E_KM_AHEAD-Magazin_2-12.pdf - Netstal
E_KM_AHEAD-Magazin_2-12.pdf - Netstal
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ahead<br />
The CUSTOMeR <strong>Magazin</strong>e Of KRaUSSMaffei Issue 02.2012<br />
InnovatIve, multIfaceted talents<br />
Leading The way wiTh<br />
TeChnOLOgiCaL expeRTiSe<br />
SOLaR eneRgy<br />
COnSTRUCTiOn MaTeRiaLS<br />
aUTOMOTive<br />
wind eneRgy<br />
UTiLiTy vehiCLeS
ediTORiaL COnTenTS<br />
Dear Customers and Readers,<br />
Many athletes have produced inspiring peak performances at the Olympic Games in<br />
London. In addition to being impressed by the athletes “wanting to give their best,”<br />
I was often struck by the reasons they gave for what they were trying to achieve and<br />
what drove them on. Usain Bolt, for example, declared with self-assurance, “I always<br />
wanted to drive myself towards achieving what no one else has ever managed<br />
to do before. I always wanted to be a trendsetter.”<br />
As is often the case, there is a close analogy between sport and the world of<br />
business. What is it that makes a businessman a trendsetter in his sector? He can<br />
do more than the competition. He sets new standards. He is innovative and exudes<br />
enormous passion and conviction for what he does. All of that also applies to<br />
KraussMaffei and, in this edition of <strong>AHEAD</strong>, we will show you how we are setting<br />
new trends in the sector time and time again. And so, we have assembled here for<br />
you many interesting contributions and market and project reports all related to this<br />
topic, which will show you how we are using our first-class machines, technologies,<br />
and solutions to bring your production to the peak of its potential.<br />
For instance, with our new GX range in 2012, we have already set a new international<br />
standard in powerful injection molding machines for numerous sectors. We are<br />
also ahead of the field in solutions for global trends in plastics. For example, when<br />
the main concern is to reduce energy consumption by following the trends in lightweight<br />
construction. In this edition, we show you some of our trendsetting solutions<br />
from MuCell to CoverForm through to high-pressure RTM processes.<br />
We are naturally proud when sector experts recognize our performance, as, for<br />
example, when we received the JEC Europe Innovation Award and the SPE Award<br />
for our brochures on fiber composite solutions this year.<br />
As a sector leader, we want to continue to set trends and are therefore developing<br />
our organization with this in mind. Through a new orientation in injection molding<br />
and reaction process machinery, we are ideally positioned in relation to our customers‘<br />
fields of activity and in future, will be able to react even more constructively<br />
to your individual needs.<br />
And you can rest assured that we protect our innovations against undesirable imitation,<br />
which is of course all to your advantage. We are maintaining our intuitive<br />
sense for forward-looking trends with currently around 1,450 patents and an annual<br />
production of between 30 to 50 inventions. Take advantage of the situation and be<br />
<strong>AHEAD</strong> with us, not just today but also tomorrow and the day after!<br />
I hope you enjoy reading the magazine.<br />
Frank Peters<br />
Executive Vice President Sales<br />
coveR stoRy<br />
4 Leading the way with technological<br />
expertise<br />
7 interview: developing the cutting edge<br />
further<br />
BRand & maRKets<br />
8 wide-ranging expertise in the field of<br />
injection molding<br />
9 first technology-spanning energy<br />
analysis<br />
10 30 years of KraussMaffei automation<br />
12 The new benchmark: The gx Series<br />
14 Major order from Saudi arabia<br />
14 “ Competence Show” in the Land of the<br />
Rising Sun<br />
15 The right man for the job<br />
15 Concentrated expertise for customers<br />
16 positive signals from southern european<br />
markets<br />
PRocesses & PRoducts<br />
20 efficient manufacturing of<br />
fiber composite components<br />
21 gx: great potential in lightweight<br />
construction<br />
21 30 percent lighter airbag housing<br />
PaRtneRs & PRojects<br />
22 Rapid growth in north america<br />
23 “ pURtrain” is on target for the automotive<br />
industry<br />
KRaussmaffeI gRouP<br />
24 group presence without borders<br />
25 Technical treats for the far east<br />
26 energy efficiency: Smart pipes<br />
26 eLiOn 3200: a successful concept<br />
26 plant expansion in Slovakia and China<br />
27 property rights secure<br />
technological advantages<br />
27 imprint
KraussMaffei Contents<br />
4<br />
Technology leadership KraussMaffei is a pioneer in several<br />
fields, which enables it to help its customers be technological<br />
leaders.<br />
16<br />
Southern Europe The classic holiday countries offer more than just sun and sea. They also have some good news,<br />
especially when it comes to the plastics sector. The CX 300-1400 PolySet completes the machinery package offered<br />
by the Greek company Dasyc S.A.<br />
10<br />
30 years of KraussMaffei automation Exciting exhibition<br />
pieces demonstrated what industrial and linear robots can do.<br />
3
4 Cover story<br />
<strong>AHEAD</strong> Issue 02.2012<br />
DEMANDING<br />
In many business areas, such as automotive and commercial vehicle manufacturing,<br />
the component requirements are becoming more demanding.<br />
The typical demands include greater mechanical strength and lower weight.
KraussMaffei Cover story<br />
INNoVaTIVe, MulTIfaCeTed TaleNTS<br />
LEADING THE wAy wITH TEcHNoLoGIcAL ExpErTISE<br />
Technological leaders are characterized by their tendency to not only detect important market trends, but also to<br />
set them in the first place. KraussMaffei is carrying out pioneering work in several fields, which enables it to help its<br />
customers be technological leaders.<br />
TexT: JoaCHIM WebeR, eVa MÜNZeNMaIeR PHoToS: HaRald MeHNeRT<br />
T<br />
he JEC Europe Innovation Award, which KraussMaffei won in<br />
April 2012 (more information on page 23), was symptomatic<br />
of its excellence. On one hand, it proved yet again that innovation<br />
frequently springs from collaboration between different<br />
disciplines. On the another hand, it reaffirms KraussMaffei’s<br />
strategy with regard to innovation and technology, in which lightweight<br />
construction plays an important role as one of the biggest technological<br />
trends.<br />
“Developing innovative and ready-to-use operational process solutions<br />
to replace conventional materials with plastic is one of our core<br />
competencies,” explains Jochen Mitzler, Manager of the Strategic<br />
Product Management Department. “Our clients’ requirements are<br />
increasing across sectors: the plastic parts have to be lighter than<br />
conventional materials yet just as stable. At the same time, several<br />
functions must be integrated, which makes the manufacturing process<br />
more complex, yet the assembly costs must be reduced. In order<br />
to appear high-quality, the visible parts must also be visually attractive<br />
and must have pleasant haptics – and all of this at optimized manufacturing<br />
costs.” KraussMaffei has reinforced its expertise: Munich<br />
is home to the world’s most versatile TechCenter for lightweight components<br />
and fiber composite technology. Customers benefit from<br />
KraussMaffei’s expertise in the fields of injection molding machinery<br />
and reactive materials processing, which produce a wide range of customized<br />
and process-specific solutions.<br />
Supporting customers throughout the entire value-adding chain<br />
According to Thomas Elfroth, Sales and Product Manager Composite/Surfaces:<br />
“When it comes to new processes, our customers demand<br />
a clear reduction in costs along with qualitative improvements<br />
throughout the process.” These requirements can be seen not only<br />
in the automotive sector, but also in the consumer electronics sector,<br />
the household appliances sector, and the packing industry. At the<br />
same time, there is also a standing order to increase the efficiency<br />
of the manufacturing process. Ever-decreasing cycle times, lower<br />
HoLISTIc<br />
KraussMaffei’s new light construction center is<br />
opening up new horizons for processspanning<br />
solutions.<br />
scrap rates, lower energy consumption, and reducing material costs –<br />
all these are additional goals that have to be attained simultaneously.<br />
Since the keyword is “multifunctionality,” an ever-increasing level of<br />
integration between the operations has to be achieved as well.<br />
A facility that KraussMaffei installed for a large European car manufacturer<br />
reveals what lies behind this approach. Two double swivelplate<br />
machines use a fully automated process to produce components<br />
having an outer skin and a sub-structure. Both of them are injectionmolded<br />
separately, joined together accurately by rotating the two<br />
swivel plates, and connected tightly with a third plastic component.<br />
This serves to integrate a large part of the assembly process into the<br />
plastics processing phase.<br />
High and versatile expertise in process engineering across sectors<br />
KraussMaffei’s process engineering is always impressive. The<br />
“FiberForm” process is ideally suited to applications in which<br />
strength is more important than the surface aesthetics, such as the<br />
supporting structures found in vehicles. The so-called organic sheets<br />
or endless fiber fabrics that are found in the thermoplastic matrix are<br />
thermally reformed in the injection mold. They are then over-molded,<br />
back-molded, or over-fed with another thermoplast, such as a glassfiber-reinforced<br />
polyamide. This makes it possible to “integrate”<br />
other functions, such as stiffening ribs or extension elements. With<br />
its high degree of automation and cycle times of less than 60 seconds,<br />
FiberForm is ideally suited to the large-series production of<br />
new, light structural components.<br />
The HP-RTM process, which is another process used for the production<br />
of structural components, is generally used for small and medium-sized<br />
series because its current cycle times range from three<br />
to five minutes, depending on the size of the component. In this process,<br />
