Wide-reaching expertise with Technology3. Pooled Know-How. KraussMaffei Group. KraussMaffei. KraussMaffei. Netstal. Berstorff. Extrusion Technology

Transcription

1 The Customer Magazine of NETSTAL Issue Issue AHEAD THe Customer magazine of Netstal Ahead The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in blue. In the white-coloured regions, the Group is represented by over 570 sales and service partners. KraussMaffei Group Netstal KraussMaffei Injection Molding Machinery Injection Molding Machinery Reaction Process Machinery KraussMaffei Berstorff Extrusion Technology PET Business Area KraussMaffei Group Wide-reaching expertise with Technology3 The KraussMaffei Group is the only provider in the world to possess the essential machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Extrusion Technology and Reaction Process Machinery. The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry. Further information available at: Pooled Know-How Strengthens Market Presence Preblow A New Development Reduces Costs

2 Editorial CONTENTS Cover story 4 Pooled know-how strengthens market presence Concentration of PET expertise as a strategic success Brand & markets 8 Preblow A new development reduces costs 10 total efficiency and cleanliness Dear Customers and Readers, I am very excited to present to you our new customer magazine with its new format and fresh content. We have also given our magazine a new name: AHEAD. With AHEAD, we have purposely chosen a strong title that, for one, clearly expresses our forward-looking approach in all areas based on our technological expertise. It also highlights the competitive edge you gain from the high quality of our machines and our extensive skills and knowledge base. The fact that we are marching ahead of the pack with our performance and innovation strengths is readily apparent based on the cover story. The move towards an enhanced brand image in the PET business area has proved to be worthwhile since we can offer you the right product bearing the Netstal or KraussMaffei brand from a larger product portfolio. Sales of the premium quality and efficient PET-LINE and PETForm products are being extended throughout the world under the overall control of Netstal on a needs-oriented basis and according to your requirements. We aim to offer you added value across your value-adding chain. The KraussMaffei Group is therefore strengthening its injection molding activities throughout the world. Dr. Hans Ulrich Golz, a proven mechanical engineering specialist, has now become President of the Group-wide Injection Molding Machinery Segment; in the past he successfully made his mark in the company as Head of the Extrusion Technology Segment and Managing Director of KraussMaffei Berstorff. As a result of the restructuring measures, Mr. Bernhard Merki, CEO of Netstal, decided to resign from his offices and leave the company. He has worked for Netstal in various functions since We would like to thank him for all his work and wish him all the best for the future. In future we want to jointly extend your industry leading edge with powerful technologies. One impressive example is the further development of the PET-LINE Calitec System. The innovative Preblow process, which is the subject of a patent application, will open up entirely new opportunities in this business area. During this process, the preform is blown out in the base area directly after the injection molding process. You can now look forward to a new breath of fresh air, but also proven Netstal quality along with pioneering and cross-technological system solutions in injection molding machinery. Our range of services will give you long-term planning security. Come along with us into a secure future. Join us for the journey AHEAD! I hope you enjoy reading the magazine. Processes & products 12 Successful launch of axos the new generation control system 14 Low energy high performance Partners & projects 16 Success in China 20 Netstal scores highly with system expertise for 64-cavity pipettes 22 american customers believe in Netstal's packaging expertise KRAUSSMAFFEI GROUP 24 Interview with CEO Jan Siebert 25 New and strong brand presence 26 Latest news from KraussMaffei 26 latest news from KraussMaffei Berstorff 27 KraussMaffei Group appoints Dr. Hans Ulrich Golz as the new President of the Injection Molding Machinery Segment 27 Imprint Visit us in the Internet: Thomas Anderegg Vice President Sales Netstal

3 Contents 3 4 Pooled know-how strengthens market presence Concentration of PET expertise as a strategic success Successful launch of axos the new generation control system Total efficiency and cleanliness essential in medical research

4 4 Cover story AHEAD Issue

5 Netstal Cover story 5 Pooled know-how strengthens market presence in the PET business area In 2011 the KraussMaffei Group brought together all of its PET activities under the umbrella of Netstal. Our experiences from the first few months have proved that this was the right step. Customers have accepted the restructuring under the overall control of Netstal and are now benefiting from a wider range of products. Text: CHRISTINE GROB Photos: Harald Mehnert, Eberhard Franke, Group-internal photos B oth Netstal and KraussMaffei have been working successfully for years on the global PET market (PET: polyethylene terephthalate, a plastic used primarily to manufacture drinks bottles). We consolidated Sales and Marketing for the first-class and efficient PET machines in the PET-LINE series of the Netstal brand and the PETForm series of the KraussMaffei brand under one roof. This step was initially greeted by skepticism from the industry. However, our customers' misgivings were allayed after six months. The decision to concentrate the entire PET portfolio of the KraussMaffei Group in Netstal has proved to be worthwhile. The response has been extremely positive, a fact demonstrated by the number of incoming orders, emphasized Thomas Anderegg, Vice President Sales at Netstal. First-class high-performance and high-precision injection molding machinery and system solutions One major advantage for our customers is the wider product range from a single source. It ensures that we can configure for every customer the right system solution with the right machine, a solution which is geared entirely towards the individual needs of the particular customer and his application. Thanks to the joint presence on the PET market, our customers can use the advantages of our machines even more effectively. MARKET LEADER In the drinks industry, approximately 80 percent of PET packaging worldwide a re used for carbonated soft drinks (CSD) or non-carbonated water and juices.

