their best, I was often struck by the reasons they gave for what they were trying to achieve and what drove them on. Usain Bolt, for example, declared with self-assurance, I always wanted to drive myself towards achieving what no one else has ever managed to do before. I always wanted to be a trendsetter. As is often the case, there is a close analogy between sport and the world of business. What is it that makes a businessman a trendsetter in his sector? He can do more than the competition. He sets new standards. He is innovative and exudes enormous passion and conviction for what he does. All of that also applies to KraussMaffei and, in this edition of AHEAD, we will show you how we are setting new trends in the sector time and time again. And so, we have assembled here for you many interesting contributions and market and project reports all related to this topic, which will show you how we are using our first-class machines, technologies, and solutions to bring your production to the peak of its potential. For instance, with our new GX range in 2012, we have already set a new international standard in powerful injection molding machines for numerous sectors. We are also ahead of the field in solutions for global trends in plastics. For example, when the main concern is to reduce energy consumption by following the trends in lightweight construction. In this edition, we show you some of our trendsetting solutions from MuCell to CoverForm through to high-pressure RTM processes. We are naturally proud when sector experts recognize our performance, as, for example, when we received the JEC Europe Innovation Award and the SPE Award for our brochures on fiber composite solutions this year. As a sector leader, we want to continue to set trends and are therefore developing our organization with this in mind. Through a new orientation in injection molding and reaction process machinery, we are ideally positioned in relation to our customers fields of activity and in future, will be able to react even more constructively to your individual needs. And you can rest assured that we protect our innovations against undesirable imitation, which is of course all to your advantage. We are maintaining our intuitive sense for forward-looking trends with currently around 1,450 patents and an annual production of between 30 to 50 inventions. Take advantage of the situation and be AHEAD with us, not just today but also tomorrow and the day after! I hope you enjoy reading the magazine. Frank Peters Executive Vice President Sales 8 Wide-ranging expertise in the field of injection molding 9 first technology-spanning energy analysis years of KraussMaffei Automation 12 The new benchmark: The GX Series 14 Major order from Saudi Arabia 14 Competence Show in the Land of the Rising Sun 15 The right man for the job 15 Concentrated expertise for customers 16 positive signals from southern European markets Processes & products 20 efficient manufacturing of fiber composite components 21 gx: Great potential in lightweight construction percent lighter airbag housing Partners & projects 22 Rapid growth in North America 23 purtrain is on target for the automotive industry KRAUSSMAFFEI GROUP 24 Group presence without borders 25 Technical treats for the Far East 26 Energy efficiency: Smart pipes 26 ELION 3200: A successful concept 26 Plant expansion in Slovakia and China 27 property rights secure technological advantages 27 Imprint

3 KraussMaffei Contents 3 4 Technology leadership KraussMaffei is a pioneer in several fields, which enables it to help its customers be technological leaders years of KraussMaffei automation Exciting exhibition pieces demonstrated what industrial and linear robots can do. 16 Southern Europe The classic holiday countries offer more than just sun and sea. They also have some good news, especially when it comes to the plastics sector. The CX PolySet completes the machinery package offered by the Greek company Dasyc S.A.

4 4 Cover story AHEAD Issue DEMANDING In many business areas, such as automotive and commercial vehicle manufacturing, the component requirements are becoming more demanding. The typical demands include greater mechanical strength and lower weight.

5 KraussMaffei Cover story 5 Innovative, multifaceted talents Leading the way with technological expertise Technological leaders are characterized by their tendency to not only detect important market trends, but also to set them in the first place. KraussMaffei is carrying out pioneering work in several fields, which enables it to help its customers be technological leaders. Text: Joachim Weber, EVA MÜNZENMAIER Photos: Harald Mehnert T he JEC Europe Innovation Award, which KraussMaffei won in April 2012 (more information on page 23), was symptomatic of its excellence. On one hand, it proved yet again that innovation frequently springs from collaboration between different disciplines. On the another hand, it reaffirms KraussMaffei s strategy with regard to innovation and technology, in which lightweight construction plays an important role as one of the biggest technological trends. Developing innovative and ready-to-use operational process solutions to replace conventional materials with plastic is one of our core competencies, explains Jochen Mitzler, Manager of the Strategic Product Management Department. Our clients requirements are increasing across sectors: the plastic parts have to be lighter than conventional materials yet just as stable. At the same time, several functions must be integrated, which makes the manufacturing process more complex, yet the assembly costs must be reduced. In order to appear high-quality, the visible parts must also be visually attractive and must have pleasant haptics and all of this at optimized manufacturing costs. KraussMaffei has reinforced its expertise: Munich is home to the world s most versatile TechCenter for lightweight components and fiber composite technology. Customers benefit from KraussMaffei s expertise in the fields of injection molding machinery and reactive materials processing, which produce a wide range of customized and process-specific solutions. Supporting customers throughout the entire value-adding chain According to Thomas Elfroth, Sales and Product Manager Composite/Surfaces: When it comes to new processes, our customers demand a clear reduction in costs along with qualitative improvements throughout the process. These requirements can be seen not only in the automotive sector, but also in the consumer electronics sector, the household appliances sector, and the packing industry. At the same time, there is also a standing order to increase the efficiency of the manufacturing process. Ever-decreasing cycle times, lower scrap rates, lower energy consumption, and reducing material costs all these are additional goals that have to be attained simultaneously. Since the keyword is multifunctionality, an ever-increasing level of integration between the operations has to be achieved as well. A facility that KraussMaffei installed for a large European car manufacturer reveals what lies behind this approach. Two double swivelplate machines use a fully automated process to produce components having an outer skin and a sub-structure. Both of them are injectionmolded separately, joined together accurately by rotating the two swivel plates, and connected tightly with a third plastic component. This serves to integrate a large part of the assembly process into the plastics processing phase. High and versatile expertise in process engineering across sectors KraussMaffei s process engineering is always impressive. The FiberForm process is ideally suited to applications in which strength is more important than the surface aesthetics, such as the supporting structures found in vehicles. The so-called organic sheets or endless fiber fabrics that are found in the thermoplastic matrix are thermally reformed in the injection mold. They are then over-molded, back-molded, or over-fed with another thermoplast, such as a glassfiber-reinforced polyamide. This makes it possible to integrate other functions, such as stiffening ribs or extension elements. With its high degree of automation and cycle times of less than 60 seconds, FiberForm is ideally suited to the large-series production of new, light structural components. The HP-RTM process, which is another process used for the production of structural components, is generally used for small and medium-sized series because its current cycle times range from three to five minutes, depending on the size of the component. In this process, a pre-finished reinforcing material, such as carbon fiber tissue, is soaked into a sealed, evacuated mold that has no air voids with the help of an epoxy resin, which eventually hardens. HP-RTM HIGH-PRESSURE RESIN TRANSFER MOLDING HOLISTIC KraussMaffei s new light construction center is opening up new horizons for process-spanning solutions. 1. Semi-finished products from the roll 2. Handling the ready-made semifinished products 3. Transfer to the preform station 4. Preforming 5. Transfer the preform to HP-RTM station 6. Pull vacuum (optional) 7. Resin transfer/hardening 8. Component removal