a pre-finished reinforcing material, such as carbon fiber tissue,<br />
is soaked into a sealed, evacuated mold that has no air voids with the<br />
help of an epoxy resin, which eventually hardens.<br />
Hp-rTM – HIGH-prESSUrE rESIN TrANSFEr MoLDING<br />
8.<br />
1. 2.<br />
3.<br />
1. Semifinished products from the roll<br />
2. Handling the readymade semifinished<br />
products<br />
3. Transfer to the preform station<br />
4. Preforming<br />
7.<br />
6.<br />
5.<br />
5. Transfer the preform<br />
to HPRTM station<br />
6. Pull vacuum (optional)<br />
7. Resin transfer/hardening<br />
8. Component removal<br />
4.<br />
5
6 Cover story<br />
<strong>AHEAD</strong> Issue 02.2012<br />
cELLForM (MUcELL TM )<br />
Rear RSP<br />
(nonreturn valve)<br />
SCf injector<br />
front RSP<br />
(nonreturn valve)<br />
Complete<br />
SCf dissolution<br />
in the melt<br />
SCf<br />
injection<br />
Plasticizing the<br />
plastic melt<br />
SCf interface kit<br />
SCf metering system<br />
Erich Fries, Manager of the Composites/Surfaces business unit,<br />
thinks the carbon fiber composite parts have a lot of potential. “If, in<br />
the course of future E-mobility, the automotive industry is forced to<br />
make up for heavy batteries in other places, there is hardly an alternative<br />
to structural components based on RTM. In the future, the process<br />
will also be used in large-scale production,” he says. “Our goal<br />
is to enable automation of the entire process, right from unwinding<br />
the carbon fiber to cutting the finished part.” He believes that cost reduction<br />
options are present not just with regard to fiber material, but<br />
also with regard to plastics: “There have already been attempts to<br />
replace the epoxy resin with polyurethane or modified polyamides.”<br />
The process of producing thermoplastic foam structures with the<br />
help of chemical or physical foaming technology is another lightweight<br />
construction method. In the case of CellForm processing or<br />
foaming, the granulated or gaseous blowing agent is fed into the melt<br />
in order to reduce the density of the plastic. Chemical and physical<br />
foaming make it possible to reduce the density and eliminate the<br />
holding pressure of the plastic, which has several advantages: faster<br />
cycles, less material usage, dimensional stability and lower costs.<br />
Improved surfaces through innovative processes The goals of several<br />
surface techniques, which combine various process steps into a<br />
single step, lie between achieving aesthetic value and attaining costeffectiveness.<br />
For example, SkinForm combines injection molding<br />
processes and reaction process machinery: a thermoplastic component<br />
is injected into a mold and it is then flow-coated with polyurethane<br />
during the second cycle. This produces a component that is<br />
characterized by, among other things, leather-like haptics, soft touch,<br />
high scratch-resistance, and polychromatic if required.<br />
The ColorForm process has a similar functionality, in that it makes<br />
it possible to imprint thin layers of lacquer onto various plastics directly<br />
in the mold. In a single step, it creates perfect high-gloss surfaces<br />
in conjunction with the production of the parts, without having<br />
to go through the usual process steps, such as cleansing or prime<br />
coating. The CoverForm process was the result of interdisciplinary<br />
collaboration with the material manufacturing company Evonic.<br />
Here, the PMMA injection-molded parts are given a thin, transparent,<br />
scratch-resistant and chemical-resistant surface using a<br />
multi-component reactive system, which has an acrylate base, both<br />
in a mold and a process.<br />
N2<br />
Premium-quality clean-room standards Various plastic components<br />
are also coming to the fore in medical technology and the pharmaceutical<br />
industry. Irrespective of whether they are used as product<br />
components or as packaging material, hygiene is always the top<br />
priority. Consequently, plastic processing machines that conform to<br />
clean-room technology standards are in great demand. Conformity<br />
with the strict guidelines is guaranteed by various engineering-<br />
related details, such as encapsulated lubrication, using water cooling<br />
instead of air cooling, flat surfaces, anti-static paints, and control<br />
systems that satisfy the strict documentation-related requirements,<br />
including those applicable to the production of pharmaceuticals.<br />
Even in this context, various group sectors work together closely. According<br />
to Mitzler, this is because: “In our case, new products and<br />
processes are increasingly the result of close collaboration with our<br />
clients and the synergy that exists between our areas of expertise,<br />
which are injection molding technology, extrusion technology, and<br />
reaction process machinery. This unique combination really sets us<br />
apart and is what our Technology 3 formula stands for.”<br />
→ rEAD MorE!<br />
We would be happy to send you brochures about the automotive<br />
industry, fiber composite technology, surface technology, RTM<br />
or other innovative technology. For more information, visit:<br />
www.kraussmaffei.com<br />
YOUR CONTACT<br />
The Mx 400024500 uses the process known as structural foam<br />
injection molding. Components are created with a compact outer<br />
skin and foam structure on the inside.<br />
Jochen Mitzler<br />
Manager – Strategic Product Management –<br />
Injection Molding Machinery<br />
KraussMaffei Technologies GmbH<br />
jochen.mitzler@kraussmaffei.com
KraussMaffei Cover story<br />
7<br />
DEvELopING THE cUT-<br />
TING EDGE FUrTHEr<br />
When it comes to reducing the weight and thus<br />
vehicles’ energy consumption (which in future will<br />
include an everincreasing number of electric<br />
cars), lightweight construction solutions and, in<br />
particular, fiberreinforced plastics are of critical<br />
importance. erich fries, Manager of the Composites/Surfaces<br />
(fiber composite and surfaces) business<br />
unit talks about the challenges and potential<br />
opportunities facing composite parts.<br />
THe INTeRVIeW WaS CoNduCTed by MaRKuS beTSCHe.<br />
<strong>AHEAD</strong>: what goals you have set for yourself?<br />
Fries: As always, fiber composite and lightweight components have<br />
a lot of potential. New reports dealing with new fields of application,<br />
technology, or materials are coming in almost every day. our goal is<br />
to expand our cutting edge in this business area further and to adapt<br />
our technology to “carbon,” the fiber of the future. our motto is “one<br />
must pray for miracles, but work hard for changes” (Thomas Aquinas).<br />
we are going to encounter a wide range of new and interesting<br />
technology. we consider this challenge to be an opportunity that we<br />
can overcome as a team.<br />
<strong>AHEAD</strong>: what are the target groups you are looking at?<br />
Fries: our clients from the automotive industry, the utility vehicle<br />
sector, the transport sector (for example rail transport), and the<br />
aircraft construction sector are looking for a competent partner who<br />
can support them across the entire process chain, which ranges from<br />
the very first component idea to series production. In this regards, we<br />
are currently well placed with our products and services, as well as<br />
with our partners Dieffenbacher, Fraunhofer, and Lcc, for example.<br />
our goal is to further strengthen and expand this collaboration. For<br />
us, being a frontrunner also means assuming a leading role vis-à-vis<br />
networks and clusters.<br />
<strong>AHEAD</strong>: when it comes to composites, which materials do you think<br />
will come out on top?<br />
Fries: Even today, when they hear the word “composites,” most<br />
people think of carbon-fiber-reinforced components in an epoxy<br />
resin matrix. For us, the field is a lot wider than that. In the case of<br />
reactive materials, we see polyurethane and casting polyamides as<br />
good alternatives, and when it comes to thermoplastic materials, pA<br />
and polypropylene have already proven themselves. when it comes<br />
to reinforcement, the situation can involve any of the different types<br />
of fibers that are more or less well established, depending on the<br />
client’s requirement. There is not yet a clear trend in this dynamic<br />
developmental environment but at the moment, everything seems<br />
to be pointing toward carbon. However, you cannot ignore the hybrid<br />
formulations either: the vehicles of the future will have a combination<br />
of different materials (carbon/aluminum combinations).<br />
ErIcH FrIES considers the market for composite facilities to be a growing market.<br />
<strong>AHEAD</strong>: Are the processing techniques already well established?<br />
Fries: In the field of composites, there are several old and wellknown<br />
manufacturing processes that have already proven themselves<br />
in production environments and there are several new approaches<br />
as well. The highly complex requirements due to the required unit<br />
numbers, the automated processes, the need to guarantee reasonable<br />
material costs, and the maximum possible reduction in the<br />
component’s weight lead to many variants. Developing this procedure<br />
definitely has not yet reached its conclusion. In case of the Hp-rTM,<br />
two process variants, namely compression rTM and wet molding,<br />
were developed recently and both have their own specific advantages.<br />
For example, in case of wet molding, the carbon fibers (scrap produced<br />
during the preform production) can be recycled as piece goods.<br />
<strong>AHEAD</strong>: what motivates you?<br />
Fries: when customers reward our performance with orders! At the<br />
moment, we are particularly happy about successfully completing<br />
a development project that we carried out in collaboration with a<br />
well-known car manufacturer, who awarded a contract worth several<br />
million euros to us and Dieffenbacher, one of our partners. right from<br />
the beginning, we were closely involved with the component development<br />
process and working out the manufacturing process. And we<br />
are already looking forward to the next step, which involves activating<br />
the complete Hp-rTM line.