6 6 Cover story AHEAD Issue That's because we can now always offer you the right product, irrespective of whether it comes from the Netstal brand or the Krauss- Maffei brand, said Anderegg. The PET-LINE under the Netstal brand is an ultramodern production system for PET preforms and stands for the highest possible cost-effectiveness and efficient production. Since the market launch, Netstal has concentrated on the continuous further development of all system components and thus further optimized the high technical level. The PET-LINE product line makes us one of the world's leading suppliers of injection molding machines for PET preforms. The PET-LINE systems are based on a clearly defined platform strategy. Customers can therefore configure every system according to their capacity requirements. A wide variety of mold and cavity sizes can be combined on the basis of three clamping force sizes: 2,000 kn, 4,000 kn and 6,000 kn. The advantage is: Minimum production costs with maximum output. The PETForm series of the KraussMaffei brand is an efficient module platform for manufacturing PET bottle preforms. With their vertical clamping unit design and an electric plasticizing unit, the machines are primarily characterized by their high efficiency and excellent uptime. This is proved by the low production costs of the TOP QUALITY PREFORMS PET LINE is an ultramodern production system for PET preforms and stands for the highest possible costeffectiveness and efficient production.

7 Netstal Cover story 7 EFFICIENT MODULE PLATFORM PETForm is an efficient module platform for producing PET bottle preforms. manufactured products and the long mold service life. PETForm machines are therefore economic high-performance cells and a reliable solution for the drinks industry. With clamping forces ranging between 1,750 and 3,500 kn and a corresponding modular system, the PETForm systems feature an ideal balance between high cost-efficiency and the lowest possible clamping force for mold sizes up to 112 cavities. Our customers profit from high productivity and flexibility together with excellent uptime. Process structures optimized By combining the PET activities in a business unit, we have optimized our internal processes in regard to customers' needs. A specific country focus ensures that this optimization is accepted by our customers throughout the world. The technical and commercial strengths of both companies are also ideally exploited. Pooling of PET activities not only opens up new opportunities for us in the area of customer advice it also enables us to react even more efficiently and more flexibly. Finally, we can adapt the product portfolio in future even more specifically to the needs of our customers, said Klaus Zeiler, Director of PETForm Systems. For more information, contact: pet@netstal.com

8 8 Brand & markets AHEAD Issue Brand & markets INNOVATION Preblow a new development reduces costs Netstal has further developed the proven PET-LINE Calitec System. This innovative cooling system supports preform cooling through internal pressure in the preform. The PET preforms are therefore intensively post-cooled without interruption after demolding. Preblow extends this cooling phase with a blow-out process in the base area. The advantages of Calitec are therefore increased still further: Shorter cycle times and continuously improved molding quality. INNOVATION Description of the Preblow process T he innovative Preblow process, which is the subject of a patent application, opens up new and even more efficient opportunities for our customers. Its special aspect: During this process, the preform is blown out in the base area directly after the injection molding process. This means that both the base contour and, thus, the surface area can be changed for the first time. By increasing the size of the base contour through the blowing process, we also obtain a thinner wall in the critical base area. During the subsequent blowing process, this effect can be used to heat the base area more specifically and more efficiently. With a larger surface area, the UV lamps in the blowing machine have to heat a thinner wall. The result: LightBase. There is a clear advantage compared with the EcoBase and Cappello Design solutions now available on the market since complete consistency is guaranteed throughout the entire process. In addition to the change in the contour, the Netstal experts exerted more influence on the much more important parameters wall thickness

