the profilers 01-2009 - Greiner Extrusions Technik

Information oF Greiner Extrusion
PRODUCTION
COMPETENCE
1/2009
Edition 3
Photo: This product is the registered property of CHIALI PROFIPLAST with brand and patent registered or applied for.
The six-fold PowerTooling dry calibration unit.
A CALIBRATION OF ITS OWN:
SOLID STEEL FROM TOP TO TOE
The PowerTooling dry calibration unit is the only one worldwide that is 100 percent steel.
This means enduring high productivity due to robust wear-and-tear and corrosion resistance.
Greiner Extrusion replaced all aluminum parts for
steel for all its PowerTooling dry calibration units
back in 2004.
Cover, base plate and base supports have all
been produced standardized in high-grade steel
like the core of the calibration unit itself since that
date.
Know-how makes it possible
A composite construction in aluminum and steel
is susceptible to corrosion and abrasion.
“I have worked in the industry for 40 years and
know the problems with aluminum parts all too
well. Pitting corrosion and electrostatic charges
constantly cause faults and downtime in highperformance
extrusion operation. That is why
I am really happy that the opportunity exists to
construct calibration units entirely in high-grade
steel and that this has been the case now for the
past four years.
It is the unique Greiner Extrusion manufacturing
technology that makes this possible”,
Jürgen Kock, Senior Technical Engineer at Greiner
Extrusion explained.
The material is decisive
Greiner Extrusion uses exclusively the highest
grade corrosion and abrasion resistant steel. The
base supports on which the calibrator is fixed included;
steel in the PowerTooling calibration units
ensures that they are sealed and stay permanently
tight and it is resistant to wear-and-tear.
High performance
The pure steel structure has brought high customer
satisfaction in every market. The basis for
this satisfaction is the increased productivity with
stable production processes that customers are
now able to achieve. Dry calibration units in 100
percent steel are significantly more secure against
downtime due to their robust wear-and-tear behavior.
Problems caused by pitting corrosion and
electrostatic charges that are facilitated and occur
in the use of different materials are a thing of the
past. The clear proof is that ever since the calibration
components for PowerTooling have been in
steel from top to toe, there have been virtually no
complaints of material deficiency in covers, base
plates or base supports made from steel.
Proprietor / Publisher Greiner Extrusion GmbH Responsible for the content Greiner Extrusion, Friedrich-Schiedel-Strasse 1, 4542 Nussbach, Austria, www.greiner-extrusion.at Company headquarters Krems münster,
District court of Steyr, Austria Commercial register no. FN 285487 i UID ATU 62967347 Design / Concept seso media group gmbh Photos Greiner Extrusion GmbH, Working Group for PVC and the Environment
registered association Text / Layout Kommhaus Media Enterprise, www.mediaenterprise.at Printing Bösmüller Publication 6 times annually Total circulation 750
Information OF Greiner Extrusion
Quality is no accident (page 2)
A future for PVC? (page 3)
A calibration of its own: solid steel from top to toe (page 4)
January 2009

Information oF Greiner Extrusion
1/2009
1/2009
Edition 3
focus quality INSIDE PARTNERSHIP
Edition 3
Information oF Greiner Extrusion
WHAT IS
QUALITY
Dear Business Partner,
“The ordinary gives the world its existence, the extraordinary
its value.”
oscar Wilde
There is no question about where we stand at
Greiner Extrusion and how we want to be seen.
Our goal is to offer you the right profile extrusion
solution by providing an extraordinary service.
Our services will enable you to produce top quality
products with full process security.
Fulfilling your requirements is how we see quality;
providing you with the reliability of stable production
conditions through our services and putting
absolute high-performance at your finger tips if
this is what you want – with our tailored solutions
for profile extrusion.
Quality is no accident. Intelligence and willpower
are needed for this. In the case of an intelligent
solution the price is never the most important
issue. What matters is that it pays off. Because
there is scarcely anything to be had in this world
of ours that someone else will not be able to make
a great deal worse for a little less money.
Our aim, however, is to see to it that our business
partners only get the finest quality. This is
why we continue to develop our highly functional
services and work constantly on innovation. Your
success, your process security and manufacturing
quality give us our drive. And that is what
quality means to us.
Best wishes,
Yours,
Robert Grieshofer
CEO
QUALITY
IS NO ACCIDENT
Checking processes and tolerances assures continuous high reliability.
Perfectly coordinated extrusion tooling and machines
are of vital importance for an optimal extrusion
process. Continuous quality management
(QM) assures a permanent equal standard for the
products that are delivered.
“Our production is not mass production. With our
individually tailored tooling, systematic control
methods ensure that quality is not something that
happens by a lucky chance, but it is the result of
processes that are fully under control”, Norbert
Freund, head of QM at Greiner Extrusion said.
Check lists and documentation
Greiner Extrusion maintains its own department
for the assurance and management of product
quality with a staff of three and has done so for
the past five years.
The tasks of this department include supporting
quality thinking among the employees, the processing
of complaints as well as checking goods
on both issue and arrival. Extensive check list
and photo documentation assures that all tooling
and machinery is in perfect order on issue for
delivery.
“When our products permanently meet the requirements
of our customers – that is the point
when we can begin to talk about quality”, Norbert
Freund said.