8 Brand & markets<br />
<strong>AHEAD</strong> Issue 02.2012<br />
brand & markets<br />
wIDE-rANGING ExpErTISE<br />
IN THE FIELD oF INjEcTIoN MoLDING<br />
„ We want to use our performance capabilities and outstanding<br />
machine technology to generate even more value added for our<br />
customers along their entire valueadding chain. To this end,<br />
we will maintain the separate market presence of the <strong>Netstal</strong><br />
and KraussMaffei brands with a clearly defined product portfolio<br />
and their independently operating sales organizations.“<br />
dr. Hans ulrich Golz, President of the Injection Molding Machinery Segment<br />
our motto is: Together, we are stronger. Since<br />
1 July 2012, the KraussMaffei Group has added a<br />
comprehensive sector: injection molding machinery.<br />
It unites the KraussMaffei and <strong>Netstal</strong> brands.<br />
The company has consciously decided to take<br />
this step, to increasingly align its services to its<br />
customers’ requirements along the valueadding<br />
chain, to utilize the market potentials better, and to<br />
use the innovative strengths of both these brands<br />
more aggressively by joining them together.<br />
The advantage for our customers: both the brands’ strengths are retained<br />
with a clearly defined product portfolio. The most important<br />
objective is “to offer the customer the best solution, irrespective of<br />
the brand and the location.” Dr. Hans Ulrich Golz, President of this<br />
sector, is very happy that he “could virtually fill all management positions<br />
in the Injection Molding Machinery sector with experienced<br />
and highly competent managers from the KraussMaffei Group.”<br />
In addition to his task as the head of the sector, Dr. Golz has also assumed<br />
the task of leading the sales division for the <strong>Netstal</strong> brand.<br />
Mr. Frank Peters is the Executive Vice President Sales. Dr. Karlheinz<br />
Bourdon is responsible for the Technology fields (among<br />
others, Research and Development, Processing, and Automation).<br />
„ by pooling the excellent knowhow of two strong brands, we<br />
can offer our customers the right product of the right brand for<br />
them from our wide and powerful product portfolio, as well as<br />
the corresponding services tailored to their individual needs.<br />
We are also emphasizing our technology leadership on the<br />
market. We are highly motivated and are gaining momentum.“<br />
frank Peters, executive Vice President Sales<br />
Dr. Bernd Thurat heads the Operations Department and Renzo<br />
Davatz heads the Service Department, including the Used Machinery<br />
Business.<br />
The Injection Molding Machinery sector is presenting itself to customers<br />
with a new consolidated distribution channel. The entire<br />
injection molding business will be divided into seven business<br />
units in the future and these will be oriented towards the target<br />
markets:<br />
• Automotive, led by Mr. Bengt Schmidt, under the KraussMaffei<br />
brand<br />
• Technology, led by Mr. Klaus Bange, under KraussMaffei with the<br />
KraussMaffei and <strong>Netstal</strong> brands<br />
• Logistics and Packaging (thick-walled), led by Mr. Bengt Schmidt,<br />
under the KraussMaffei brand<br />
• Packaging (thin-walled), led by Mr. Markus DalPian, under the<br />
<strong>Netstal</strong> brand<br />
• Screw-cap closures (CAP), led by Mr. Markus DalPian, under the<br />
<strong>Netstal</strong> brand<br />
• PET, also led by Mr. Markus DalPian, under <strong>Netstal</strong> with the<br />
KraussMaffei and <strong>Netstal</strong> brands<br />
• “In the Medicine BU, we will continue with the two-brand strategy<br />
under the leadership of Mr. Patrick Blessing,” said Dr. Golz. “This<br />
is because we have two complementary product portfolios and excellent<br />
expertise in the field medical technology at both locations.<br />
Therefore, we believe that we can better tap growth opportunities<br />
in this way.” EM
KraussMaffei Brand & markets<br />
fIRST TeCHNoloGy-SPaNNING eNeRGy aNalySIS<br />
“BLUE powEr” MEETS “THINK BLUE. FAcTory.”<br />
It was a first: Together with Siemens, KraussMaffei carried out an extensive, energyrelated machinesystem analysis for<br />
Volkswagen. The goal was to evaluate the energy consumption associated with the production of instrument panels. The holistic<br />
inspection of the complex process provided the fundamental principles for further optimization of the processes, the drive technology,<br />
and the thermal budget.<br />
The production lines for instrument panels are highly complex structures.<br />
The overall process incorporates several different processing<br />
techniques and automation components. In order to be able to work economically<br />
and in a way that makes efficient use of resources and energy,<br />
the separate process steps must first be aligned with each other in a<br />
manner that cuts across different technologies. Concrete measures can<br />
be derived from the product-specific total energy consumption. Several<br />
analyses of this nature have already been carried for individual injection<br />
molding machines and extrusion lines. But Volkswagen, Siemens, and<br />
KraussMaffei were the first to examine an entire production line.<br />
Challenging roles As part of the “Think Blue. Factory.” program,<br />
Volks wagen has set clear goals for itself in terms of an ecological installation:<br />
based on the annual values for the year 2010, the company<br />
is planning to reduce the environmental pollution caused by all of its<br />
facilities by 25 percent by the year 2018. This applies to the CO 2 emissions,<br />
the amount of waste produced, the energy consumption of each<br />
vehicle, and the amount of water consumed by the factories. These<br />
goals are being met with the help of KraussMaffei’s “BluePower” initiative,<br />
which is aimed at the efficient use of energy and resources.<br />
Every journey begins with the first step Each optimization process begins<br />
with a detailed analysis of the energy consumption of every single<br />
consumer load. The list of the included system components makes<br />
clear just how important the holistic approach is. In the case of the production<br />
line for instrument panels, the list included, along with the injection<br />
molding machine and the facility for the production of the slush<br />
skins, a prewarming station, a round table with 12 mold carriers (each<br />
with a clamping station and an opening), a mixing machine, a metering<br />
machine, three robots, several heating units and heaters, and various<br />
pumps. A total of 25 measuring devices had to be installed on the round<br />
table, after which they had to be connected to a central PC via a WLAN<br />
connection, thus enabling data recording. The measurements were recorded<br />
over more than ten days so that the energy-related interaction<br />
between the system components during downtimes and over the weekend<br />
can be recorded. The power consumption levels of various injection<br />
units were measured and counters were used to measure the consumption<br />
of compressed air and cooling water. The recorded data was<br />
used to determine the specific energy consumption of every component.<br />
Process management determines the potential for savings The biggest<br />
consumer of the round table was the process of tempering the<br />
molds, followed by the vacuum supply, the metering system, and the<br />
exhaust system. The detailed analysis of different system statuses<br />
provided interesting savings potentials. The results can be applied to<br />
other productions as they are, after which they are incorporated into<br />
the development of new generations of machines. For example, an optimized<br />
operation with individual components of the round table that<br />
were designed in accordance with the results opened up savings potential<br />
of up to 10 percent. The system control unit plays a decisive role<br />
in this process: In this case, it is possible to save intelligent processes<br />
that control the operational behavior of the system components, depending<br />
on the process requirements. The individual measures alone<br />
can save up to 30 MWh of electrical energy per annum. MB<br />
TaKING CoMPlex PRoduCTIoN SySTeMS INTo CoNSIdeRaTIoN<br />
kWh/cycle<br />
2.0<br />
1.85<br />
1.8<br />
1.76<br />
1.50<br />
1.6<br />
1.33<br />
1.4<br />
1.2<br />
1.0<br />
0.72<br />
0.8<br />
0.6<br />
0.61<br />
0.52<br />
0.4<br />
0.2<br />
0<br />
0.14 0.12<br />
0.15 0.10<br />
0.19<br />
0.18 0.07<br />
0.33<br />
0.23<br />
0.22<br />
0.13<br />
0.06<br />
<strong>KM</strong>130012000Mx <strong>KM</strong>270024500Mx <strong>KM</strong>320017200Mx<br />
Power consumption [kW]<br />
0.65<br />
kWh/kg<br />
0.60<br />
0.55<br />
0.50<br />
0.45<br />
12:39:02<br />
Poly<br />
Iso<br />
Pump P<br />
12:39:46<br />
12:40:29<br />
Puming<br />
station<br />
12:41:12<br />
Stirring device<br />
Pump<br />
disc filter<br />
Venting<br />
Tempering unit<br />
Poly Heat exchanger<br />
°C<br />
Stirring device<br />
Pump<br />
disc filter<br />
Venting<br />
Iso<br />
12:41:55<br />
Timeline<br />
Tempering unit<br />
Heat exchanger<br />
°C<br />
Compressed air<br />
Compressor<br />
cooler<br />
Hydraulic<br />
power pack<br />
Chiller for<br />
water supply<br />
Pump I Mixing head hydraulic<br />
ExTENSIvE MEASUrEMENTS AND EvALUATIoNS provide a thorough<br />
understanding of the energy consumption that is required by the process<br />
and their correlations.<br />
12:42:38<br />
12:43:22<br />
12:44:05<br />
Specific gas consumption Mean value<br />
12:44:48<br />
12:45:31<br />
0.40<br />
200,000 240,000 280,000 320,000 360,000 400,000<br />
9
10 Brand & markets<br />
<strong>AHEAD</strong> Issue 02.2012<br />
vErSATILE<br />
Several exhibits demonstrated to visitors the<br />
versatility of the KraussMaffei industrial and<br />
linear robots.