6 6 Cover story AHEAD Issue CeLLForm (MuCell TM ) Rear RSP (non-return valve) SCF interface kit The MX uses the process known as structural foam injection molding. Components are created with a compact outer skin and foam structure on the inside. SCF injector Front RSP (non-return valve) Complete SCF dissolution in the melt N2 SCF injection SCF metering system Plasticizing the plastic melt Erich Fries, Manager of the Composites/Surfaces business unit, thinks the carbon fiber composite parts have a lot of potential. If, in the course of future E-mobility, the automotive industry is forced to make up for heavy batteries in other places, there is hardly an alternative to structural components based on RTM. In the future, the process will also be used in large-scale production, he says. Our goal is to enable automation of the entire process, right from unwinding the carbon fiber to cutting the finished part. He believes that cost reduction options are present not just with regard to fiber material, but also with regard to plastics: There have already been attempts to replace the epoxy resin with polyurethane or modified polyamides. The process of producing thermoplastic foam structures with the help of chemical or physical foaming technology is another lightweight construction method. In the case of CellForm processing or foaming, the granulated or gaseous blowing agent is fed into the melt in order to reduce the density of the plastic. Chemical and physical foaming make it possible to reduce the density and eliminate the holding pressure of the plastic, which has several advantages: faster cycles, less material usage, dimensional stability and lower costs. Premium-quality clean-room standards Various plastic components are also coming to the fore in medical technology and the pharmaceutical industry. Irrespective of whether they are used as product components or as packaging material, hygiene is always the top priority. Consequently, plastic processing machines that conform to clean-room technology standards are in great demand. Conformity with the strict guidelines is guaranteed by various engineeringrelated details, such as encapsulated lubrication, using water cooling instead of air cooling, flat surfaces, anti-static paints, and control systems that satisfy the strict documentation-related requirements, including those applicable to the production of pharmaceuticals. Even in this context, various group sectors work together closely. According to Mitzler, this is because: In our case, new products and processes are increasingly the result of close collaboration with our clients and the synergy that exists between our areas of expertise, which are injection molding technology, extrusion technology, and reaction process machinery. This unique combination really sets us apart and is what our Technology 3 formula stands for. Improved surfaces through innovative processes The goals of several surface techniques, which combine various process steps into a single step, lie between achieving aesthetic value and attaining costeffectiveness. For example, SkinForm combines injection molding processes and reaction process machinery: a thermoplastic component is injected into a mold and it is then flow-coated with polyurethane during the second cycle. This produces a component that is characterized by, among other things, leather-like haptics, soft touch, high scratch-resistance, and polychromatic if required. Read more! We would be happy to send you brochures about the automotive industry, fiber composite technology, surface technology, RTM or other innovative technology. For more information, visit: The ColorForm process has a similar functionality, in that it makes it possible to imprint thin layers of lacquer onto various plastics directly in the mold. In a single step, it creates perfect high-gloss surfaces in conjunction with the production of the parts, without having to go through the usual process steps, such as cleansing or prime coating. The CoverForm process was the result of interdisciplinary collaboration with the material manufacturing company Evonic. Here, the PMMA injection-molded parts are given a thin, transparent, scratch-resistant and chemical-resistant surface using a multi-component reactive system, which has an acrylate base, both in a mold and a process. YOUR CONTACT Jochen Mitzler Manager Strategic Product Management Injection Molding Machinery KraussMaffei Technologies GmbH jochen.mitzler@kraussmaffei.com

7 KraussMaffei Cover story 7 Developing the cutting edge further When it comes to reducing the weight and thus vehicles energy consumption (which in future will include an ever-increasing number of electric cars), lightweight construction solutions and, in particular, fiber-reinforced plastics are of critical importance. Erich Fries, Manager of the Composites/Surfaces (fiber composite and surfaces) business unit talks about the challenges and potential opportunities facing composite parts. the Interview was conducted by Markus Betsche. AHEAD: What goals you have set for yourself? Fries: As always, fiber composite and lightweight components have a lot of potential. New reports dealing with new fields of application, technology, or materials are coming in almost every day. Our goal is to expand our cutting edge in this business area further and to adapt our technology to carbon, the fiber of the future. Our motto is one must pray for miracles, but work hard for changes (Thomas Aquinas). We are going to encounter a wide range of new and interesting technology. We consider this challenge to be an opportunity that we can overcome as a team. AHEAD: What are the target groups you are looking at? Fries: Our clients from the automotive industry, the utility vehicle sector, the transport sector (for example rail transport), and the aircraft construction sector are looking for a competent partner who can support them across the entire process chain, which ranges from the very first component idea to series production. In this regards, we are currently well placed with our products and services, as well as with our partners Dieffenbacher, Fraunhofer, and LCC, for example. Our goal is to further strengthen and expand this collaboration. For us, being a frontrunner also means assuming a leading role vis-à-vis networks and clusters. AHEAD: When it comes to composites, which materials do you think will come out on top? Fries: Even today, when they hear the word composites, most people think of carbon-fiber-reinforced components in an epoxy resin matrix. For us, the field is a lot wider than that. In the case of reactive materials, we see polyurethane and casting polyamides as good alternatives, and when it comes to thermoplastic materials, PA and polypropylene have already proven themselves. When it comes to reinforcement, the situation can involve any of the different types of fibers that are more or less well established, depending on the client s requirement. There is not yet a clear trend in this dynamic developmental environment but at the moment, everything seems to be pointing toward carbon. However, you cannot ignore the hybrid formulations either: the vehicles of the future will have a combination of different materials (carbon/aluminum combinations). Erich Fries considers the market for composite facilities to be a growing market. AHEAD: Are the processing techniques already well established? Fries: In the field of composites, there are several old and wellknown manufacturing processes that have already proven themselves in production environments and there are several new approaches as well. The highly complex requirements due to the required unit numbers, the automated processes, the need to guarantee reasonable material costs, and the maximum possible reduction in the component s weight lead to many variants. Developing this procedure definitely has not yet reached its conclusion. In case of the HP-RTM, two process variants, namely compression RTM and wet molding, were developed recently and both have their own specific advantages. For example, in case of wet molding, the carbon fibers (scrap produced during the preform production) can be recycled as piece goods. AHEAD: What motivates you? Fries: When customers reward our performance with orders! At the moment, we are particularly happy about successfully completing a development project that we carried out in collaboration with a well-known car manufacturer, who awarded a contract worth several million euros to us and Dieffenbacher, one of our partners. Right from the beginning, we were closely involved with the component development process and working out the manufacturing process. And we are already looking forward to the next step, which involves activating the complete HP-RTM line.

8 8 Brand & markets AHEAD Issue Brand & markets Wide-ranging expertise in the field of injection molding We want to use our performance capabilities and outstanding machine technology to generate even more value added for our customers along their entire value-adding chain. To this end, we will maintain the separate market presence of the Netstal and KraussMaffei brands with a clearly defined product portfolio and their independently operating sales organizations. Dr. Hans Ulrich Golz, President of the Injection Molding Machinery Segment by pooling the excellent know-how of two strong brands, we can offer our customers the right product of the right brand for them from our wide and powerful product portfolio, as well as the corresponding services tailored to their individual needs. We are also emphasizing our technology leadership on the market. We are highly motivated and are gaining momentum. Frank Peters, Executive Vice President Sales Our motto is: Together, we are stronger. Since 1 July 2012, the KraussMaffei Group has added a comprehensive sector: injection molding machinery. It unites the KraussMaffei and Netstal brands. The company has consciously decided to take this step, to increasingly align its services to its customers requirements along the value-adding chain, to utilize the market potentials better, and to use the innovative strengths of both these brands more aggressively by joining them together. The advantage for our customers: both the brands strengths are retained with a clearly defined product portfolio. The most important objective is to offer the customer the best solution, irrespective of the brand and the location. Dr. Hans Ulrich Golz, President of this sector, is very happy that he could virtually fill all management positions in the Injection Molding Machinery sector with experienced and highly competent managers from the KraussMaffei Group. In addition to his task as the head of the sector, Dr. Golz has also assumed the task of leading the sales division for the Netstal brand. Mr. Frank Peters is the Executive Vice President Sales. Dr. Karlheinz Bourdon is responsible for the Technology fields (among others, Research and Development, Processing, and Automation). Dr. Bernd Thurat heads the Operations Department and Renzo Davatz heads the Service Department, including the Used Machinery Business. The Injection Molding Machinery sector is presenting itself to customers with a new consolidated distribution channel. The entire injection molding business will be divided into seven business units in the future and these will be oriented towards the target markets: Automotive, led by Mr. Bengt Schmidt, under the KraussMaffei brand Technology, led by Mr. Klaus Bange, under KraussMaffei with the KraussMaffei and Netstal brands Logistics and Packaging (thick-walled), led by Mr. Bengt Schmidt, under the KraussMaffei brand Packaging (thin-walled), led by Mr. Markus DalPian, under the Netstal brand Screw-cap closures (CAP), led by Mr. Markus DalPian, under the Netstal brand PET, also led by Mr. Markus DalPian, under Netstal with the KraussMaffei and Netstal brands In the Medicine BU, we will continue with the two-brand strategy under the leadership of Mr. Patrick Blessing, said Dr. Golz. This is because we have two complementary product portfolios and excellent expertise in the field medical technology at both locations. Therefore, we believe that we can better tap growth opportunities in this way. EM