9 Netstal Brand & markets 9 Weight saving Influence of the different preform tips on the bottle bases and material build-up and improved them significantly. Finally, the wall thickness in an optimum injection molding process is almost invariable. During an initial test with 1-liter juice bottles, a weight reduction of more than 1 g was attained. The wall thickness was also increased substantially. At the Chinaplas exhibition in April 2012, Netstal Application example: 0.5 l water bottle presented a system which produced a preform weighing 15.8 g for non-carbonated water. Although the bottle quality remained identical, material consumption was reduced by at least 0.5 g material. Calculated over the year, this corresponds to a saving of around 255 tonnes. The preforms were produced with 128 cavities at a cycle time of around 7.2 seconds. All 128 preforms were then reliably blown out identically. The high reproducibility and the much simpler blowing process compared with EcoBase and Cappello spoke a clear language and impressed the visitors. OLD preform weight (g) NEW preform weight (g) Cycle time (s) 7.2 Number of cavities 128 Output / year (mio. units) at 8,400 h and 95% Material consumption / year (t) 8,095 Weight saving (g) 0.5 Weight saving (%) 3.2 Material saving / year (t) 255 Material costs / tonne 1, Material cost saving / year 370, Through the development of the Preblow process, Netstal has managed to achieve a first-rate innovative technology. Thomas Anderegg Through the development of the Preblow process, Netstal has managed to achieve a first-rate innovative technology. The larger process window in the blowing process and the additionally reduced cycle time due to lower material build-up on the base represent considerable advances in the production of PET bottles, said Thomas Anderegg, Vice President Sales at Netstal. CG/SB

10 10 Brand & markets AHEAD Issue

11 Netstal Brand & markets 11 Injection molding in a cleanroom Total efficiency and cleanliness A cleanroom is essential in medical technology production to manufacture sterile or so-called clean parts. Any company wanting to take account of current and future requirements relating to quality and cost-effectiveness in the medical and pharmaceutical industries will have no alternative but to adopt this production culture and follow the recommendations in Good Manufacturing Practice (GMP) regulations. High requirements The production of plastic parts for medical and pharmaceutical use is subject to far stricter requirements than the production of technical parts. The first priority in quality assurance is close monitoring of the conditions in the cleanroom. Firstly, a constant production environment must be ensured through continuous monitoring of the parameters of temperature, humidity and pressure, as well as through their related control. Secondly, however, special attention must be paid to the cleanness criterion it self. Compliance with the limit values for bacteria counts and particle loads is an important factor in ensuring that the products conform to GMP. Ensuring this conformity is the task of a properly documented, qualified and validated cleanroom system in every company involved in the medical and pharmaceutical industries. The positioning of the particle sensors and control of the air filter system play just an important role in this respect as staff training and discipline in handling the sluice system and cleanroom clothing. Thoroughness can also be cost-effective in this case. If, for example, a cleanroom is systematically planned and designed according to the pharmaceutical guidelines for manufacturing and packing medicaments, a subsequent complex and expensive sterilization process can normally be avoided completely. The basis of the success of our customers is also our excellent machine technology in this area. The standard version of the allelectric ELION has become established as an economical solution standard for medical applications and is ideally suitable for use according to cleanroom class specifications in ISO 7. A higher cleanroom class can be obtained with a few additional options. For example, we can install covers to alleviate laminar air problems, use closed drag chains, integrate media distribution (air, water, electricity) flexibly and completely in the safety cover, and do much more besides. Quality assurance plays a vital role in the production of pharmaceuticals. Even the slightest deviations from the quality standards may have direct impacts on the health of consumers. Netstal will support you with an ideal solution throughout the entire calibration process based on its high expertise and experience in the area of measuring technology. We guarantee FDA/GMP-conform calibration, savings in regard to time, costs and resources or the use of calibrated and measuring instruments matching your machines. These are just some of the tasks which Netstal will perform on your behalf. CG/AB For more information, contact: med@netstal.com

12 12 Processes & products AHEAD Issue Processes & products ELION SERIES Successful launch of axos the new generation control system The axos control system enables users to implement the required production process on a cost-effective basis according to their individual needs.

13 Netstal Processes & products 13 Statuses of the keys Injection unit Possible presentations of the control panel (1) Standard Inactive Active Possible presentation of the control panel (2): White Dimmed Yellow Yellow The key command can be used. The key command cannot be used in this operating mode. The key command executes a movement. End position status is reached. Your advantages with axos Graphic sequence editor Graphic processes to control machine processes can be created using the sequence editor. Flexible auxiliary controls The interaction between machine programming and manual operation of individual machine axes assists the user in his daily work on the production machine. All the machine peripherals can be freely configured to currently required equipment components based on specific molds and can be supplemented with individual denomination. Integrated safety package Monitoring routines predefined by the manufacturer and locking devices ensure maximum mold protection. These safety precautions are automatically included by the control unit in the validation of sequences. As a result, the machine and mold are fully protected against collisions. 1. Display of end position A 2. Display of movement function A 3. Numerical position setting 4. Function symbol 5. Display of movement function B 6. Display of end position B 7. Index number 8. Activation of movement function A 9. Designation of function / component 10. Activation of movement function B Control keyboard The control keyboard is equipped with direct access keys in order to provide the fastest possible access to the required system processes. The control keyboard also features navigation keys, a track ball and a numerical input field. The keyboard is ergonomically designed and can be folded down for maintenance. Input assistant with visual presentation The input assistant visually supports the operator during changes by means of graphic elements and refers directly to possible irregularities. Storage of change history Using two keys Undo/Restore, the machine operator can move forwards and backwards in the change history of inputs. Convenient search function A search function can be used to look for parameters or texts in the entire control process and to select them by means of direct access keys. Successful launch The products which our customers produce in injection molding machines are becoming increasingly more diverse and complex. A good control system can help the user to produce an economical tailor-made production process. Netstal launched the new generation axos control system last year. It not only features an innovative control unit, but also a sequence editor which can be used to graphically create any number of production sequences. Due to the positive response from customers, Netstal is equipping the new models in the ELION series with the latest generation axos control system as a standard feature. Innovative and more user-friendly than ever The focal points of the operating philosophy of axos are the very different requirements of operators from the numerous application areas of injection molding machines. The control keyboard therefore offers the user numerous advantages, for example the direct access keys with which he can access the required system processes as quickly as possible or the 17" flat screen which acts as a display medium for the entire process programming setup. The key elements of axos are graphic programming and presentation of processes. The machine operator therefore obtains an overview of the processes and connections between the process steps that have to be executed. Thanks to the additional status information e.g. path, stroke movement, end position, the machine operator can also constantly see what is happening during production. Thanks to the powerful RISC processors and the X86 computer, the operator can see the status information completely simultaneously with the real machine movement and the machine function. CG/EK