KraussMaffei Brand & markets<br />
30-yeaR aNNIVeRSaRy of KRauSS-MaffeI auToMaTIoN aG<br />
ExpErIENcING roBoTS<br />
FIrST-HAND<br />
TexT: eVa MÜNZeNMaIeR PHoToS: STefaN KRuPPa<br />
did you known that robots can tell<br />
different brands of candy bars<br />
apart? No? And that they can put<br />
on a puppet show? Again, no? A<br />
few peculiar exhibits at the event<br />
marking this year’s 30th anniversary of<br />
Krauss-Maffei Automation AG made it clear<br />
that, in the world of robots, there are few<br />
limits. When it comes to plastic processing,<br />
KraussMaffei’s industrial and linear robots<br />
perform the most complex tasks throughout<br />
the production flow. They are always accurate,<br />
quick, and efficient.<br />
The highlights among the exhibits were a<br />
robot equipped with a camera system, which<br />
served guests the candy bars of their choice,<br />
and an industrial robot produced by Kuka,<br />
which used meticulous movements to perform<br />
a puppet show – entertainment of a different<br />
kind. “The more complex the task, the<br />
more it delights our technicians,” explains<br />
General Sales Manager Thomas Marufke<br />
with a smile. “Regardless of the application,<br />
we find a way of setting it up as efficiently as<br />
possible for our clients.”<br />
Efficient production and complex robotics<br />
were just two of the themes that held the<br />
attention of over one thousand visitors, clients,<br />
suppliers, and employees who were<br />
present at the Schwaig facility in July. “Our<br />
company has been ordering machines made<br />
by KraussMaffei, including the associated<br />
automation solutions, for twelve years.<br />
Thanks to KraussMaffei’s consistently positive<br />
and quick implementation, we are looking<br />
forward to a successful collaboration<br />
with them in the future as well,” explains<br />
Erhard Dietsch, who is responsible for automation<br />
technology at Schaeffler Technologies<br />
AG & Co KG. “These anniversary celebrations<br />
gave us the opportunity to once<br />
again get to know several new approaches<br />
and ideas, some of which came from our interactions<br />
with other clients, regarding how<br />
we could use automation to make our production<br />
more efficient.”<br />
“After all the work we have done together<br />
over so many years, it was great to see so<br />
many familiar faces at a celebration of this<br />
nature. All you can do is congratulate them<br />
for throwing such a wonderful birthday<br />
party,” agrees Johann Kerler, Maintenance<br />
Manager at Mouldtec Kunststoff GmbH,<br />
which is located in the city of Kaufbeuren. “I<br />
was particularly impressed by the Augsburg<br />
Puppet Theater exhibition. We have been a<br />
client of KraussMaffei Automation for more<br />
than 20 years. Their innovative and sustainable<br />
solutions never cease to amaze us!<br />
Many of our oldest systems are still running<br />
in a three-shift operation.”<br />
Steady growth with automation solutions<br />
At present, work can be carried out simultaneously<br />
in up to 15 production cells in the<br />
workshops in Schwaig. KraussMaffei develops<br />
between 300 and 350 three-axis linear<br />
robots and about 50 six-axis industrial robots<br />
every year. “And the numbers are going up,”<br />
according to Thomas Marufke. Six months<br />
ago, the production and assembly facilities in<br />
Schwaig were doubled to about 1,700 square<br />
meters. It is now working at full capacity and<br />
nine vacancies have been announced at the<br />
company’s headquarters.<br />
In order to ensure that the company’s growth<br />
continues to be sustainable and successful,<br />
the people in Schwaig are banking on a longterm<br />
relationship with professionals and<br />
trainees from the region. Mechatronics engineers<br />
and managers are trained on a regular<br />
basis. On the open house day, guests were<br />
able find out about the current job openings<br />
and training opportunities. “This is the third<br />
year in a row since 2009 in which we have<br />
outdone ourselves,” reports Marufke. The<br />
export share is already 60 percent and we<br />
thus need to think carefully about further expansions.<br />
“These days, even non- European<br />
clients want us to set up production facilities<br />
in their countries.” Krauss-Maffei<br />
Automation AG, which was founded by Josef<br />
Neureder, has expanded steadily over the<br />
last 30 years. It now has a total workforce of<br />
about 180 employees, ten of whom are apprentices,<br />
at the main plant in Schwaig and<br />
the branches in Munich and Schwerin. Since<br />
2002, the company has been a subsidiary of<br />
the KraussMaffei Group.<br />
According to Thomas Marufke, Sales and<br />
Commercial Manager, the company’s strategy<br />
has been conclusively confirmed by the<br />
fact that it was necessary to constantly increase<br />
the workforce and production area<br />
in the last three decades in order to cope<br />
with the demand for automation solutions<br />
in the industry: “As a mechanical engineering<br />
specialist, we are very successful thanks<br />
to our flexible size and the expertise of our<br />
skilled workers. We supply customers both<br />
with standard products and with customized,<br />
highly complex automation solutions. We will<br />
continue to apply this recipe for success in<br />
future as well and will market our products<br />
even more extensively throughout the world.”<br />
1,000th large robot from Schwerin There was<br />
yet another reason to celebrate, too. Just in<br />
time for the company’s anniversary, the branch<br />
factory in Schwerin delivered its 1,000th robot.<br />
The LRX-S 350 linear robot has a payload<br />
of 35 kg and will be installed in future at a<br />
customer in the USA on a KraussMaffei<br />
CX 350-3000 injection molding machine.<br />
The plant in Schwerin was established in<br />
2000 and started producing robots in 2001.<br />
A total of 22 employees now produce large<br />
linear robot devices in the LRX/LRX-S 250<br />
to 1000 Series with a payload of between<br />
25 and 100 kg, as well as side-entry robots.<br />
Along with standard “pick-and-place” tasks,<br />
these devices can also perform challenging<br />
tasks, such as inserting metal parts like contacts,<br />
rings, sockets, and plugs. However, the<br />
product portfolio also includes complete solutions<br />
for demolding injection molded parts<br />
and for separating, sorting, or packing product<br />
units (for example a cutlery set comprising<br />
a knife, fork, spoon, and serviette).<br />
11
12 Brand & markets<br />
<strong>AHEAD</strong> Issue 02.2012<br />
prEMIUM-cLASS<br />
The Gx Series sets new standards in terms of<br />
performance, usability, and value retention.<br />
WITH a “NeW dIMeNSIoN” oN THe Global MaRKeT<br />
THE NEw BENcHMArK: THE Gx SErIES<br />
TexT: eVa MÜNZeNMaIeR PHoToS: HaRald MeHNeRT<br />
A murmur went through the 400 guests, the drum roll rang out,<br />
the fireworks went off, and the curtain fell, giving the world its first<br />
glimpse of the first next-generation machine: the GX – a new dimension<br />
in injection molding.<br />
But the audience of trade professionals was treated to a lot more than<br />
just that. At the world premiere of the GX Series, which took place<br />
in May, KraussMaffei unveiled and operated a total of six machines<br />
of various sizes, which boasted clamping forces of between 400 and<br />
650 tons and were fully equipped for the production requirements<br />
of a variety of sectors. A light tap on the notebook-sized touchscreen<br />
maneuvered parts of the machinery that weighed several tons – as<br />
easy as operating an iPad.<br />
As if by magic, the bulk of plastic moved through the various production<br />
flow stations until it was finally turned into a bottle cap, a box<br />
for vegetables, or cheese packaging. The “self-test” on the clamping<br />
dummy proved to be especially popular. Everyone was able to personally<br />
experience the clamping unit’s free movement. Premium-quality<br />
technical presentations and a successful celebration with music, and<br />
lots of good food rounded off the launch ceremony. A special success:<br />
KraussMaffei managed to sell all six exhibits, including the laboratory<br />
machine.<br />
“Our clients were particularly interested in the modular automation<br />
cells, which featured linear and industrial robots in many different<br />
configurations,” explains Dr. Karlheinz Bourdon, Vice President<br />
Technology (injection molding machines) at KraussMaffei. “And<br />
I would like to emphasize that the GX is the best machine concept on<br />
the market!”<br />
The GX Series widens the product portfolio in the hydro-mechanical<br />
dual-plate machine sector in the medium clamping force range.<br />
The passionate engineering of the developers is manifested in a firstclass<br />
machine concept featuring intelligent product innovations such<br />
as the GearX locking device and the GuideX guide shoe. The GX Series<br />
sets new standards in terms of performance, usability, and value<br />
retention. The GX machines are impressive during the production of<br />
free-falling packaging parts and premium-quality articles for the<br />
automotive industry or the consumer goods sector.