9 KraussMaffei Brand & markets 9 First technology-spanning energy analysis Blue power meets think blue. Factory. It was a first: Together with Siemens, KraussMaffei carried out an extensive, energy-related machine-system analysis for Volkswagen. The goal was to evaluate the energy consumption associated with the production of instrument panels. The holistic inspection of the complex process provided the fundamental principles for further optimization of the processes, the drive technology, and the thermal budget. The production lines for instrument panels are highly complex structures. The overall process incorporates several different processing techniques and automation components. In order to be able to work economically and in a way that makes efficient use of resources and energy, the separate process steps must first be aligned with each other in a manner that cuts across different technologies. Concrete measures can be derived from the product-specific total energy consumption. Several analyses of this nature have already been carried for individual injection molding machines and extrusion lines. But Volkswagen, Siemens, and KraussMaffei were the first to examine an entire production line. Challenging roles As part of the Think Blue. Factory. program, Volks wagen has set clear goals for itself in terms of an ecological installation: based on the annual values for the year 2010, the company is planning to reduce the environmental pollution caused by all of its facilities by 25 percent by the year This applies to the CO 2 emissions, the amount of waste produced, the energy consumption of each vehicle, and the amount of water consumed by the factories. These goals are being met with the help of KraussMaffei s BluePower initiative, which is aimed at the efficient use of energy and resources. Every journey begins with the first step Each optimization process begins with a detailed analysis of the energy consumption of every single consumer load. The list of the included system components makes clear just how important the holistic approach is. In the case of the production line for instrument panels, the list included, along with the injection molding machine and the facility for the production of the slush skins, a prewarming station, a round table with 12 mold carriers (each with a clamping station and an opening), a mixing machine, a metering machine, three robots, several heating units and heaters, and various pumps. A total of 25 measuring devices had to be installed on the round table, after which they had to be connected to a central PC via a WLAN connection, thus enabling data recording. The measurements were recorded over more than ten days so that the energy-related interaction between the system components during downtimes and over the weekend can be recorded. The power consumption levels of various injection units were measured and counters were used to measure the consumption of compressed air and cooling water. The recorded data was used to determine the specific energy consumption of every component. Process management determines the potential for savings The biggest consumer of the round table was the process of tempering the molds, followed by the vacuum supply, the metering system, and the exhaust system. The detailed analysis of different system statuses provided interesting savings potentials. The results can be applied to other productions as they are, after which they are incorporated into the development of new generations of machines. For example, an optimized operation with individual components of the round table that were designed in accordance with the results opened up savings potential of up to 10 percent. The system control unit plays a decisive role in this process: In this case, it is possible to save intelligent processes that control the operational behavior of the system components, depending on the process requirements. The individual measures alone can save up to 30 MWh of electrical energy per annum. MB Taking complex production systems into consideration kwh/cycle KM MX KM MX KM MX Power consumption [kw] 0.65 kwh/kg :39:02 Poly Iso Pump P 12:39:46 12:40:29 Puming station 12:41:12 Pump I Stirring device Disc filter Poly Extensive measurements and evaluations provide a thorough understanding of the energy consumption that is required by the process and their correlations. Pump Pump Venting Tempering unit Heat exchanger C Stirring device Disc filter Iso 12:41:55 Timeline Venting Tempering unit Heat exchanger C Compressed air 12:42:38 Specific gas consumption 12:43:22 Compressor cooler 12:44:05 Hydraulic power pack Chiller for water supply Mixing head hydraulic Mean value 12:44:48 12:45: , , , , , ,000

10 10 Brand & markets AHEAD Issue Versatile Several exhibits demonstrated to visitors the versatility of the KraussMaffei industrial and linear robots.

11 KraussMaffei Brand & markets year anniversary of Krauss-Maffei Automation AG Experiencing robots first-hand Text: Eva Münzenmaier Photos: Stefan Kruppa Did you known that robots can tell different brands of candy bars apart? No? And that they can put on a puppet show? Again, no? A few peculiar exhibits at the event marking this year s 30th anniversary of Krauss-Maffei Automation AG made it clear that, in the world of robots, there are few limits. When it comes to plastic processing, KraussMaffei s industrial and linear robots perform the most complex tasks throughout the production flow. They are always accurate, quick, and efficient. The highlights among the exhibits were a robot equipped with a camera system, which served guests the candy bars of their choice, and an industrial robot produced by Kuka, which used meticulous movements to perform a puppet show entertainment of a different kind. The more complex the task, the more it delights our technicians, explains General Sales Manager Thomas Marufke with a smile. Regardless of the application, we find a way of setting it up as efficiently as possible for our clients. Efficient production and complex robotics were just two of the themes that held the attention of over one thousand visitors, clients, suppliers, and employees who were present at the Schwaig facility in July. Our company has been ordering machines made by KraussMaffei, including the associated automation solutions, for twelve years. Thanks to KraussMaffei s consistently positive and quick implementation, we are looking forward to a successful collaboration with them in the future as well, explains Erhard Dietsch, who is responsible for automation technology at Schaeffler Technologies AG & Co KG. These anniversary celebrations gave us the opportunity to once again get to know several new approaches and ideas, some of which came from our interactions with other clients, regarding how we could use automation to make our production more efficient. After all the work we have done together over so many years, it was great to see so many familiar faces at a celebration of this nature. All you can do is congratulate them for throwing such a wonderful birthday party, agrees Johann Kerler, Maintenance Manager at Mouldtec Kunststoff GmbH, which is located in the city of Kaufbeuren. I was particularly impressed by the Augsburg Puppet Theater exhibition. We have been a client of KraussMaffei Automation for more than 20 years. Their innovative and sustainable solutions never cease to amaze us! Many of our oldest systems are still running in a three-shift operation. Steady growth with automation solutions At present, work can be carried out simultaneously in up to 15 production cells in the workshops in Schwaig. KraussMaffei develops between 300 and 350 three-axis linear robots and about 50 six-axis industrial robots every year. And the numbers are going up, according to Thomas Marufke. Six months ago, the production and assembly facilities in Schwaig were doubled to about 1,700 square meters. It is now working at full capacity and nine vacancies have been announced at the company s headquarters. In order to ensure that the company s growth continues to be sustainable and successful, the people in Schwaig are banking on a longterm relationship with professionals and trainees from the region. Mechatronics engineers and managers are trained on a regular basis. On the open house day, guests were able find out about the current job openings and training opportunities. This is the third year in a row since 2009 in which we have outdone ourselves, reports Marufke. The export share is already 60 percent and we thus need to think carefully about further expansions. These days, even non- European clients want us to set up production facilities in their countries. Krauss-Maffei Automation AG, which was founded by Josef Neureder, has expanded steadily over the last 30 years. It now has a total workforce of about 180 employees, ten of whom are apprentices, at the main plant in Schwaig and the branches in Munich and Schwerin. Since 2002, the company has been a subsidiary of the KraussMaffei Group. According to Thomas Marufke, Sales and Commercial Manager, the company s strategy has been conclusively confirmed by the fact that it was necessary to constantly increase the workforce and production area in the last three decades in order to cope with the demand for automation solutions in the industry: As a mechanical engineering specialist, we are very successful thanks to our flexible size and the expertise of our skilled workers. We supply customers both with standard products and with customized, highly complex automation solutions. We will continue to apply this recipe for success in future as well and will market our products even more extensively throughout the world. 1,000th large robot from Schwerin There was yet another reason to celebrate, too. Just in time for the company s anniversary, the branch factory in Schwerin delivered its 1,000th robot. The LRX-S 350 linear robot has a payload of 35 kg and will be installed in future at a customer in the USA on a KraussMaffei CX injection molding machine. The plant in Schwerin was established in 2000 and started producing robots in A total of 22 employees now produce large linear robot devices in the LRX/LRX-S 250 to 1000 Series with a payload of between 25 and 100 kg, as well as side-entry robots. Along with standard pick-and-place tasks, these devices can also perform challenging tasks, such as inserting metal parts like contacts, rings, sockets, and plugs. However, the product portfolio also includes complete solutions for demolding injection molded parts and for separating, sorting, or packing product units (for example a cutlery set comprising a knife, fork, spoon, and serviette).

12 12 Brand & markets AHEAD Issue PREMIUM-CLASS The GX Series sets new standards in terms of performance, usability, and value retention. WITH A NEW DIMENSION ON THE GLOBAL MARKET THE NEW BENCHMARK: THE GX SERIES Text: Eva Münzenmaier Photos: Harald Mehnert A murmur went through the 400 guests, the drum roll rang out, the fireworks went off, and the curtain fell, giving the world its first glimpse of the first next-generation machine: the GX a new dimension in injection molding. But the audience of trade professionals was treated to a lot more than just that. At the world premiere of the GX Series, which took place in May, KraussMaffei unveiled and operated a total of six machines of various sizes, which boasted clamping forces of between 400 and 650 tons and were fully equipped for the production requirements of a variety of sectors. A light tap on the notebook-sized touchscreen maneuvered parts of the machinery that weighed several tons as easy as operating an ipad. As if by magic, the bulk of plastic moved through the various production flow stations until it was finally turned into a bottle cap, a box for vegetables, or cheese packaging. The self-test on the clamping dummy proved to be especially popular. Everyone was able to personally experience the clamping unit s free movement. Premium-quality technical presentations and a successful celebration with music, and lots of good food rounded off the launch ceremony. A special success: KraussMaffei managed to sell all six exhibits, including the laboratory machine. Our clients were particularly interested in the modular automation cells, which featured linear and industrial robots in many different configurations, explains Dr. Karlheinz Bourdon, Vice President Technology (injection molding machines) at KraussMaffei. And I would like to emphasize that the GX is the best machine concept on the market! The GX Series widens the product portfolio in the hydro-mechanical dual-plate machine sector in the medium clamping force range. The passionate engineering of the developers is manifested in a firstclass machine concept featuring intelligent product innovations such as the GearX locking device and the GuideX guide shoe. The GX Series sets new standards in terms of performance, usability, and value retention. The GX machines are impressive during the production of free-falling packaging parts and premium-quality articles for the automotive industry or the consumer goods sector.