14 14 Processes & products AHEAD Issue Gaining energy advantages through Netstal expertise Low energy, high performance The reduction in energy consumption has been a key discussion topic for many years. In the last few years Netstal has also paid special attention to increased energy efficiency of injection molding machines. For the benefit of customers. Sound energy Heat emissions Electrical energy Compressed air Water (machine cooling) Thermal energy Efficient Customers also profit from higher productivity and less commissioning in the form of shorter delivery times and faster production processes. Shaping (work) Water (mold cooling) Thermal energy Energy cannot be generated or destroyed. However, it is possible to convert energy into different forms. Different forms of energy occur in connection with injection molding machines (see above photo). Increased efficiency firstly reduces the absorbed energy of the machine. Secondly, it increases the energy proportion which is required for shaping (i.e. production of the injection-molded part). The machine emissions (heat, sound) are therefore reduced. Energy advantages of the ELION series Actual operation of the machine represents by far the largest proportion in regard to energy consumption. Thanks to the new generation of the ELION series, we have increased energy efficiency enormously. We used the leitmotif Low energy, high performance when developing this series. This means: Maximum performance and optimum energy efficiency. We developed a completely new power unit with this objective. The Eco Powerunit attains unprecedented energy savings with hybrid injection molding machines. The following properties make a major contribution in this respect: Recovery of kinetic energy Adaptive drive regulation Power converter network Optimum working point at maximum efficiency.

15 Netstal Processes & products 15 By using the Eco Powerunit, energy savings of up to 50 percent can be made compared with conventional hydraulic machines. If an allelectric machine is used, an additional efficiency advantage of around 20 percent is attained. Energy consumption 100% 50% 50% 20% 30% We attain the high energy efficiency of our PET-LINE thanks to the following factors: Electric drive unit Toggle lever on the clamping unit Much lower dry air consumption Vertical robot which consumes much less energy Energetically optimized system between drying unit and machine Due to the vertical concept, our PETForm systems also have an energetic advantage over rival systems. The clamping unit in the PET- Form systems is vertically arranged. This has far-reaching impacts on the entire demolding and downstream process: Conventional solution Conventional, energy-optimized All-electric, recuperated Low-moving masses Less work during the clamping movement Increased efficiency thanks to vertical technology Energy advantages when producing PET preforms One other example of the very high energy efficiency of injection molding systems from Netstal are the special machines designed for maximum productivity for producing preforms for PET bottles. Netstal supplies these machines under the names PET-LINE of the Netstal brand and PETForm of the KraussMaffei brand for different output rates. A comparison with competitors reveals that our systems are well ahead, a fact proved conclusively by the following example of a direct comparison measurement. The PET-LINE from Netstal and the rival machine produced the same number of preforms during the measurement operation (10.5 g twist off 25/30). The impressive result of the test was an energy consumption of 0.28 kwh/kg during production on a PET- LINE. This represented an energy saving of 25 percent compared with our best competitors. Thanks to the vertical clamping concept and the ultralight demolding gripper, only very small masses have to be moved during demolding. That's because the post-cooling required during preform production is autarkic and must not be moved into the clamping unit. The vertical design ensures that the preforms need not actively be demolded using energy, but can drop with guidance. Energy efficiency is not just a current buzzword It is foreseeable that energy costs will rise still further in future. In addition to material costs, the proportion of energy costs will become the second most important cost factor. Netstal is devoting its entire innovative capacity to the development of systems and solutions which ensure maximum energy efficiency and maximum productivity. Strictly according to the motto: Low energy, high performance. CG/SB/MC/KZ Comparison of energy consumption between a PET-LINE R and a comparable machine of our main competitor* * Measured at the customer's premises (October 2011) (Preform weight 10.5 g) Main competitor measured Netstal measured Netstal calculated Energy (Wh/kg) Low energy, high performance By comparison with our main competitor, a PET-LINE from Netstal achieved an energy saving of 25 percent ,000 1,100 Material output (kg/h)

16 16 Partners & projects AHEAD Issue Partners & projects

17 Netstal Partners & projects 17 Success in China Greater industrialization and strong economic growth for example on account of increasing urbanization and technical progress. These are common characteristics of the BRIC states (Brazil, Russia, India and China). In 2011 Netstal laid the foundations for its further growth in these emerging countries. Here is an intermediate report from China in this respect.