KraussMaffei<br />
A powerful team: GearX and GuideX The GX Series’ hydro-mechanical<br />
clamping unit raises the bar when it comes to quality and productivity.<br />
The excellent dual-platen technology scores highly with a wide range of<br />
innovations. "In my opinion, the GX machines represent the best overall<br />
concept," underlined Bourdon. "We talk about a new dimension because<br />
our customers can use the machine to get the best results from<br />
their production." With the ingenious GuideX guide shoe, forces are ideally<br />
absorbed and the service life of the molds is increased. As an intelligent<br />
fixed bearing joint with an optimized FEM design, the GuideX is<br />
not just an “eye-catcher” but a genuine highlight, which ensures excellent<br />
platen parallelism due to its stable design and guarantees smooth,<br />
energy-saving movements.<br />
The innovative GearX locking system is reliably activated straightaway<br />
within the shortest possible time and continuously produces quick<br />
machine movements. Arranged in a space-saving way behind the<br />
moving mold-fixing platen, it facilitates simple access and numerous<br />
customer-specific options. With a patented locking system and a<br />
guide shoe, the new generation of machines gives the sector exactly<br />
what it wants: even faster production, lower material consumption,<br />
and better-quality products. Furthermore, the machines really save<br />
when it comes to energy consumption because they can be adapted to<br />
the production capacity utilization.<br />
Powerful injection unit with a tried-and-tested plasticizing system<br />
When it came to the GX Series, the designers stuck to KraussMaffei’s<br />
proven screw system, which guarantees a wide field of application. Our<br />
standard plasticizing unit assures optimal melting quality and high<br />
throughput. “Being an expert in specialty polymers, our company also<br />
offers our clients a plethora of material-specific plasticizing solutions,”<br />
explains Frank Peters, Executive Vice President Sales at KraussMaffei.<br />
The Plasticizing Competence Center provides customers with competent<br />
advice and there are hardly any limits on areas of application.<br />
The new MC6 control system offers a multifaceted degrees of<br />
freedom “With the MC6, we have developed a control system that<br />
satisfies all our clients’ usability-related requirements,” explains<br />
Bourdon. “Thanks to the SplitScreen and the ProcessDesigner functions,<br />
it is clear and unbelievably easy to operate.” In keeping with<br />
our overall energy-efficient design, the MC6 control system has been<br />
equipped with a so-called eco button for the first time. The machine<br />
can thus be optimally configured in terms of energy consumption at<br />
the touch of a button.<br />
The perfect symbiosis of automation and machinery KraussMaffei is<br />
also one step ahead when it comes to fully integrated production systems<br />
comprising both machinery and automation. Machine and handling<br />
form a functional unit in this combination. The MC6 can also be<br />
used in this way. As a common control system, it allows both functional<br />
units – the machine and the automation – to be controlled from<br />
any control panel, which represents added value for clients.<br />
The dialog-based programming wizard in the MC6 control system<br />
even allows beginners to create basic demolding processes in the<br />
shortest possible time. The interactive communication between the<br />
user and the control system makes manual programming superfluous<br />
and eliminates programming errors.<br />
oN THE rIGHT TrAcK<br />
The launch was successful: the product demand and the sales figures endorse<br />
the overall concept of the Gx Series.<br />
“ When it came to the launch of the Gx, our team really did accomplish<br />
a lot. The overall machine concept is marvelous, and<br />
I think the company is going to continue to concentrate passionately<br />
on the task at hand. and the rewards are being reaped:<br />
the worldwide demand for the products and the sales figures<br />
that we have generated so far have exceeded our expectations.<br />
The numerous worldwide product presentations are proceeding<br />
smoothly. We even managed to sell all the machines that<br />
were exhibited at the world premiere in Munich in May.”<br />
frank Peters, executive Vice President Sales<br />
The new international dimension The GX Series is also on the right<br />
track internationally. Several customer events took place after the<br />
world premiere in Munich, including in the United Kingdom and in<br />
Mexico, among others. The GX 550-4300, which can run a 450-gram<br />
packaging application with a cycle time of 9.8 seconds, was presented<br />
in Mexico. Various technical presentations provided information about<br />
the new, innovative technology and mechanisms of the series. Numerous<br />
visitors were clearly impressed.<br />
Read MoRe abouT IT<br />
Our product brochure “Gx Series<br />
Machines” contains further information<br />
about the new dimension<br />
of injection molding. Your sales<br />
partner would be happy to send<br />
you a copy.<br />
The new dimension<br />
of injection molding<br />
Machines in the GX Series<br />
Engineering Passion<br />
Brand & markets 13
14 Brand & markets<br />
<strong>AHEAD</strong> Issue 02.2012<br />
SuCCeSS SToRy<br />
MAjor orDEr FroM<br />
SAUDI ArABIA<br />
SabIC is one of the largest petrochemical companies in<br />
the world. The Saudi arabian company has had a business<br />
relationship with KraussMaffei for several decades. a major<br />
order that was placed in June provided yet more evidence<br />
of the trusting teamwork that has existed between the two<br />
sides for so many years: KraussMaffei and KraussMaffei<br />
berstorff are to set up a fully fledged technological laboratory<br />
at the new SabIC Plastics applications development<br />
Center in Riyadh, the capital of the kingdom of Saudi arabia.<br />
Such packages of orders don’t come along every day: complete extrusion<br />
lines for the PVC pipe, profile, and sheet extrusions as well<br />
as a twin-screw extruder, a few particularly powerful injection<br />
molding machines from the C3 and EX Series – all of this was on the<br />
“wish list” turned in by SABIC Plastics Applications Development<br />
Center. These systems are to be used by the company’s newest development<br />
center to equip the technological laboratory in Riyadh.<br />
The laboratory is eventually supposed to develop and test new materials<br />
and innovative production processes. SABIC currently operates<br />
a total of 17 specialized technological and innovation units of<br />
this nature in Saudi Arabia, the USA, the Netherlands, Spain, Japan,<br />
India, and South Korea. More than 8,000 patents bear witness to the<br />
expertise of SABIC’s researchers and developers.<br />
With more than 40,000 employees in 40 different countries, a turnover<br />
equivalent to more than 50 billion US dollars, and profits equivalent<br />
to 7.9 billion dollars, SABIC is in the top tier of the global petrochemical<br />
sector. Founded through a royal decree in 1976, the<br />
corporation (70 percent owned by the government, with the rest held<br />
by private investors from Saudi Arabia and other Gulf states) has<br />
grown rapidly. SABIC may be among the most successful companies<br />
that were founded in the Middle East in the 1970s with the goal of not<br />
only producing oil, but also processing it in order to create added<br />
value in their countries.<br />
SABIC has been working with KraussMaffei for several decades,<br />
which is an expression of the trust shared by the two companies<br />
– something that always plays an important role in relationships<br />
with Arabian companies. “We will do everything we can to once<br />
again completely and thoroughly justify this trust,” said Dr. Karlheinz<br />
Bourdon, Vice President Technologies, after the contract was<br />
awarded. “This contract, which has been awarded by a company<br />
whose technological requirements are extremely high, attests to our<br />
overarching expertise with respect to our unique technology.” MB<br />
“CoMPeTeNCe SHoW” IN THe laNd of THe RISING SuN<br />
In just six years, KraussMaffei’s Japanese subsidiary,<br />
which was founded in 2006, has become the market<br />
leader in the Japanese market for reaction process machinery.<br />
This is reason enough to celebrate this success<br />
as part of a “competence show,” whose primary theme<br />
is “Composite Materials & Combined Systems.”<br />
This competence show, which included technical lectures delivered<br />
by international experts as well as a trade show, took<br />
place in July in Okazaki, in Japan. More than 40 practical examples<br />
held the undivided attention of the more than 200 visitors.<br />
The displayed components were grouped according to individual<br />
processes in a theme-oriented manner. The visitors were<br />
especially interested in the fiber composite technology featuring<br />
HP-RTM (high-pressure RTM) and the fiber spray process,<br />
as well as the process combinations like SkinForm and<br />
ColorForm.<br />
KraussMaffei’s employees had their hands full answering visitors’<br />
questions, addressing inquiries, and acquiring projects.<br />
The presentations supplied the listeners with the latest information<br />
regarding the latest developments and trends in fiber<br />
composite technology and the production of premium-quality<br />
surfaces. “For us, the event was a complete success, as evidenced<br />
by the visitors’ reactions and the many new projects<br />
that we acquired during the event,” says Noriyuki Kanoh, Representative<br />
Director of the Krauss-Maffei Japan Corporation.<br />
The Japanese workers and their colleagues from Munich then<br />
celebrated the company’s six-year anniversary with a traditional<br />
Japanese dinner and a visit to a hot spring. On the way<br />
there, they stopped at the “<strong>KM</strong>26,” a 120-year-old KraussMaffei<br />
locomotive, which is considered to be a tourist attraction in<br />
Japan. The local press and three television channels were<br />
present when Mr. Nishi, chairman of the regional tourism<br />
office, inquired whether this well-preserved locomotive could<br />
be made operational again, and thus fulfill a childhood fantasy<br />
of many Japanese people. MB
KraussMaffei Brand & markets<br />
ReaCTIoN PRoCeSS MaCHINeRy<br />
THE rIGHT MAN<br />
For THE joB<br />
Composites/Surfaces business unit<br />
Erich Fries<br />
After working with various companies, the environmental<br />
engineer who also has management expertise<br />
joined KraussMaffei in 2003. In August 2012, he was<br />
appointed as the head of the Fiber Composites/Surfaces<br />
business unit. Thomas Aquinas provided him<br />
with the guiding principle for his work: “One must pray for miracles, but<br />
work hard for changes.” He is already looking forward to the challenges<br />
that will arise in the future as a result of new and interesting technology:<br />
“We will overcome them as a team.” He is already focusing on a new<br />
development: using carbon fibers in large series production. Fries enjoys<br />
traveling, playing handball, and is interested in Japanese gardens.<br />
Construction/Insulation business unit<br />
Dr. Michael Loferer<br />
He has been responsible for the Construction/Insulation<br />
business unit since August 2012. He is highly<br />
qualified for this role. After completing a degree<br />
in production engineering at the technical university<br />
in Munich, he worked as the Head of Design and<br />