13 KraussMaffei Brand & markets 13 A powerful team: GearX and GuideX The GX Series hydro-mechanical clamping unit raises the bar when it comes to quality and productivity. The excellent dual-platen technology scores highly with a wide range of innovations. "In my opinion, the GX machines represent the best overall concept," underlined Bourdon. "We talk about a new dimension because our customers can use the machine to get the best results from their production." With the ingenious GuideX guide shoe, forces are ideally absorbed and the service life of the molds is increased. As an intelligent fixed bearing joint with an optimized FEM design, the GuideX is not just an eye-catcher but a genuine highlight, which ensures excellent platen parallelism due to its stable design and guarantees smooth, energy-saving movements. The innovative GearX locking system is reliably activated straightaway within the shortest possible time and continuously produces quick machine movements. Arranged in a space-saving way behind the moving mold-fixing platen, it facilitates simple access and numerous customer-specific options. With a patented locking system and a guide shoe, the new generation of machines gives the sector exactly what it wants: even faster production, lower material consumption, and better-quality products. Furthermore, the machines really save when it comes to energy consumption because they can be adapted to the production capacity utilization. Powerful injection unit with a tried-and-tested plasticizing system When it came to the GX Series, the designers stuck to KraussMaffei s proven screw system, which guarantees a wide field of application. Our standard plasticizing unit assures optimal melting quality and high throughput. Being an expert in specialty polymers, our company also offers our clients a plethora of material-specific plasticizing solutions, explains Frank Peters, Executive Vice President Sales at KraussMaffei. The Plasticizing Competence Center provides customers with competent advice and there are hardly any limits on areas of application. The new MC6 control system offers a multifaceted degrees of freedom With the MC6, we have developed a control system that satisfies all our clients usability-related requirements, explains Bourdon. Thanks to the SplitScreen and the ProcessDesigner functions, it is clear and unbelievably easy to operate. In keeping with our overall energy-efficient design, the MC6 control system has been equipped with a so-called eco button for the first time. The machine can thus be optimally configured in terms of energy consumption at the touch of a button. On the right track The launch was successful: the product demand and the sales figures endorse the overall concept of the GX Series. When it came to the launch of the GX, our team really did accomplish a lot. The overall machine concept is marvelous, and I think the company is going to continue to concentrate passionately on the task at hand. And the rewards are being reaped: the worldwide demand for the products and the sales figures that we have generated so far have exceeded our expectations. The numerous worldwide product presentations are proceeding smoothly. We even managed to sell all the machines that were exhibited at the world premiere in Munich in May. Frank Peters, Executive Vice President Sales The new international dimension The GX Series is also on the right track internationally. Several customer events took place after the world premiere in Munich, including in the United Kingdom and in Mexico, among others. The GX , which can run a 450-gram packaging application with a cycle time of 9.8 seconds, was presented in Mexico. Various technical presentations provided information about the new, innovative technology and mechanisms of the series. Numerous visitors were clearly impressed. The perfect symbiosis of automation and machinery KraussMaffei is also one step ahead when it comes to fully integrated production systems comprising both machinery and automation. Machine and handling form a functional unit in this combination. The MC6 can also be used in this way. As a common control system, it allows both functional units the machine and the automation to be controlled from any control panel, which represents added value for clients. The dialog-based programming wizard in the MC6 control system even allows beginners to create basic demolding processes in the shortest possible time. The interactive communication between the user and the control system makes manual programming superfluous and eliminates programming errors. Read more about it Our product brochure GX Series Machines contains further information about the new dimension of injection molding. Your sales partner would be happy to send you a copy. The new dimension of injection molding Machines in the GX Series Engineering Passion

14 14 Brand & markets AHEAD Issue Competence Show in the Land of the Rising Sun Success story Major order from Saudi Arabia SABIC is one of the largest petrochemical companies in the world. The Saudi Arabian company has had a business relationship with KraussMaffei for several decades. A major order that was placed in June provided yet more evidence of the trusting teamwork that has existed between the two sides for so many years: KraussMaffei and KraussMaffei Berstorff are to set up a fully fledged technological laboratory at the new SABIC Plastics Applications Development Center in Riyadh, the capital of the kingdom of Saudi Arabia. Such packages of orders don t come along every day: complete extrusion lines for the PVC pipe, profile, and sheet extrusions as well as a twin-screw extruder, a few particularly powerful injection molding machines from the C3 and EX Series all of this was on the wish list turned in by SABIC Plastics Applications Development Center. These systems are to be used by the company s newest development center to equip the technological laboratory in Riyadh. The laboratory is eventually supposed to develop and test new materials and innovative production processes. SABIC currently operates a total of 17 specialized technological and innovation units of this nature in Saudi Arabia, the USA, the Netherlands, Spain, Japan, India, and South Korea. More than 8,000 patents bear witness to the expertise of SABIC s researchers and developers. With more than 40,000 employees in 40 different countries, a turnover equivalent to more than 50 billion US dollars, and profits equivalent to 7.9 billion dollars, SABIC is in the top tier of the global petrochemical sector. Founded through a royal decree in 1976, the corporation (70 percent owned by the government, with the rest held by private investors from Saudi Arabia and other Gulf states) has grown rapidly. SABIC may be among the most successful companies that were founded in the Middle East in the 1970s with the goal of not only producing oil, but also processing it in order to create added value in their countries. In just six years, KraussMaffei s Japanese subsidiary, which was founded in 2006, has become the market leader in the Japanese market for reaction process machinery. This is reason enough to celebrate this success as part of a competence show, whose primary theme is Composite Materials & Combined Systems. This competence show, which included technical lectures delivered by international experts as well as a trade show, took place in July in Okazaki, in Japan. More than 40 practical examples held the undivided attention of the more than 200 visitors. The displayed components were grouped according to individual processes in a theme-oriented manner. The visitors were especially interested in the fiber composite technology featuring HP-RTM (high-pressure RTM) and the fiber spray process, as well as the process combinations like SkinForm and ColorForm. KraussMaffei s employees had their hands full answering visitors questions, addressing inquiries, and acquiring projects. The presentations supplied the listeners with the latest information regarding the latest developments and trends in fiber composite technology and the production of premium-quality surfaces. For us, the event was a complete success, as evidenced by the visitors reactions and the many new projects that we acquired during the event, says Noriyuki Kanoh, Representative Director of the Krauss-Maffei Japan Corporation. The Japanese workers and their colleagues from Munich then celebrated the company s six-year anniversary with a traditional Japanese dinner and a visit to a hot spring. On the way there, they stopped at the KM26, a 120-year-old KraussMaffei locomotive, which is considered to be a tourist attraction in Japan. The local press and three television channels were present when Mr. Nishi, chairman of the regional tourism office, inquired whether this well-preserved locomotive could be made operational again, and thus fulfill a childhood fantasy of many Japanese people. MB SABIC has been working with KraussMaffei for several decades, which is an expression of the trust shared by the two companies something that always plays an important role in relationships with Arabian companies. We will do everything we can to once again completely and thoroughly justify this trust, said Dr. Karlheinz Bourdon, Vice President Technologies, after the contract was awarded. This contract, which has been awarded by a company whose technological requirements are extremely high, attests to our overarching expertise with respect to our unique technology. MB