18 18 Partners & projects AHEAD Issue A strong partner As one of the world's largest suppliers to Apple, the Chinese company Foxconn manufactures its products on more than 10,000 injection molding machines, including numerous machines from KraussMaffei. New technologies for products in the area of electrics/electronics will be developed for the future on four machines from the CX and MX series. Netstal has been present on the growth market of China for more than ten years. The company has a very good position there and is recognized as a competent partner. Our business also developed positively in the last fiscal year. In order to tap further market potential, we have pooled our Group-wide strengths and competencies under the umbrella of the KraussMaffei Group. Harald Schweitzer, Managing Director of the Chinese subsidiary, is looking forward to 2012 with confidence: The agreed expansion of our plant in Haiyan is the basis for long-term growth in China and Asia. The start of production of injection molding machines will also clearly improve our market position. We are also operating on the market with a strong team of 300 employees. This is important since in China the size of a company is an indication of its strength. A large number of new orders this year prove that our customers welcome our strategic step. For example, we have already sold numerous machines for PET and closure applications, and:

19 Netstal Partners & projects 19 PET-LINE 3500 at Chinaplas 2012 in Shanghai we have achieved the best start for sales of Netstal machines in China since we entered the market. David Tso We have achieved the best start for sales of Netstal machines in China since we entered the market, said a proud David Tso, who is responsible for sales of Netstal machines. Schweitzer himself is looking even further ahead. Customers are welcoming the wider scope of our product and service portfolio. We are now intensively strengthening the competence of the service team for all products in order to increase implementation efficiency and reduce the reaction time for the benefit of customers, said the Managing Director of the Chinese subsidiary. Wahaha The Chinese company Wahaha has been the leader on the Chinese drinks market for 13 years. With a workforce of around 30,000 employees, it produces plastic parts for the drinks industry on more than 150 injection molding machines. Wahaha has its own first-class moldmaking department which matches the European standard. After many years of negotiations, Netstal succeeded in becoming a second source supplier. This was made possible through a complete package which was fully adapted to the requirements of the Chinese company. Nine PET systems will be delivered to China between June and September The main reasons for our decision were the excellent service package and the excellent price-performance ratio, said Zong Quinghou, General Manager of Wahaha. Together with its competent partners, Netstal fulfilled the high expectations of the customer and once again demonstrated its system expertise in injection molding machinery. Foxconn The Chinese company Foxconn is one of the world's largest suppliers to Apple and manufactures its products in China on more than 10,000 injection molding machines, including numerous machines from KraussMaffei. Johnny Xu, who is responsible for the production of Apple products at Foxconn, and Michael Müller, General Sales Manager for injection molding machines in China, opened the KraussMaffei Technology Center at the Foxconn plant in Shenzen in December Technologies for new products in the field of electrics/electronics will be jointly developed on four machines in the CX and MX Series. These technologies will include, for example, thin-wall, light-conducting optical functional parts for producing computers and television sets. CG

20 20 Partners & projects AHEAD Issue Schlosser Netstal scores highly with system expertise for 64-cavity pipettes A garage company founded by Benno Schlosser in 1969 has now become one of the leading injection molders for plastic medical parts. New markets were opened up for the medium-sized enterprise after it was taken over by the American Nypro Group at the start of Schlosser Medizintechnik relies here on the machines and competence of Netstal. The history of plastics processing at Schlosser started with the production of optical components, e.g. spectacle frames and lenses. The company also soon used its experience in precision injection molding for medical plastic parts. The production of pipettes, which are used for analysis in laboratories, now represents around 95 percent of the total production volume. We chose Netstal because the company perfectly produces systems for 64-cavity pipettes, praised Marco Glöckler, Project Manager at Schlosser. Schlosser has a workforce of around 200 employees at present. Production is carried out on 70 machines in a 3-shift operation. A production reliability department also operates in the same rhythm to ensure that the required high quality standards are observed. The company also has its own moldmaking department. Schlosser produces around 1.6 billion pipettes every year in Knittlingen. Arranged individually in racks, they can be simply demolded automatically in laboratories. System expertise Pipettes produced on the ELION are placed individually in racks and reprocessed. One striking aspect of production, which predominantly takes place in cleanrooms, is the high level of automation. Manpower deployment is limited to the technical personnel for operating the system and employees responsible for cleanroom feeding and transportation of the complete racks. Cooperation between Schlosser and Netstal came about quickly. In 2010 Schlosser purchased a total of seven all-electric ELION injection molding machines with a clamping force ranging between 80 and 175 tonnes. The main reasons were the excellent know-how in the field of medical applications and the already implemented systems.