the Head of Technology at Siempelkamp Handling Systeme GmbH. “In<br />
this era of ever-diminishing resources, the importance of energy-efficient<br />
buildings is ever-increasing”, he believes. “Our aim is to develop<br />
new products and tailor-made solutions for our customers using innovative<br />
ideas combined with tried-and-tested production technology.”<br />
In his spare time, Dr. Loferer likes to spend time in the mountains,<br />
both in the summer and winter.<br />
White Appliances business unit<br />
Gabriele Amodeo<br />
The Italian is not new to the KraussMaffei Group. As<br />
a General Manager, he is responsible for managing<br />
KraussMaffei’s Italian subsidiary. In August 2012, he<br />
took on an additional role as the head of the White<br />
Appliances business unit. His degree in mechanical<br />
engineering and his years of professional experience make him the<br />
ideal candidate for this role. In his free time, he likes to go sailing or<br />
skiing, depending on the time of year. His motto is based on experiences<br />
gained from sport and throughout his career: “A person is<br />
stronger when in a team.”<br />
Molded Flex/Interior Trim business unit<br />
Wolfgang Frehsdorf<br />
Wolfgang Frehsdorf has been responsible for heading<br />
the Reaction Process Machinery Technology and<br />
Production department for KraussMaffei since 1999.<br />
As of 2009, he has been the head of Reaction Process<br />
Machinery Operations. In August 2012, he became the<br />
head of the Molded Flex/Interior Trim business unit. “The new business<br />
units can be quickly adapted to specific customer requirements<br />
and offer a uniform organizational structure across the world. This allows<br />
us to prepare offers and execute orders quickly,” he said, when<br />
speaking about the advantages of the new organization. The skilled<br />
electronic engineer spends his free time on the golf course.<br />
coNcENTrATED<br />
ExpErTISE<br />
For cUSToMErS<br />
Since July, KraussMaffei’s Reaction Process<br />
Machinery sector has had a new customer<br />
orientation. In an interview with aHead,<br />
Nicolas beyl, the head of the sector, explained<br />
the advantages for customers and the opportunities<br />
that will open up for the company.<br />
The fact that both of these points are closely<br />
linked is not a surprise.<br />
THe INTeRVIeW WaS CoNduCTed by IMRe SZeRdaHelyI.<br />
<strong>AHEAD</strong>: Mr. Beyl, what are the special<br />
features of the new customer orientation?<br />
And wherein lie the significant<br />
differences to your sector’s current position<br />
within the KraussMaffei Group?<br />
Beyl: with our product ranges, we are<br />
orienting ourselves to our customers’<br />
fields of work. For the white Appliances,<br />
construction/Insulation, Molded<br />
Flex/Interior Trim, and Fiber composites/Surfaces<br />
product ranges, we have defined business units<br />
that match the customers’ specific requirements. These units<br />
integrate customer-oriented functions, such as Technical Sales<br />
Support, project Engineering, and Application Technology, to<br />
particularly link the Sales and project Engineering departments<br />
more closely. we will continue to integrate extensive<br />
cross-sector functions. These include construction, Development,<br />
Service, and the “supply chain” function, which covers<br />
the Assembly and Logistics coordination.<br />
<strong>AHEAD</strong>: what are the advantages of this orientation for our<br />
customers?<br />
Beyl: The new orientation allows us to better adapt our<br />
wide-ranging and high-performance product spectrum to our<br />
customers’ requirements. we would like to use our wide range<br />
of products and services, as well as our concentrated expertise,<br />
more than ever, to ensure that our customers get individual<br />
support throughout their entire value-adding chain, and we<br />
want to do this in all our markets.<br />
<strong>AHEAD</strong>: you wish to increase your potential for growth in this<br />
manner. what makes you so confident that you will be able do<br />
this?<br />
Beyl: primarily, it is, of course, all down to our dedicated and<br />
efficient employees who have played a part in every one of our<br />
success stories up until now. we have excellent technological<br />
expertise and we are market leaders, or at least one of the<br />
lead ing global companies, for many of our product sectors. we<br />
are also part of a group that gives us innumerable possibilities<br />
to cooperate with one another – be it technically, organizationally,<br />
or simply collectively and personally.<br />
15
16 Brand & markets<br />
<strong>AHEAD</strong> Issue 02.2012<br />
poSITIvE SIGNALS<br />
FroM SoUTHErN<br />
EUropEAN MArKETS<br />
Stories about the worrying situation in southern european countries dominate our<br />
media headlines on a daily basis. but there is another way. despite the difficult economic<br />
situation, there is encouraging news from the real economy, especially from<br />
the plastics industry. Classic holiday countries offer more than just sun, sea, and sand.<br />
The following examples are certainly impressive.<br />
TexT: MaRKuS beTSCHe<br />
SoUTHErN EUropE<br />
Classic holiday countries offer more than<br />
just sun, sea, and sand.
KraussMaffei Brand & markets<br />
ITaly’S PlaSTICS PRoCeSSoRS aT THe PlaST 2012 TRade faIR<br />
THrEE SUccESS STorIES<br />
This year’s Plast 2012 trade fair provided a good opportunity to cast an eye over the Italian<br />
plastic processing industry. We have taken a closer look at three Italian manufacturers of injection<br />
molded parts for the automotive and domestic appliance industries who have benefited<br />
from KraussMaffei’s expertise in energysaving, premiumquality investment casting solutions<br />
and advanced integrated processing technology.<br />
Cromaplast srl has its headquarters in Valdagno<br />
in the province of Vicenza, where it employs<br />
140 staff and in 2011, achieved an estimated<br />
turnover of 16 million euros with the<br />
manufacture of chrome-plated automotive<br />
molded parts. All of the company’s ten injection<br />
molding machines are units with hydraulic<br />
drive provided by KraussMaffei. Their<br />
machinery includes one machine each with<br />
65, 120, 200, and 300 tons of clamping force,<br />
four with 420 tons and two with 650. Most<br />
of the KraussMaffei machines were introduced<br />
as part of a machinery modernization<br />
program in 2010. The last four Italian units<br />
were replaced by the four KraussMaffei<br />
CX machines with 420 tons of clamping force<br />
in 2011.<br />
According to Managing Director Stefano Tecchio,<br />
the grease- and dust-free KraussMaffei<br />
machines are optimally suited to meeting tight<br />
dimension tolerances and achieving the perfect<br />
surface quality that is demanded of automotive<br />
molded parts. The parts are chromeplated<br />
on production lines with a plating<br />
capacity of 1,800 square meters per day.<br />
Plast3 srl in Fiume Veneto in the province<br />
of Pordenone is one of the three injection<br />
molding companies of the Pezzutti Group.<br />
The group employs 150 staff and possesses<br />
140 injection molding machines. In 2011,<br />
their turnover achieved an estimated 42 million<br />
euros. At Plast3, 30 employees work on<br />
23 injection molding machines.<br />
The company operates with four KraussMaffei<br />
machines: one MX 850-12000 and now three<br />
C2 machines with 420 tons of clamping force,<br />
the last of which was not acquired until 2012.<br />
All machines are equipped with robots from<br />
KraussMaffei.<br />
A KraussMaffei C2 420-3500 molds transparent<br />
red and white, rectangular carry<br />
boxes made of recycled PET for the furniture<br />
manufacturer IKEA. To qualify as a supplier<br />
at IKEA, KraussMaffei’s “Blue Power” energy<br />
saving procedures, such as cylinder insulation<br />
and short cycle times, were a decisive<br />
contributory factor, because in this case,<br />
ecological aspects and a low level of CO 2<br />
emission played a special role, reports Managing<br />
Partner Ivano Castelli. Another product,<br />
which is manufactured with a Krauss-<br />
Maffei 420-ton machine, is a one-piece child<br />
seat insert made of PET.<br />
A highly integrated, 60 percent glass-fiberreinforced<br />
polyamide part manufactured<br />
with an 850-ton MX type machine is used<br />
as a component in textile machines. In this<br />
case, it was possible for the temperature of<br />
the compound to be reduced by 40 degrees<br />
through the use of a KraussMaffei HPS highperformance<br />
screw. As a result, Plast3 was<br />
able to dispense with a master batch charged<br />
with micro balls. This was previously necessary<br />
in order to achieve a better flow rate and<br />
the high level of dimensional accuracy required,<br />
as well as an aesthetically pleasing,<br />
uniformly colored surface.<br />
Sole, a manufacturer of automotive molded<br />
parts founded in 1964 with its headquarters<br />
in Oderzo (region of Veneto, province of Treviso)<br />
is part of the Gruppo Prima. The company<br />
has an eventful history. It passed from<br />
Zanussi (1973) to Electrolux and Gränges<br />
with Plastal, and entered insolvency in 2009.<br />
QUALITy GUArANTEE<br />
KraussMaffei Cx 200750 with a linear robot from<br />
KraussMaffei at Cromaplast<br />
In 2010, Plastal was taken over by the Gruppo<br />
Prima and re-assumed its original name,<br />
Sole SpA.<br />
With around 740 employees, Sole achieved<br />
an estimated turnover of 183 million<br />
euros in 2011. The eleven Italian companies<br />
in Italy and the five European non-domestic<br />
factories of Gruppo Prima probably<br />
turned over 343 million euros in 2011.<br />
The large-scale factories in Oderzo and<br />
Suzzara (three injection molding machines<br />
up to 3,000 tons in Suzzara) are<br />
supported by German firms in Ulm (assembly)<br />
and Wörth (four KraussMaffei<br />
machines). In Oderzo, Sole uses 50 injection<br />
molding machines from various leading<br />
17<br />
ContinuEd on pagE 18
18 Brand & markets<br />
aHeaD Issue 02.2012<br />
Continued from page 17<br />
providers, which, apart from the Krauss-<br />
Maffei units, are mainly Italian machines.<br />
Among the KraussMaffei machines, the six<br />
“SpinForm” machines particularly stand out<br />
and these were introduced for the first time<br />
in 2007. Five of them have a clamping force<br />
of 650 tons and one has 180 tons.<br />
A 650-ton machine (CXW 650-2000/1400),<br />
which was installed in February 2011, produces,<br />
among other things, hard-soft dual-<br />
component door sill covers made of ABS<br />
(acrylonitrite butadiene styrene)/TPU for the<br />
BMW 3 Series. Two ABB multi-axis robots<br />
(articulated arm or “industrial” version) are<br />
used for removing parts, attaching fastening<br />
clips, and fitting a metal strip to the door sill<br />
molded part.<br />
50 years of successful collaboration<br />
Coscollola – our longest partnership<br />
As early as September 1962, Coscollola (Barcelona)<br />
became the KraussMaffei agency for<br />
injection molding machinery in Spain, and<br />
from this cooperation, the first injection molding<br />
machine was delivered in January 1963,<br />
which at that time was still of the 150S MONOmat<br />
type (manufacturer: Eckert&Ziegler).<br />
But the first KraussMaffei V110-700 injection<br />
molding machine came to Spain as early<br />
as 1964. In 1966, turnover already exceeded<br />
1 million DM, a respectable result in the<br />
plastics industry, which at that time was still<br />
emerging, not least because, before its accession<br />