15 KraussMaffei Brand & markets 15 REACTION PROCESS MACHINERY The right man for the job Concentrated expertise for customers Composites/Surfaces business unit Erich Fries After working with various companies, the environmental engineer who also has management expertise joined KraussMaffei in In August 2012, he was appointed as the head of the Fiber Composites/Surfaces business unit. Thomas Aquinas provided him with the guiding principle for his work: One must pray for miracles, but work hard for changes. He is already looking forward to the challenges that will arise in the future as a result of new and interesting technology: We will overcome them as a team. He is already focusing on a new development: using carbon fibers in large series production. Fries enjoys traveling, playing handball, and is interested in Japanese gardens. Construction/Insulation business unit Dr. Michael Loferer He has been responsible for the Construction/Insulation business unit since August He is highly qualified for this role. After completing a degree in production engineering at the technical university in Munich, he worked as the Head of Design and the Head of Technology at Siempelkamp Handling Systeme GmbH. In this era of ever-diminishing resources, the importance of energy-efficient buildings is ever-increasing, he believes. Our aim is to develop new products and tailor-made solutions for our customers using innovative ideas combined with tried-and-tested production technology. In his spare time, Dr. Loferer likes to spend time in the mountains, both in the summer and winter. White Appliances business unit Gabriele Amodeo The Italian is not new to the KraussMaffei Group. As a General Manager, he is responsible for managing KraussMaffei s Italian subsidiary. In August 2012, he took on an additional role as the head of the White Appliances business unit. His degree in mechanical engineering and his years of professional experience make him the ideal candidate for this role. In his free time, he likes to go sailing or skiing, depending on the time of year. His motto is based on experiences gained from sport and throughout his career: A person is stronger when in a team. Molded Flex/Interior Trim business unit Wolfgang Frehsdorf Wolfgang Frehsdorf has been responsible for heading the Reaction Process Machinery Technology and Production department for KraussMaffei since As of 2009, he has been the head of Reaction Process Machinery Operations. In August 2012, he became the head of the Molded Flex/Interior Trim business unit. The new business units can be quickly adapted to specific customer requirements and offer a uniform organizational structure across the world. This allows us to prepare offers and execute orders quickly, he said, when speaking about the advantages of the new organization. The skilled electronic engineer spends his free time on the golf course. Since July, KraussMaffei s Reaction Process Machinery sector has had a new customer orientation. In an interview with AHEAD, Nicolas Beyl, the head of the sector, explained the advantages for customers and the opportunities that will open up for the company. The fact that both of these points are closely linked is not a surprise. The interview was conducted by Imre Szerdahelyi. AHEAD: Mr. Beyl, what are the special features of the new customer orientation? And wherein lie the significant differences to your sector s current position within the KraussMaffei Group? Beyl: With our product ranges, we are orienting ourselves to our customers fields of work. For the White Appliances, Construction/Insulation, Molded Flex/Interior Trim, and Fiber Composites/Surfaces product ranges, we have defined business units that match the customers specific requirements. These units integrate customer-oriented functions, such as Technical Sales Support, Project Engineering, and Application Technology, to particularly link the Sales and Project Engineering departments more closely. We will continue to integrate extensive cross-sector functions. These include Construction, Development, Service, and the supply chain function, which covers the Assembly and Logistics coordination. AHEAD: What are the advantages of this orientation for our customers? Beyl: The new orientation allows us to better adapt our wide-ranging and high-performance product spectrum to our customers requirements. We would like to use our wide range of products and services, as well as our concentrated expertise, more than ever, to ensure that our customers get individual support throughout their entire value-adding chain, and we want to do this in all our markets. AHEAD: You wish to increase your potential for growth in this manner. What makes you so confident that you will be able do this? Beyl: Primarily, it is, of course, all down to our dedicated and efficient employees who have played a part in every one of our success stories up until now. We have excellent technological expertise and we are market leaders, or at least one of the lead ing global companies, for many of our product sectors. We are also part of a group that gives us innumerable possibilities to cooperate with one another be it technically, organizationally, or simply collectively and personally.

16 16 Brand & markets AHEAD Issue Positive signals from Southern European markets Stories about the worrying situation in southern European countries dominate our media headlines on a daily basis. But there is another way. Despite the difficult economic situation, there is encouraging news from the real economy, especially from the plastics industry. Classic holiday countries offer more than just sun, sea, and sand. The following examples are certainly impressive. Text: Markus Betsche Southern Europe Classic holiday countries offer more than just sun, sea, and sand.

17 KraussMaffei Brand & markets 17 Italy s plastics processors at the Plast 2012 trade fair Three success stories This year s Plast 2012 trade fair provided a good opportunity to cast an eye over the Italian plastic processing industry. We have taken a closer look at three Italian manufacturers of injection molded parts for the automotive and domestic appliance industries who have benefited from KraussMaffei s expertise in energy-saving, premium-quality investment casting solutions and advanced integrated processing technology. Cromaplast srl has its headquarters in Valdagno in the province of Vicenza, where it employs 140 staff and in 2011, achieved an estimated turnover of 16 million euros with the manufacture of chrome-plated automotive molded parts. All of the company s ten injection molding machines are units with hydraulic drive provided by KraussMaffei. Their machinery includes one machine each with 65, 120, 200, and 300 tons of clamping force, four with 420 tons and two with 650. Most of the KraussMaffei machines were introduced as part of a machinery modernization program in The last four Italian units were replaced by the four KraussMaffei CX machines with 420 tons of clamping force in According to Managing Director Stefano Tecchio, the grease- and dust-free KraussMaffei machines are optimally suited to meeting tight dimension tolerances and achieving the perfect surface quality that is demanded of automotive molded parts. The parts are chromeplated on production lines with a plating capacity of 1,800 square meters per day. Plast3 srl in Fiume Veneto in the province of Pordenone is one of the three injection molding companies of the Pezzutti Group. The group employs 150 staff and possesses 140 injection molding machines. In 2011, their turnover achieved an estimated 42 million euros. At Plast3, 30 employees work on 23 injection molding machines. The company operates with four KraussMaffei machines: one MX and now three C2 machines with 420 tons of clamping force, the last of which was not acquired until All machines are equipped with robots from KraussMaffei. A KraussMaffei C molds transparent red and white, rectangular carry boxes made of recycled PET for the furniture manufacturer IKEA. To qualify as a supplier at IKEA, KraussMaffei s Blue Power energy saving procedures, such as cylinder insulation and short cycle times, were a decisive contributory factor, because in this case, ecological aspects and a low level of CO 2 emission played a special role, reports Managing Partner Ivano Castelli. Another product, which is manufactured with a Krauss- Maffei 420-ton machine, is a one-piece child seat insert made of PET. A highly integrated, 60 percent glass-fiberreinforced polyamide part manufactured with an 850-ton MX type machine is used as a component in textile machines. In this case, it was possible for the temperature of the compound to be reduced by 40 degrees through the use of a KraussMaffei HPS highperformance screw. As a result, Plast3 was able to dispense with a master batch charged with micro balls. This was previously necessary in order to achieve a better flow rate and the high level of dimensional accuracy required, as well as an aesthetically pleasing, uniformly colored surface. Sole, a manufacturer of automotive molded parts founded in 1964 with its headquarters in Oderzo (region of Veneto, province of Treviso) is part of the Gruppo Prima. The company has an eventful history. It passed from Zanussi (1973) to Electrolux and Gränges with Plastal, and entered insolvency in Quality guarantee KraussMaffei CX with a linear robot from KraussMaffei at Cromaplast In 2010, Plastal was taken over by the Gruppo Prima and re-assumed its original name, Sole SpA. With around 740 employees, Sole achieved an estimated turnover of 183 million euros in The eleven Italian companies in Italy and the five European non-domestic factories of Gruppo Prima probably turned over 343 million euros in The large-scale factories in Oderzo and Suzzara (three injection molding machines up to 3,000 tons in Suzzara) are supported by German firms in Ulm (assembly) and Wörth (four KraussMaffei machines). In Oderzo, Sole uses 50 injection molding machines from various leading Continued on page 18