21 Netstal Partners & projects 21 Powerful The all-electric ELION ensures optimum cleanroom suitability The well-known properties of the series, e.g. the high injection rate and the superb cleanroom suitability, were not the only criteria when making the investment decision. Other important criteria included the high process constancy and reproducibility. So-called axial eccentricity plays a key role here as a quality characteristic. The impressive features of the ELION series are its total injection constancy, quick cycles and a long service life. Another important aspect of the cooperation between Schlosser and Netstal was the realization of the requests and ideas of Schlosser regarding the machine design requirements for production in a Class 7 cleanroom. The machines are practically emission-free and very easy to clean. One example of this is the mold insertion and removal crane which is integrated in the machine design. Using several layouts, we together finally found an ideal solution for a production machine in a cleanroom. The cooperation with Netstal was excellent right from the very beginning, emphasized Marco Glöckler, Project Manager. This was also certainly due to the business unit organization that has been used in Sales at Netstal since Sales, application technology and project management are combined in one team in this organizational framework. This constellation helps to ensure that customers receive detailed advice and that their needs are quickly examined. Thanks to this combined know-how, we were able to give Schlosser very detailed advice beforehand and provide the company with exact Cooperation with Netstal was excellent right from the very beginning. Project Manager Marco Glöckler production proposals. It was therefore possible, for example, to show the calculated cycle times directly before acceptances and without any substantial optimizations. The target cycle times were attained straightaway on the ELION, confirmed Glöckler. The development of Schlosser Medizintechnik is continuing at a rapid pace, and the company is considering a further expansion of production in Knittlingen. Affiliation with the Nypro Group will certainly also play a major part in this respect. Together with the Nypro Group, Schlosser can develop new markets and invest in other medical applications such as cuvettes or plastic parts with capillary channels. Schlosser has already started discussions with Netstal in regard to the imminent expansion. In future Netstal will also quickly and reliably provide the company with the accustomed competent technical expertise. CG

22 22 Partners & projects AHEAD Issue tech ii American customers believe in netstal's packaging expertise The trip from Columbus to Springfield in the US state of Ohio is already a highlight: Cornfields as far as the eye can see and wonderful landscapes lead the way to our customer, Tech II. But even this experience is surpassed by the tour of the family-run injection molding company that delivers plastic packaging from this agricultural region to the entire world and which swears by Netstal while doing so.

23 Netstal ENTREPRENEUR Eric Shiffer, Vice President of Sales and Business Development at Tech II, and son of the founder Jerry Shiffer, outside the company in Orlando, USA The company was founded in 1969 by Jerry Shiffer, the father of the Shiffer family, who, starting out in a garage, initially manufactured plastic parts for IBM, and later also made plastic parts for airplanes of all sorts using the injection molding process. In the mid-1970s, thin-walled lids for cartons and metal containers were added. The orientation towards plastic packaging led to sustained growth and the injection molding machine park has grown as well. Dave Shiffer, son of the founder, joined the company in the 1990s. First as a computer specialist and later as Production Manager. We swear by the toggle technology and the Netstal machine technologies, said Dave Shiffer, current CEO at Tech II. In 2009, in the middle of the economic crisis, the company began to manufacture complete packaging for the grocery industry. Today, the proportion of covers to containers is 70 to 30, and the journey with the company's 350 employees has only just begun. The sales team has been strengthened, and the company is developing and implementing new packaging solutions made of plastic. The customers are totally involved in the process from packaging design development through to production. To do so, Tech II uses plastic designers and their own manufacturing prototypes. The company's injection molding production department has a capacity of several billion pieces per year. They produce around the clock in a three-shift operation. The company increasingly uses electronic media for customer contact. For example, on the company s website there is an input dialog box in which container dimensions for the specification of the correct cover can be entered. Tech II supplies the entire world from Springfield. This is rather uncommon for packaging parts, but has to do with the very close relationship with multinational food corporations. Since 2007, Tech II has worked with the SynErgy series from Netstal. The investment was made with an eye toward the growing demands for saving material and increasing productivity. The machine achieved these goals, and in its fourth year in operation, it still manufactures perfectly. SynErgy is the best machine in our operation, Shiffer said happily. In the case of new projects, the company also cooperates with Netstal right from the start to achieve their goals efficiently. The packaging specialists at Netstal offer optimum support during project planning, and they can respond perfectly to the requirements of Tech II and their customers. This also applies to technologies that are to be implemented in the future, for example in-mold labeling. And also to the multi-layer barrier for thin-walled plastic packaging, which was developed by Netstal and Ilsemann, and was presented at Interpack We also rely on Netstal as a partner for new technologies going forward, Shiffer confirmed. Tech II has already made its next investment in a Netstal machine. With a EVOS 5500, the company opted for larger mold dimensions and higher cavities, i.e. for another increase in productivity. The specialists in the PAC Business Unit from Switzerland and the branch in Devens, MA (USA), will also cooperate closely with Tech II in future projects in order to contribute their skills and expertise at the earliest possible stage. CG