to the EU in 1986, Spain levied an import<br />
tax of a full 45 percent on plastics machines.<br />
Today, 22 Coscollola employees attend to<br />
the needs of Spanish customers. In addition<br />
to KraussMaffei injection molding machinery<br />
and KraussMaffei Berstorff extrusion<br />
technology, they offer their customer base a<br />
wide range of peripheral equipment for processing<br />
plastics. The Coscollola team does<br />
not just regard itself as an agency, but rather<br />
as a competent partner for its customers.<br />
“Our focus is on the customer and their needs<br />
and requirements throughout the entire production<br />
period,” explains Ricardo Coscollola,<br />
Managing Director of Coscollola Comercial<br />
SL. “We therefore regard it as extremely important<br />
that we ourselves also possess competence<br />
in engineering, technical support,<br />
When Sole introduced the SpinForm machines,<br />
there was, according to Giuseppe<br />
Maiarelli, Head of Business Development, a<br />
“plan B” under which it was intended to use<br />
them with two separate molding tools as<br />
well. So far, plan B has not been implemented<br />
because Sole uses all SpinForm machines<br />
at full capacity with the usual horizontal rotary<br />
cube tool. The SpinForm technology is<br />
now also used for the manufacture of highgloss<br />
parts with a piano-lacquer-look finish<br />
in black. In this process, the first operation<br />
using transparent PMMA polymer is followed<br />
by a second that uses colored ABS/PC on the<br />
other side of the rotary cube tool. “Selectively<br />
chrome-plated” parts made of two materials,<br />
only one of which can be chrome-plated,<br />
are also created on the SpinForm.<br />
commissioning, and service. That makes us<br />
unique in the Spanish plastics market.”<br />
There is enormous competitive pressure<br />
among Spanish plastics processors, which is<br />
increased all the more due to intense global<br />
competition. And so in the current situation,<br />
many investments are postponed or completely<br />
canceled. But there are also companies<br />
with good basic conditions that operate<br />
successfully with a pronounced orientation towards<br />
exports. Some of them recently placed<br />
financially interesting orders with us, especially<br />
for injection molding machines.<br />
FPK (Bilbao) – IMC injection molding compounder<br />
for automotive structural components<br />
made of long glass-fiber-reinforced<br />
thermoplasts. This rapidly growing company<br />
ordered another MX 2700-24500 IMC injection<br />
molding compounder, including an extensive<br />
KraussMaffei automation solution for a factory<br />
in Brazil.<br />
Johnson Controls Plastics (Alicante) – Injection<br />
molding machines from the CX range<br />
with between 200 and 650 tons of clamping<br />
force produce plastic parts for batteries in the<br />
Spanish factory. With more than 20 further<br />
machines, JCP has far more than doubled its<br />
production capacities in both of the last two<br />
years.<br />
energy saving<br />
A KraussMaffei C2 420-3500 injection molding<br />
machine manufactures PET carry boxes for IKEA<br />
at Plast3.<br />
Herolse (Barcelona) – Flexible multi-color<br />
machines based on the MX range. With the<br />
newly ordered MX-Z 1450-4300/1400, the<br />
toolmaker is investing in a flexible manufacturing<br />
system for multi-color/multi-part components.<br />
A particular highlight of the machine<br />
is the movable injection units, which are able<br />
to serve the various sprue positions in the<br />
molds and as a result, is suitable for all standard<br />
sprue positions. The machine is ideally<br />
suited to carrying out trials of new molds for<br />
well-known OEM customers and also for the<br />
production of small and pre-series batches.<br />
As far as extrusion machines bearing the<br />
KraussMaffei Berstorff name are concerned,<br />
our machines made in Hanover – particularly<br />
compounding extruders – were in high demand<br />
in 2012, too. In spite of a difficult market<br />
situation in the building industry, it was possible<br />
to realize some successful projects in pipe<br />
extrusion.
KraussMaffei Brand & markets<br />
rELIABLE<br />
The Polyload aZ guarantees a constant flow<br />
of material in bMC (bulk molding compound)<br />
processing.<br />
ALL GooD THINGS<br />
coME IN THrEES<br />
Wet polyester processing in Greece<br />
In July this year, a brand new injection<br />
molding machine for wet polyester processing<br />
was delivered to Dasyc S.A. (form<br />
erly known as Technika Plastika S.A.) in<br />
Greece and put into operation. The CX 300-<br />
1400 PolySet completes the machine package<br />
in which Dasyc invested around a million<br />
euros. Two further PolySet machines<br />
for processing BMC (bulk molding compound<br />
= wet polyester) were already delivered<br />
in 2010 and 2011. And so the company<br />
has now installed the first production line<br />
for BMC parts in Greece in its factory in<br />
Thiva.<br />
Dasyc S.A. was established in 1979 and produces<br />
molded parts made of plastic and<br />
BMC as well as composites. The company<br />
provides a comprehensive service including<br />
component design and construction,<br />
component mounting, toolmaking, component<br />
manufacture, and preassembly. Extensive<br />
export experience and many years<br />
of collaboration with well-known, international<br />
industrial customers complete their<br />
areas of expertise. Today, components are<br />
produced and delivered to the automotive,<br />
military, aerospace, electrical/electronics,<br />
and domestic appliance industries.<br />
Extensive experience with duroplastic<br />
materials PolySet injection molding machines<br />
are suitable for the continuously precise<br />
processing of BMC. Based on expertise<br />
in the processing of cross-linked plastics<br />
since 1958, KraussMaffei PolySet machines<br />
stand out due to their highly effective, lowwear<br />
conveyor techniques and screws, as<br />
well as robust mechanics on the closing<br />
side in dual-platen technology.<br />
SPe (SoCIeTy of PlaSTICS<br />
eNGINeeRS) auToMoTIVe aWaRd<br />
Visualizing complex technologies and processes<br />
for customers in a clear and understandable<br />
way always poses a new challenge.<br />
KraussMaffei have been successful<br />
once again in this endeavor with their brochure<br />
on fiber-compound technology. But<br />
that’s not enough. As part of their 11th Automotive<br />
Award, the International Society<br />
of Plastic Engineers (SPE) has awarded 1st<br />
place in the image/product brochure category<br />
to the product brochure “Fiber compound<br />
solutions – for sophisticated lightweight<br />
components.” The jury recognized<br />
both the informative graphic organization<br />
of the brochure and the boldness shown in<br />
pointing to one’s own expertise and in highlighting<br />
actual deployment possibilities in<br />
the form of exemplary components, rather<br />
than merely concentrating on the machines<br />
and systems themselves.<br />
19
20 Processes & Products<br />
<strong>AHEAD</strong> Issue 02.2012<br />
Processes & Products<br />
EFFIcIENT MANUFAcTUrING oF<br />
FIBEr coMpoSITE coMpoNENTS<br />
KraussMaffei offers an entire range of processes to manufacture fiber composite components (also see the<br />
cover story on page 5). The latest processes include different variants of resin injection processes. Here is a<br />
brief overview of the latest developments.<br />
New process variants expand the RTM (resin transfer molding)<br />
technology application field Fiber-reinforced plastic parts are characterized<br />
by extremely low weight but high rigidity. “Which manufacturing<br />
process is best suited to a specific component depends on numerous<br />
factors,” said Erich Fries, “above all, the component shape,<br />
the matrix material, and the quantity required are all influencing factors.”<br />
The performance profile and the production costs of the component<br />
are also critical criteria. They determine which solution approaches<br />
and manufacturing processes should be taken into account.<br />
High-pressure resin transfer molding (HP-RTM) with quick reacting<br />
resin systems The HP-RTM process (High-pressure resin transfer<br />
molding) is suitable for large series manufacturing of lightweight<br />
and high-strength structural components made of epoxy resins.<br />
However, polyurethane or other reaction resins can also be used as<br />
matrix materials. In HP-RTM, the resin is fed into the closed mold<br />
using a self-cleaning high-pressure mixing head. The resin and hardener<br />
components are injected into the mixing chamber via separate<br />
nozzles and are mixed there quickly and intensely. This technique allows<br />
fast-reacting resin systems to be processed within short reaction<br />
times. Using high-pressure injection, the matrix resin wets the<br />
fibers faster, more intensely, and more completely than by using the<br />
low-pressure technique.<br />
The mold can be evacuated and operated with an inner pressure of up<br />
to approximately 100 bar. Even complex, three-dimensional cavities<br />
are filled faster this way and the fibers inside are saturated. At the<br />
same time, air voids are eliminated. There are constant new customer<br />
requirements in the emerging lightweight construction and fiber<br />
composite materials sector. KraussMaffei continuously develops its<br />
process and machine technology for this dynamic environment.<br />
Compression resin transfer molding (C-RTM) and wet molding<br />
– two new HP-RTM variants In C-RTM, the mold is not completely<br />
closed initially, but only up to the defined gap. Next, the resin mixture<br />
enters the mold, with or without low mold-internal pressure. Some of<br />
the fibers are already saturated by the resin; the greater part of the<br />
resin quantity, however, is virtually “floating” on the fiber above. This<br />
is followed by a compression stroke – the mold is completely closed<br />
and the cavity corresponds to the shape of the final component. The<br />
compression stroke has the effect of pushing the resin through the<br />
fiber in the Z-direction and the fiber is wetted completely. This process<br />
is advantageous for delicate preforms due to the low material<br />
flows.<br />
KraussMaffei is providing another alternative to the automated series<br />
production of fiber-reinforced lightweight components in the form of<br />
the wetmolding procedure. Here, a fiber pile is fixed in a flat state<br />
without preforming. The mixing head is not positioned directly on the<br />
mold, but is fixed on a traversing unit. While the mixing head moves<br />
in a line over the fiber stack, the application device applies a laminar<br />
thin resin layer on the fiber stack. As soon as the fibers are covered<br />
with resin, the fiber pile is transported to a mold and pressed<br />
there. The preforming of the fibers in wetmolding thus takes place<br />
first with the mold closing movement. An important advantage of the<br />
wet-molding process is that even recycled fibers can be used to reinforce<br />
components. MB<br />
c-rTM, coMprESSIoN rTM<br />
10.<br />
9.<br />
8.<br />
1. 2.<br />
7.<br />
1. Semifinished products from<br />
the roll<br />
2. Handling the readymade<br />
semifinished products<br />
3. Transfer to the preform station<br />
4. Preforming<br />
5. Transfer the preform to the<br />
CRTM station<br />
6.<br />
6. Close the mold on the compression<br />
stroke, vacuum (optional)<br />
7. Resin injection<br />
8. Press (compression)<br />
9. Hardening<br />
10. Component removal<br />
3.<br />
5.<br />
4.