18 18 Brand & markets AHeaD Issue Continued from page 17 providers, which, apart from the Krauss- Maffei units, are mainly Italian machines. Among the KraussMaffei machines, the six SpinForm machines particularly stand out and these were introduced for the first time in Five of them have a clamping force of 650 tons and one has 180 tons. A 650-ton machine (CXW /1400), which was installed in February 2011, produces, among other things, hard-soft dualcomponent door sill covers made of ABS (acrylonitrite butadiene styrene)/tpu for the BMW 3 Series. Two ABB multi-axis robots (articulated arm or industrial version) are used for removing parts, attaching fastening clips, and fitting a metal strip to the door sill molded part. When Sole introduced the SpinForm machines, there was, according to Giuseppe Maiarelli, Head of Business Development, a plan B under which it was intended to use them with two separate molding tools as well. So far, plan B has not been implemented because Sole uses all SpinForm machines at full capacity with the usual horizontal rotary cube tool. The SpinForm technology is now also used for the manufacture of highgloss parts with a piano-lacquer-look finish in black. In this process, the first operation using transparent PMMA polymer is followed by a second that uses colored ABS/PC on the other side of the rotary cube tool. Selectively chrome-plated parts made of two materials, only one of which can be chrome-plated, are also created on the SpinForm. Energy saving A KraussMaffei C injection molding machine manufactures PET carry boxes for IKEA at Plast3. 50 years of successful collaboration Coscollola our longest partnership As early as September 1962, Coscollola (Barcelona) became the KraussMaffei agency for injection molding machinery in Spain, and from this cooperation, the first injection molding machine was delivered in January 1963, which at that time was still of the 150S MONOmat type (manufacturer: Eckert&Ziegler). But the first KraussMaffei V injection molding machine came to Spain as early as In 1966, turnover already exceeded 1 million DM, a respectable result in the plastics industry, which at that time was still emerging, not least because, before its accession to the EU in 1986, Spain levied an import tax of a full 45 percent on plastics machines. Today, 22 Coscollola employees attend to the needs of Spanish customers. In addition to KraussMaffei injection molding machinery and KraussMaffei Berstorff extrusion technology, they offer their customer base a wide range of peripheral equipment for processing plastics. The Coscollola team does not just regard itself as an agency, but rather as a competent partner for its customers. Our focus is on the customer and their needs and requirements throughout the entire production period, explains Ricardo Coscollola, Managing Director of Coscollola Comercial SL. We therefore regard it as extremely important that we ourselves also possess competence in engineering, technical support, commissioning, and service. That makes us unique in the Spanish plastics market. There is enormous competitive pressure among Spanish plastics processors, which is increased all the more due to intense global competition. And so in the current situation, many investments are postponed or completely canceled. But there are also companies with good basic conditions that operate successfully with a pronounced orientation towards exports. Some of them recently placed financially interesting orders with us, especially for injection molding machines. FPK (Bilbao) IMC injection molding compounder for automotive structural components made of long glass-fiber-reinforced thermoplasts. This rapidly growing company ordered another MX IMC injection molding compounder, including an extensive KraussMaffei automation solution for a factory in Brazil. Johnson Controls Plastics (Alicante) Injection molding machines from the CX range with between 200 and 650 tons of clamping force produce plastic parts for batteries in the Spanish factory. With more than 20 further machines, JCP has far more than doubled its production capacities in both of the last two years. Herolse (Barcelona) Flexible multi-color machines based on the MX range. With the newly ordered MX-Z /1400, the toolmaker is investing in a flexible manufacturing system for multi-color/multi-part components. A particular highlight of the machine is the movable injection units, which are able to serve the various sprue positions in the molds and as a result, is suitable for all standard sprue positions. The machine is ideally suited to carrying out trials of new molds for well-known OEM customers and also for the production of small and pre-series batches. As far as extrusion machines bearing the KraussMaffei Berstorff name are concerned, our machines made in Hanover particularly compounding extruders were in high demand in 2012, too. In spite of a difficult market situation in the building industry, it was possible to realize some successful projects in pipe extrusion.

19 KraussMaffei Brand & markets 19 Reliable The Polyload AZ guarantees a constant flow of material in BMC (bulk molding compound) processing. All good things come in threes Wet polyester processing in Greece In July this year, a brand new injection molding machine for wet polyester processing was delivered to Dasyc S.A. (form erly known as Technika Plastika S.A.) in Greece and put into operation. The CX PolySet completes the machine package in which Dasyc invested around a million euros. Two further PolySet machines for processing BMC (bulk molding compound = wet polyester) were already delivered in 2010 and And so the company has now installed the first production line for BMC parts in Greece in its factory in Thiva. Dasyc S.A. was established in 1979 and produces molded parts made of plastic and BMC as well as composites. The company provides a comprehensive service including component design and construction, component mounting, toolmaking, component manufacture, and preassembly. Extensive export experience and many years of collaboration with well-known, international industrial customers complete their areas of expertise. Today, components are produced and delivered to the automotive, military, aerospace, electrical/electronics, and domestic appliance industries. Extensive experience with duroplastic materials PolySet injection molding machines are suitable for the continuously precise processing of BMC. Based on expertise in the processing of cross-linked plastics since 1958, KraussMaffei PolySet machines stand out due to their highly effective, lowwear conveyor techniques and screws, as well as robust mechanics on the closing side in dual-platen technology. SPE (Society of Plastics Engineers) Automotive Award Visualizing complex technologies and processes for customers in a clear and understandable way always poses a new challenge. KraussMaffei have been successful once again in this endeavor with their brochure on fiber-compound technology. But that s not enough. As part of their 11th Automotive Award, the International Society of Plastic Engineers (SPE) has awarded 1st place in the image/product brochure category to the product brochure Fiber compound solutions for sophisticated lightweight components. The jury recognized both the informative graphic organization of the brochure and the boldness shown in pointing to one s own expertise and in highlighting actual deployment possibilities in the form of exemplary components, rather than merely concentrating on the machines and systems themselves.

20 20 Processes & Products AHEAD Issue Processes & Products Efficient manufacturing of fiber composite components KraussMaffei offers an entire range of processes to manufacture fiber composite components (also see the cover story on page 5). The latest processes include different variants of resin injection processes. Here is a brief overview of the latest developments. New process variants expand the RTM (resin transfer molding) technology application field Fiber-reinforced plastic parts are characterized by extremely low weight but high rigidity. Which manufacturing process is best suited to a specific component depends on numerous factors, said Erich Fries, above all, the component shape, the matrix material, and the quantity required are all influencing factors. The performance profile and the production costs of the component are also critical criteria. They determine which solution approaches and manufacturing processes should be taken into account. High-pressure resin transfer molding (HP-RTM) with quick reacting resin systems The HP-RTM process (High-pressure resin transfer molding) is suitable for large series manufacturing of lightweight and high-strength structural components made of epoxy resins. However, polyurethane or other reaction resins can also be used as matrix materials. In HP-RTM, the resin is fed into the closed mold using a self-cleaning high-pressure mixing head. The resin and hardener components are injected into the mixing chamber via separate nozzles and are mixed there quickly and intensely. This technique allows fast-reacting resin systems to be processed within short reaction times. Using high-pressure injection, the matrix resin wets the fibers faster, more intensely, and more completely than by using the low-pressure technique. KraussMaffei is providing another alternative to the automated series production of fiber-reinforced lightweight components in the form of the wetmolding procedure. Here, a fiber pile is fixed in a flat state without preforming. The mixing head is not positioned directly on the mold, but is fixed on a traversing unit. While the mixing head moves in a line over the fiber stack, the application device applies a laminar thin resin layer on the fiber stack. As soon as the fibers are covered with resin, the fiber pile is transported to a mold and pressed there. The preforming of the fibers in wetmolding thus takes place first with the mold closing movement. An important advantage of the wet-molding process is that even recycled fibers can be used to reinforce components. MB C-RTM, Compression RTM The mold can be evacuated and operated with an inner pressure of up to approximately 100 bar. Even complex, three-dimensional cavities are filled faster this way and the fibers inside are saturated. At the same time, air voids are eliminated. There are constant new customer requirements in the emerging lightweight construction and fiber composite materials sector. KraussMaffei continuously develops its process and machine technology for this dynamic environment. Compression resin transfer molding (C-RTM) and wet molding two new HP-RTM variants In C-RTM, the mold is not completely closed initially, but only up to the defined gap. Next, the resin mixture enters the mold, with or without low mold-internal pressure. Some of the fibers are already saturated by the resin; the greater part of the resin quantity, however, is virtually floating on the fiber above. This is followed by a compression stroke the mold is completely closed and the cavity corresponds to the shape of the final component. The compression stroke has the effect of pushing the resin through the fiber in the Z-direction and the fiber is wetted completely. This process is advantageous for delicate preforms due to the low material flows Semi-finished products from the roll 2. Handling the ready-made semi-finished products 3. Transfer to the preform station 4. Preforming 5. Transfer the preform to the CRTM station Close the mold on the compression stroke, vacuum (optional) 7. Resin injection 8. Press (compression) 9. Hardening 10. Component removal 5.