24 24 KraussMaffei Group AHEAD Issue KraussMaffei Group Interview Changing technology leadership into global market leadership Jan Siebert has been CEO of KraussMaffei AG since January 1, In an interview with Ahead's editor, the Aerospace Engineering graduate talked about the potential of the KraussMaffei Group. The interview was conducted by Imre Szerdahelyi. Ahead: Mr. Siebert, for a little more than four months now you have been at the top of the KraussMaffei Group. How would you summarize the first months? Siebert: The first months have been very positive for me. I have visited many locations and purposely focused on entering into personal conversations with employees at all levels. By doing so, I gained a very good overview of current projects and processes. Additionally, I spoke with numerous customers and business partners worldwide, who have given me a good sense of their interests. This provided me with a wellfounded overview of the requirements of the markets and customers. Ahead: What made a particular impression on you? Siebert: My customer visits assured me of the great acceptance for the high quality and performance of the machines and systems of our KraussMaffei, KraussMaffei Berstorff, and Netstal brands. This made a particular impression on me at the Chinaplas trade show in Shanghai. I was also impressed by the high level of specialized expertise of our employees in regard to technologies, procedures, and applications. That makes us the most treasured partner worldwide at the side of our customers. Additionally, I perceived strong motivation in the company, passionate commitment, and unconditional striving to develop the best possible solution for the customer at all times. Ahead: Now you have the typical 100 days in the company behind you. Are you already able to make some statements about the future strategy of the KraussMaffei Group? Siebert: Our strategy for the KraussMaffei Group is in place and we will now implement it in the company, so I would like to give just a rough outline here. In principle I see us as very well positioned worldwide. We will consistently work to strengthen business in the core markets as well as to expand our presence in the worldwide growth markets, especially in the BRIC countries and Asia. An essential foundation for improving delivery capability is the expansion of our international production capacities, particularly in China. In addition, we will concentrate more consistently on being market-oriented and providing our customers with a range of products and services that is high-quality and requirements-based, but also affordable. We will stand by our Jan Siebert, CEO (*1966) As an Aerospace Engineering graduate, Jan Siebert has more than 18 years of experience in leading management positions with esteemed industrial companies in the areas of strategy, Research and Development as well as Sales and Marketing. customers with this range of products and services across their entire value chain and offer them significant added value with respect to efficiency and productivity. Ahead: The KraussMaffei Group has distinguished itself with its leadership in technology and innovation. Where do you see potential here? Siebert: Here we have a clear competitive advantage and we will continue to push this forward. As a technology leader, in the future we will continue to invest in the consistent further development of our machine and systems engineering as well as in our leading application knowledge. I see future potential for our technology portfolio particularly due to processors' efforts toward sustainable and economical management. This includes resource conservation and material savings as well as improved energy, process, and product efficiency. In the future we will continue to develop new trendsetting processes with which we will make a significant contribution to the economic success of our customers. Along with this, however, I have the task of developing our technological leadership into a global market leadership. Ahead: Where do you see the greatest growth potential overall? Siebert: I see numerous global market trends that lead to an increased demand for high-quality machines and systems for producing and processing plastic and rubber. Along with the described trend towards sustainability, I see the greatest growth potential in aspects such as the continuously growing world population and an increasing rise in the standard of living in growing and emerging countries. This presents numerous business opportunities for us, including in the areas of medicine, infrastructure, and the packaging industry for foodstuffs and consumer goods. The KraussMaffei Group is positioned very well technologically with its product and service portfolio and we want to take advantage of that.