In step with practice and totally efficient
QM means more than simply assuring quality. It
comprises the whole issue of evaluating and optimizing
current working processes, responsibilities
and the clarity of digital documentation. The
analysis and causal research of faults, getting rid
of all fault sources and strengthening of quality
consciousness are among the QM tasks.
All employees have the opportunity to participate
in regular group discussions on quality assurance
measures, in our quality circles. What this
does is it changes the people affected into active
participants in the quality process while motivating
them to take part in bringing all our efforts
in line with real current practice. The experience
and the suggestions our people bring in are valuable
support.
Fast start-up
When the coordination process has been completed
the finished product must cover all tolerances
to ensure that customer acceptance can
be swiftly and efficiently carried out. Success is
the confirmation of the effort put in by the QM
employees. Complaints have been cut down to a
minimum, product reliability and process security
boosted and the time taken for a start-up process
minimized.
Extensive check lists and photo documentation assures that the tooling is in a thoroughly satisfactory condition in the course of the
goods issue controlling.
Service
and more
The Service Department
intensifies its technical consulting.
Process engineer Oliver Schürrer was been appointed
a technical customer consultant in October
reinforcing the Service Department that was
set up five years ago. His tasks include the expert
appraisal, coordination of repair work and the general
overhauling of tooling together with the planning
of technician assignments. The enthusiastic
Oliver Schürrer, a senior technician with many years experience abroad.
mountain biker has been in the company for ten
years and has completed the demanding company
internal technical training course. Greiner Extrusion
uses DigiOM, the digital system for the documentation
and optimization in tooling production for the
replacement, repair and the general overhauling of
tooling. This system available exclusively to Greiner
Extrusion customers has the benefit of making
traceability and the exchange of information in the
renewal and repair of tooling easier.
a future for PVC?
Sustainability is the decisive issue.
PVC is not only one of the most important plastics;
it is also one of the most controversial. PVC expert
Werner Preusker states his view and provides perspectives
for PVC in this interview.
What does the future hold for PVC?
Preusker: PVC has a positive outlook for the future
thanks to its versatility. What the future holds is to
a great extent dependent on efforts in the industry
too and how successful it is in making PVC a more
sustainable material. This is a continuous task and
process. The crux of the matter here is for the entire
PVC industry with everyone involved - and this includes
the processors, manufacturers and machinery
producers - to give full support to the continued
development of the sustainability initiative. I see the
starting point for this as very favorable on the basis
of what we have achieved so far.
How is PVC performing on the market?
PVC is achieving good growth rates in Europe as a
result of the good value for money it represents plus
its sound properties as a material. PVC has been
able to demonstrate its full repertoire of strengths
in the window profile area in particular and it is the
number one material choice. Among its advantages
is the fact that it does not need to be painted.
Are there new applications for plastic windows?
Ever more producers on the market are offering
windows for passive energy houses. These windows
have a low thermal transmittance value. The
insulation values of the frame and the pane must be
equal otherwise condensation gathers in the frame.
Scarcely any other material can achieve this requirement
better than PVC. Fiber reinforced window profiles
are a recent development that is also on offer.
Extruding, printing and pressing have now made
possible an optimized extrusion line concept from
Greiner Extrusion. The integrated system has already
proved itself in practice in the UK, South
America and Russia.
Three functions on a single strand
The expanded extrusion line slashes time, personnel
and space requirements. A complete and
ready product is manufactured in a single working
process. “Everything can be perfectly coordinated
and the customer has the advantage of getting it all
from a single source. Up to two employees per line
can be saved.” Project Manager Walter Roidinger
said, explaining the convincing benefits.
Technical
Punching is done in the manufacture of many technical
profiles such as cable ducts and roller shutter.
The punching unit is placed between the calibration
table and the haul-off unit. It can be used for
These replace the steel or aluminum reinforcement
in the window. The fiber used is cheaper than the
metal variant while providing comparable stability.
What are the trends in the building industry?
In window profiles both the overall quantity and the
market share is increasing. PVC is losing ground with
its market share in the classic areas of floor coverings
and pipes, but in absolute terms use of the material
is growing. The trend to use plastics in modern construction
can readily be established. This is partly the
result of the organic structures of the buildings such
as the dramatic Kunsthaus in Graz, but also light
construction methods such as the membrane roofs
of the big new football stadiums. What architects
value in these projects is the design flexibility and
the possibilities PVC and other plastics give them.
Recycled material is also of increasing importance in
production. Both the annually collected quantity of
PVC for recycling and the quantity of recycling material
that it is now technically possible to include in the
end product are on the increase.
Werner Preusker is the CEO of the working group PVC and the
Environment, an initiative of the PVC industry.
Inline punching and printing
This new extension takes care of punching and printing during the extrusion process.
The punching unit as a part of the extrusion line.
both single and twin strand tooling. It is a very
simple matter to return the punching waste to the
extrusion process in this integrated configuration.
Profiles are printed primarily with the barcodes that
are used for the automated logistics and warehouse
management systems. Cutting marks can also be
placed if required. The printer is integrated between
the haul-off unit and the cut-off device.
The controls
A measuring wheel placed on the profile sends the
impulse to the controls that operate the punching
unit and the printer to a tenth of a millimeter precision.
The punch unit moves in synchronization with
the profile on the basis of the information received
on the profile speed. The printer also operated in
dependence on the profile speed. Punch positions
and barcodes can be stored on the basis of profile
lengths. Up to 300 lengths including printing positions
and punching positions can be saved in the
system memory.