21 KraussMaffei Processes & Products 21 GX: Great potential in lightweight construction The GX Series, which was introduced in May 2012, has already proven itself to be a market leader in only four months. The high worldwide demand is not a surprise and KraussMaffei is going one step further. Thanks to the presentation of a MuCell application at the Fakuma 2012 trade fair, the GX Series has unlocked a new area of application. Finely graduated modular design with high productive efficiency Thanks to its extensive option catalog, the GX Series offers a base for versatile injection molding processes. At the Fakuma trade fair, a GX powered with CellForm technology used a physical foam (MuCell) to produce an interior trim component for the automotive industry. The physical foam is part of KraussMaffei s Cell- Form technology for foamed thermoplasts in injection molding processes. When combined with a MuCell equipment package and a precise injection and plasticizing unit, the GX Series is almost predestined for process-reliable production of foamed parts, said Dr. Bourdon, Vice President Technology at KraussMaffei. This application shows the enormous potential still contained in lightweight thermoplastic solutions. The high shot-weight constancy (of less than +/ 0.1 percent deviation) ensures reliable production, even with the highest possible demands. Productivity is therefore maintained. As the fastest dual-plate machine on the market, the GX and the GearX interlock offer the shortest travel times and maximum productivity. The smooth-running mechanics and the GuideX guide shoe reduce traction resistance by up to 80 percent, and ensure, together with the hydraulic concept that has been designed for minimum flow losses, maximum energy efficiency. MB The production cell using GX and LRX robots can also be operated from the rear side of the machine using the hand-held robot. Your advantages at a glance Less viscosity and better flow properties Holding pressure phase omitted Sunk spots omitted Shorter cycle times Low warpage Clamping forces considerably reduced 30 percent lighter airbag housing Lightweight, thin but still stable Organic-sheet hybrid technology has considerable potential for lightweight construction. As far as green mobility is concerned, this technology can contribute by reducing the weight, the fuel consumption, and vehicle emissions considerably. The example of a passenger airbag module housing demonstrated this clearly. Compared to an injection-molded, series-manufactured module made from glass-fiber-reinforced polyamide 6, the housing manufactured from the organic sheet was lighter by over 30 percent. The demonstration product was designed as part of a joint pre-development project between TAKATA AG in Aschaffenburg, LANXESS AG in Leverkusen, Bond-Laminates GmbH in Brilon, Christian Karl Siebenwurst GmbH & Co. KG in Dietfurt, and KraussMaffei. The airbag housing contains the gas generator and the folded airbag. Its long sidewall panels are made of molded organic sheet containing 47 percent of volume endless fibers in polyamide 6 and are over-molded and reinforced in specific areas with polyamide 6 that is modified with impact-resistant properties. Owing to the design of organic-sheet hybrid technology, the thickness of sidewall panels can be reduced by three to four millimeters, to 0.5 to 1 millimeters. As a result, it is possible to reduce the weight. MB Information about ITHEC trade fair The first international conference and specialist trade fair with a focus on thermoplastic composites will take place on October 29/30, 2012 in Bremen. On the topic of manufacturing processes, Martin Würtele, Head of Technology and Development at KraussMaffei, will give a lecture on fully automatic injection molding production of textile-reinforced components. Furthermore, on its trade fair stand, KraussMaffei will present options using fiber-reinforced thermoplasts, as well as composites with reactive matrix systems. Visitors have the opportunity to talk with our on-site experts and get more information about the technology that is ideally suited to them. The passenger airbag module housing, which is made using organic-sheet hybrid technology, is over 30 percent lighter compared to an injection-molded, series-manufactured model made from glass-fiberreinforced polyamide 6. Photo: TAKATA AG

22 22 Partners & projects AHEAD Issue Partners & projects Success story KraussMaffei sheds new light on American plastics processing companies. Rapid growth in North America Quality is the key KraussMaffei has been present in the USA for more than 45 years and in that time, the company has constantly adapted its product and service range to this particular market and has thus become a renowned company. The encouraging developments in the North American market were evident to us thanks to the increase in orders over the last year, said Paul Caprio, the head of the US-subsidiary of KraussMaffei Corporation. We are extremely pleased with the consistently high demand for our products this year and our customers very positive response to our machine and service quality. The complete machine range from 35 to 4,000 t clamping force, and the optimally adapted automation solutions precisely fulfill our US customers requirements, to be able to compete successfully in the international market. The latest orders from two demanding US-based companies have proved this in an exemplary way. Large machines at SLP Lighting begin production With over 40 years of experience in the field of commercial lighting products, the Koller-Craft subsidiary, SLP Lighting, is one of the leading American manufacturers of lights and lighting systems for industrial applications and of lighting systems in the automotive sector. SLP is now also using premium-quality KraussMaffei machines at its plant in Sullivan, Missouri. Two injection molding machines, sizes MX and MX , began producing transparent diffusion lenses this year. We were impressed from the very beginning by the efficiency of the MX machines where part quality and productivity are concerned, said David Koller, SLP Managing Director. The professional working methods of the KMC employees during the project phase and the machine installation showed us that KraussMaffei is the right partner for our company. Thanks to the increased production capacity, SLP can respond to the ever-rising demand for premium-quality lamps and still keep to short lead times. Multi-component machines for rear lights at Proper Group International Molds used to produce automobile headlights are part of the core business of Proper Group International, along with injection molds for textile back injection or glass insert molding for multi-component parts and also for premium-quality visible parts. The company also supplies molds for polyurethane processing. After signing a strategic partnership agreement in 2008, the Proper Group and KraussMaffei have successfully positioned themselves as system partners for injection molding technology and polyurethane technology in the US market. They have been successfully providing complete ready-for-use solutions ever since. A live demonstration for manufacturing SkinForm components from thermoplastic substrates with premium-quality soft-touch surfaces at the NPE 2012 trade show proved this in an impressive manner. At Proper s joint technology center in Warren (Michigan), KraussMaffei can use injection molding machines with a clamping force of between 80 and 2,700 t for development, testing, and mold trials. In the course of this cooperation, Proper has recently ordered an MXZ /3000 multi-component machine that should serve for mold trials and manufacturing reflector housings for the automotive industry. MB

23 KraussMaffei Partners & projects 23 Award-winning purtrain is on target for the automotive industry Although eight partners had to share the JEC Innovation Award 2012, none of them was bothered by it. On the contrary, they were all proud of the award that they had received collectively for a lightweight construction application for rail vehicles. KraussMaffei was one of the prizewinners. Paris, March 2012: At the world s largest fiber composites trade show, JEC Composite Show, Jan Kuppinger from the Fraunhofer-Institut für Chemische Technologie (Fraunhofer Institute for Chemical Technology) (ICT) accepted the JEC Innovation Award 2012 in the Manufacturing Process category, as a representative of the network of eight partners, who collectively made headway in the field of lightweight construction. Their creation may not sound interesting at first glance: a selfsupporting diesel engine housing for rail vehicles. Although the length and the width of the demonstration prototype, based on a polyurethane sandwich structure, were only 4.50 meters and 2.50 meters, respectively, it made the engineers hearts beat faster. The part has the same properties, but it is 35 percent lighter than its counterpart made of steel and aluminum, and comprises fewer parts. Together with ICT and Bombardier Transportation, Werk Hennigsdorf, and with support from the Federal Ministry of Education and Research, the partners KraussMaffei, Bayer MaterialScience, DECS GmbH, the DLR-Institut für Fahrzeugkonzepte (DLR Institute for Vehicle Concepts), the Institut für Flugzeugbau der Universität Stuttgart (Stuttgart University Institute of Aircraft Design), and the Karlsruher Institut für Technologie (Karls ruhe Institute of Technology) have pooled their expertise to find a completely new solution in just three and half years. Josef Renkl, the R&D Director of KraussMaffei s Reaction Process Machinery, emphasized in Paris that it is a solution that can be directly applied to other sectors such as the automotive industry. KraussMaffei develops new manufacturing processes The work for the PURtrain project was anything but trivial. This is because it was not at all meant to replicate a metallic engine housing using plastic. The partners had to work together closely to carry out extensive development activities along the entire value-adding chain. The tasks included developing new manufacturing processes (for which KraussMaffei was responsible), new sandwich-core and top-layer materials, new fire protection systems, in-house design principles, and even computation methods. The result was a sandwich component made using a glass-fiber-reinforced polyurethane layer and a paperboard honeycomb core. The polyurethane (PUR) was initially modified in such a way that it complied with fire protection regulations. Then the fiber-spraying process used to apply PUR layers was optimized. A new mixing head made it possible to manufacture even the most complex structures which was necessary to reduce the number of components in the sizes required. The demonstration component fulfilled all requirements stipulated in the requirement specifications, e.g., puncture strength, which is an important criterion. This is important since the engine housing is suspended under the passenger compartment and above rails. Its task is to protect the engine from the impacts of stones, collect any oil that may leak, and prevent fire from spreading in case of fire. In the meantime, extensive tests must be conducted to check whether the jointly developed product can cope with all of these challenges. Erich Fries is visibly proud: It is an exciting project, which once again showed that lightweight construction is not only relevant in the automotive industry. JW JEC Europe Innovation Award The development consortium around Fraunhofer ICT was also able to score points. The SCS process (Structural Component Spraying), a manufacturing process for lightweight structures which is based on sandwich structures, and spraying processes for glass-fiber-reinforced polyurethane resins, was awarded the JEC Europe Innovation Award 2012 in the Manufacturing Process category.