25 Netstal KraussMaffei Group 25 Corporate Identity New and strong brand presence Starting immediately, the KraussMaffei Group with its three strong brands KraussMaffei, KraussMaffei Berstorff, and Netstal has a new appearance. Text: Eva Münzenmaier Coca-Cola, adidas, BMW: Brands play a large role in consumer business. They stand for lifestyle, prestige and not to be underestimated quality and utility. Brands convey emotions and specific value perceptions. To a certain extent, this also applies to the global market of investment goods, though this more rational world clearly gives priority to other factors: customer benefit, the gain in productivity, efficiency and flexibility. The KraussMaffei Group is characterized by the fact that it has had three strong brands for many years. These are KraussMaffei, KraussMaffei Berstorff and Netstal. In order to solidify our claim to market leadership, we improved the brand image of the KraussMaffei Group in cooperation with customers and enhanced the profile of each individual brand, explains Imre Szerdahelyi, who as Corporate Communications and Marketing Manager is responsible for the new profile. The result clearly distinguishes us from our competitors and ensures an individual and unmistakable profile of each individual brand on the market, which significantly increases the respective product and technology expertise. Furthermore, a consistent group profile is ensured that reflects our brand-encompassing expertise and the unique selling proposition of Technology 3 the capability of integrating all areas of application in injection molding, extrusion, and reaction technology. KraussMaffei is internationally synonymous with future-oriented and cross-technology system and process solutions in injection molding machinery, reaction process machinery and automation. proven, powerful, passionate Engineering Passion KraussMaffei Berstorff stands internationally for state-of-the-art and high-quality solutions in extrusion technology: engaged, reliable, proven value Engineering Value Netstal stands internationally for premium quality high-performance and high-precision injection molding technology and system solutions: fascinating, continuous, first-class Engineering Excellence The current image of the three brands is a consistent thread through all short-term and long-term communications media and venues that customers of the KraussMaffei Group encounter. The starting shot for implementation was fired at the Fakuma 2011 trade show, where the visitors could marvel at the new profile on two trade show stands. The starting shot for the new brand concept was a uniform profile of all three brands at the Fakuma 2011 trade show. Because we make our products exclusively with machines from the KraussMaffei Group, their booth at the Fakuma trade show is of course an important starting point for us. There, we can speak professionally with plastics specialists on the subject and learn more about the newest development trends and service options. Of course, it is also interesting to experience the new systems engineering once again in person. With the integrated trade show concept of the three brands, the synergy potential of the various plastic finishing areas of injection molding technology, reaction technology, automation and extrusion are for the first time presented to us visually as well. Alfred Becker, Managing Director at Becker Kunststofftechnik GmbH

26 26 KraussMaffei Group AHEAD Issue Polyurethane (PUR) 75 years young Four and a half decades of process and machine expertise at KraussMaffei Text: Markus Betsche Photo: Harald Mehnert It would be hard to think of everyday plastics without also thinking of products made of polyurethane (commonly called PU or PUR). The versatile chemistry of polyurethanes facilitates the creation of components with virtually unlimited property profiles from soft foams in automotive seat upholstery through to extremely light, high-strength carbon fiber composites. Polyurethanes are found in virtually all industries and areas of application. KraussMaffei starts machine production in record time Polyurethanes are an extremely young group of materials. Their birth certificate is represented by the German Patent DRP , issued to the inventor Otto Bayer on November 13, Since then, polyurethane has been continuously breaking new ground in finding ever more new applications. KraussMaffei has been engaged in producing machines and systems for processing polyurethane for 45 years making us a pioneer in the use of polyurethane. As early as one year after the start in 1967, the first machines were appearing on the market. In close collabo ration with raw material manufacturers and processors, we developed ever more new fields of application, processes and machines. Expertise presentation in Florida Just at the time of polyurethane's anniversary, we were opportunely able to demonstrate polyurethane processing live at the trade fair in Orlando based on an armrest which was created using the Skin- Form process. That allowed us to demonstrate the Technology 3 expertise of KraussMaffei, says Nicolas Beyl, Head of the Reaction Process Machinery Division at KraussMaffei. Machines, automation, tool technology and a solution for trimming - we provided all these things. Innovative Armrests manufactured using the SkinForm process EVA film recycling without quality problems EVA Films FOR SOLAR MODULES With the new, patented technology of a special flat-film extrusion line, KraussMaffei Berstorff offers an exciting solution from an ecological and economical perspective for manufacturing EVA films. TEXT: TONI NIPPE, HOLGER SCHAARSCHmIDT, PROF. DR. BERND POLTERSDORF With the new flat-film extrusion system from KraussMaffei Berstorff, ethylene vinyl acetate (EVA) films can be produced at high speeds with a width of up to 3.2 m while featuring optimum visual property pattern and low shrinkage even when recycling the edge trimming. between 420 and 1100 nm of 99 percent. At the same time, the shrinkage that now occurs has been reduced by up to 45 percent so that it is now lower than 5 percent. And the highlight of these results is that they were determined for both a commercial formula for a new product and for a sample that had been recycled three times. The fields of application include the rapidly growing photovoltaic industry where, in 95 percent of applications, EVA films are now used as standard as encapsulation films for silicon cells in solar modules. The application in laminated safety glass panes is also interesting since EVA films are more cost-effective than the polyvinyl butyral (PVB) that are used today and can be produced more easily. Tests carried out by the Fraunhofer Center for Silicon Photo voltaics (CSP) in Halle have proved that EVA films that are manufactured on the new extrusion system are highly transparent. They feature transmission in a glass-eva-glass test sample in the spectral range Versatile ZEUTX twin-screw extruder gently prepares the EVA material