24 24 KraussMaffei Group AHEAD Issue KraussMaffei Group International trade fairs Group presence without borders Through joint brand launches, for example, at leading trade fairs in Italy and the USA, the KraussMaffei Group and its strong brands are recognized throughout the world. Text: EVA Münzenmaier Plast Milan Efficiency and resource savings are also increasingly decisive factors for Italian processors when deciding to invest. The KraussMaffei Group entered the race on precisely these topics with intelligent solutions at the Plast Milan 2012 trade fair. All around the world The NPE trade fair in Orlando and Plast in Milan were just two examples of successful joint exhibition appearances. The KraussMaffei Group will also be exhibiting as a complete entity at the Fakuma 2012 trade fair. NPE Orlando KraussMaffei presented energy-efficient machines from the AX Series, as well as powerful and integrated manufacturing concepts based on the CX and MX Series. There were also polyurethane solutions for premium-quality surface finishes on display, classic foaming processes, lightweight construction processes, as well as insulation applications for the white goods sector. One of the highlights, previously unprecedented in the USA, was the live presentation of the SkinForm process in one production cell with a CX hybrid injection molding machine and a RimStar hybrid mixing and metering system for polyurethane processing. In presenting the AX and EX Series, KraussMaffei exhibited powerful, all-electric machines for all production requirements. In a live demonstration, liquid silicone rubber (LSR) was processed under clean-room conditions and complex, technical formed parts were produced in an energy-efficient process. Netstal displayed a system solution specially optimized for packaging tasks, created from the powerful ELION 1200, which included mold, automation, and other peripherals. During the demonstration of thinwall injection molding, it was possible to save up to 60 percent in energy consumption compared with conventional drive systems. KraussMaffei Berstorff received numerous inquiries from the building industry, especially in the polyolefin pipe extrusion sector. The QuickSwitch system in particular generated a great deal of interest, with which pipe dimensions can be changed at the press of a button without interrupting the production process. Visitors to the trade fair were also greatly interested in systems to manufacture technical films made of ethylene vinyl acetate (EVA). More efficient production thanks to constant improvements: Netstal presented highly efficient production of closures on an ELION 2800 with the new electric form closure with energy recuperation. The PCO 1881 drinks closures were produced at a cycle rate of 3.5 seconds using a 72-cavity mold. The energy-efficient IPC system from KraussMaffei Berstorff was in great demand. This system cools the pipe in addition to conventional external cooling, using ambient air from the inside. American customers are particularly impressed by the significant increase in output of up to 60 percent, which achieved by this system, especially as resources and energy consumption is also significantly reduced. Two criteria are critical for our American customers in their decision to buy, namely perfect product quality and extremely high output performance. In this case, we offered first-class solutions at the NPE trade fair. Customers were really impressed, explains Paul Caprio, Head of the American subsidiary. This is the motto under which the KraussMaffei Group will be presenting the best-in-class solutions for efficient production with outstanding results at this year s Fakuma trade fair. You can experience the new dimension in injection molding for the first time live at stand 7303/7304 in hall A7 a GX Cell- Form with LRX 250 linear robot as a technology platform with a thermoplastic lightweight construction application. You can also look forward to other high-tech exhibits and processes from the KraussMaffei, KraussMaffei Berstorff, and Netstal brands for an efficient production process in injection molding, reaction, and extrusion technology.

25 KraussMaffei KraussMaffei Group 25 Trade fair and production location in China Technical treats for the Far East The KraussMaffei Group took several important steps towards developing its joint presence in China with its three brands KraussMaffei, KraussMaffei Berstorff, and Netstal in China. Text: EVA Münzenmaier Impressive According to an old Chinese saying, a long journey always starts with the first step. The KraussMaffei Group took a few great strides forward this year at the Chinaplas exhibition and in the plant at Haiyan. Chinaplas 2012 Chinaplas once again confirmed that, for Chinese processors, reliable and innovative machine technology bearing the Made in Europe stamp is very popular. The KraussMaffei Group offered a good many technical treats for innovation-hungry plastics processors, with applications from injection molding, reaction, and extrusion technology. High on the visitors list of interest was the MX swivel plate and embossing machine from KraussMaffei. This machine has positioned itself just as successfully in the Chinese market as the CX Multinject for multicolor and multiple component applications. Performance and efficiency in the PET sector. Netstal presented a high-quality application on the PET-LINE. This application was based on a platform with 3,500 kn clamping force and covered the range of 48 to 128-cavity molds with a highly cost-efficient total system. With this system, we provide an excellent solution for the growing drinks and foodstuffs packaging sector in China, explained Markus DalPian, Head of the PET business unit at Netstal. KraussMaffei Berstorff scores points with products that are manufactured locally. Our customers in Asia attach a lot of importance to locally manufactured machines, which also satisfy extremely high technological demands, informed Fan Kai Jun, General Sales Manager for Extrusion Technology in China. A rising demand in the PVC, pipe, and profile extrusion sectors proves him right. And with its proven 36D single-screw series, KraussMaffei Berstorff is well equipped to cope with the requirements of the rapidly growing Chinese polyolefin pipe market. Open house in the plant at Haiyan During the Chinaplas trade fair, the KraussMaffei Group opened the gates of its production plant in Haiyan. This gave customers the opportunity to view machines and systems, which had been specifically designed for Chinese requirements and locally manufactured, actually in operation. KraussMaffei presented a type MX850 injection molding machine, which is entirely manufactured in Haiyan. Also high on the list of interest were machines, systems and tooling systems for polyurethane foam applications, for example refrigerators, insulation applications, or lightweight components. KraussMaffei Berstorff showed two pipe extrusion lines which, processed material of local origin. The high-speed systems produced hotwater pipes made of PP-R for the supply of fresh water with diameters ranging from 20 to 63 mm, as well as heating pipes made of PE-RT from 20 to 32 mm. Since the initial start-up of our own manufacturing plant, we have been producing, among other things, the core components for both systems, the KME B/R single-screw extruder and the KM-RKW 32 spiral mandrel distributor pipe heads from the Performance series, explained Harald Schweitzer, Head of the Chinese subsidiary. As from now, we offer our customers complete pipe extrusion systems with all downstream units locally manufactured, which set new standards in terms of quality and performance.

26 26 KraussMaffei Group AHEAD Issue Smart pipes One of the current global mega-trends is energy efficiency. KraussMaffei Berstorff is not just following this trend when it comes to their own products. Their customers can also score points on the market thanks to their results from increasing their energy efficiency. Pipes full of intelligence Energy-efficient transportation in polyurethane-insulated pipes It is becoming increasingly common to make effective use of heat and cold, which are often the by-products of other processes. It is important that these forms of energy can be transported across both short and long distances with as little loss as possible. For this reason, KraussMaffei Berstorff has developed a solution: insulated pipes, in which several plastics have been integrated to form a highly efficient compound. Their extremely low thermal conductivity (for experts: at a minimum at 0.02 to 0.03 W per Kelvin and meter) makes them the ideal transport medium for both heat and cold. These plastic pipes, which usually have one or two medium pipes on the inside and are surrounded by polyurethane insulation and have an outer coating of polyethylene, are not only considerably more compact, more flexible, more leakproof, and easier to lay. Thanks to a continuous manufacturing procedure with a high level of automation, they are also significantly more cost-effective. In short, they really are smart just like the systems that produce them. ELION 3200: A successful concept continues to grow The ELION Series has successfully established itself on the market. With the new 3200 model, Netstal is offering a highly efficient solution to manufacture complex moldings. In 2003, Netstal launched its all-electric ELION Series. This high-performance injection molding machine quickly proved itself to be one of the most efficient and most precise all-electric machines on the market. And not much has changed since then. At the Fakuma 2012 trade fair, Netstal is presenting the latest newcomer to the series: the ELION Together with Müller Fabriques SA, Netstal is displaying a complete system for manufacturing thin-walled covers for cream cheese packaging. The polypropylene molding has been developed with a total cycle time of less than 3.5 seconds on a 4+4-cavity multi-daylight mold. A completely automated system inserts the labels, removes the finished parts, and stacks these parts. The maximum output is 8,230 pieces per hour. The electrically driven clamping unit can be combined with the hydraulic high-performance injection unit from the EVOS Series. The energy-saving potential of this hybrid technology with innovative Eco Powerunit drive unit has been put to full use. When compared to a conventional hydraulically driven toggle-lever machine, the ELION hybrid can save energy by up to 50 percent. +++ News ticker +++ News ticker +++ News ticker +++ Plant expansion in Slovakia The expansion of the KraussMaffei Group production plant in Sučany (Slovakia) is making very good progress. Production in the second assembly hall is expected to be able to start as early as the end of 2012, rather than in the first quarter of 2013, as originally planned, said Plant Manager Vladimir Boda. The intention in the future is to use the production plant in Sučany, which covers a production surface area of around 13,000 m 2, to additionally manufacture robots, injection molding machines from the EX Series, and machines and systems for reaction process machinery, as well as trimming components of the KraussMaffei brand. Plant expansion in china The extension of the production capacities at the production plant of the KraussMaffei Group in Haiyan (China) is going according to plan. By spring 2013, it is intended to double the production surface area to around 22,000 m 2. In future, injection molding machines for PET applications of the Netstal brand will be manufactured here, in addition to machines and systems for reaction and extrusion technology. The MX injection molding machine from the KraussMaffei brand with a clamping force ranging from 8,500 to 40,000 kn will also be produced for the Chinese and Asian markets.