KraussMaffei Processes & Products<br />
Gx: GrEAT poTENTIAL<br />
IN LIGHTwEIGHT<br />
coNSTrUcTIoN<br />
The Gx Series, which was introduced in May 2012, has<br />
already proven itself to be a market leader in only four<br />
months. The high worldwide demand is not a surprise and<br />
KraussMaffei is going one step further. Thanks to the presentation<br />
of a MuCell application at the fakuma 2012 trade<br />
fair, the Gx Series has unlocked a new area of application.<br />
Finely graduated modular design with high<br />
productive efficiency Thanks to its extensive<br />
option catalog, the GX Series offers a base<br />
for versatile injection molding processes. At<br />
the Fakuma trade fair, a GX 450-3000 powered<br />
with CellForm technology used a physical<br />
foam (MuCell) to produce an interior trim<br />
component for the automotive industry. The<br />
physical foam is part of KraussMaffei’s Cell-<br />
Form technology for foamed thermoplasts<br />
in injection molding processes. “When combined<br />
with a MuCell equipment package and<br />
a precise injection and plasticizing unit, the<br />
GX Series is almost predestined for process-reliable<br />
production of foamed parts,”<br />
said Dr. Bourdon, Vice President Technology<br />
at KraussMaffei. “This application shows<br />
the enormous potential still contained in<br />
lightweight thermoplastic solutions.” The<br />
high shot-weight constancy (of less than<br />
+/– 0.1 percent deviation) ensures reliable<br />
production, even with the highest possible<br />
demands. Productivity is therefore maintained.<br />
As the fastest dual-plate machine on<br />
the market, the GX and the GearX interlock<br />
offer the shortest travel times and maximum<br />
productivity. The smooth-running mechanics<br />
and the GuideX guide shoe reduce traction<br />
resistance by up to 80 percent, and ensure,<br />
together with the hydraulic concept that has<br />
been designed for minimum flow losses,<br />
maximum energy efficiency. MB<br />
30 pErcENT LIGHTEr AIrBAG HoUSING<br />
Lightweight, thin but still stable Organic-sheet hybrid technology has considerable potential for<br />
lightweight construction. As far as green mobility is concerned, this technology can contribute by<br />
reducing the weight, the fuel consumption, and vehicle emissions considerably. The example of<br />
a passenger airbag module housing demonstrated this clearly. Compared to an injection-molded,<br />
series-manufactured module made from glass-fiber-reinforced polyamide 6, the housing<br />
manufactured from the organic sheet was lighter by over 30 percent. The demonstration product<br />
was designed as part of a joint pre-development project between TAKATA AG in Aschaffenburg,<br />
LANXESS AG in Leverkusen, Bond-Laminates GmbH in Brilon, Christian Karl Siebenwurst<br />
GmbH & Co. KG in Dietfurt, and KraussMaffei. The airbag housing contains the gas generator<br />
and the folded airbag. Its long sidewall panels are made of molded organic sheet containing<br />
47 percent of volume endless fibers in polyamide 6 and are over-molded and reinforced in specific<br />
areas with polyamide 6 that is modified with impact-resistant properties. Owing to the design<br />
of organic-sheet hybrid technology, the thickness of sidewall panels can be reduced by three to<br />
four millimeters, to 0.5 to 1 millimeters. As a result, it is possible to reduce the weight. MB<br />
→ INForMATIoN ABoUT ITHEc TrADE FAIr<br />
The first international conference and specialist trade fair with a focus on “thermoplastic<br />
composites” will take place on October 29/30, 2012 in Bremen. On the topic of manufacturing<br />
processes, Martin Würtele, Head of Technology and Development at KraussMaffei, will give a<br />
lecture on “ fully automatic injection molding production of textile-reinforced components.”<br />
Furthermore, on its trade fair stand, KraussMaffei will present options using fiber-reinforced<br />
thermoplasts, as well as composites with reactive matrix systems. Visitors have the opportunity<br />
to talk with our on-site experts and get more information about the technology that is<br />
ideally suited to them.<br />
THe PRoduCTIoN Cell using Gx and lRx robots<br />
can also be operated from the rear side of the<br />
machine using the handheld robot.<br />
youR adVaNTaGeS aT a GlaNCe<br />
• Less viscosity and better flow<br />
properties<br />
• Holding pressure phase omitted<br />
• Sunk spots omitted<br />
• Shorter cycle times<br />
• Low warpage<br />
• Clamping forces considerably reduced<br />
The passenger airbag module housing, which is<br />
made using organicsheet hybrid technology, is over<br />
30 percent lighter compared to an injectionmolded,<br />
seriesmanufactured model made from glassfiberreinforced<br />
polyamide 6.<br />
21<br />
Photo: TaKaTa aG
22 Partners & projects<br />
<strong>AHEAD</strong> Issue 02.2012<br />
Partners & projects<br />
SUccESS STory<br />
KraussMaffei sheds new<br />
light on american plastics<br />
processing companies.<br />
RaPId GRoWTH IN NoRTH aMeRICa<br />
QUALITy IS THE KEy<br />
KraussMaffei has been present in the uSa for more than 45 years and in that time, the<br />
company has constantly adapted its product and service range to this particular market<br />
and has thus become a renowned company.<br />
“The encouraging developments in the North American market were<br />
evident to us thanks to the increase in orders over the last year,” said<br />
Paul Caprio, the head of the US-subsidiary of KraussMaffei Corporation.<br />
“We are extremely pleased with the consistently high demand for<br />
our products this year and our customers’ very positive response to our<br />
machine and service quality. The complete machine range from 35 to<br />
4,000 t clamping force, and the optimally adapted automation solutions<br />
precisely fulfill our US customers’ requirements, to be able to compete<br />
successfully in the international market.“ The latest orders from two<br />
demanding US-based companies have proved this in an exemplary way.<br />
Large machines at SLP Lighting begin production With over<br />
40 years of experience in the field of commercial lighting products,<br />
the Koller-Craft subsidiary, SLP Lighting, is one of the leading<br />
American manufacturers of lights and lighting systems for industrial<br />
applications and of lighting systems in the automotive sector. SLP<br />
is now also using premium-quality KraussMaffei machines at its<br />
plant in Sullivan, Missouri. Two injection molding machines, sizes<br />
MX 2000-12000 and MX 2700-17200, began producing transparent<br />
diffusion lenses this year.<br />
“We were impressed from the very beginning by the efficiency of the<br />
MX machines where part quality and productivity are concerned,”<br />
said David Koller, SLP Managing Director. “The professional working<br />
methods of the <strong>KM</strong>C employees during the project phase and the machine<br />
installation showed us that KraussMaffei is the right partner for<br />
our company.” Thanks to the increased production capacity, SLP can<br />
respond to the ever-rising demand for premium-quality lamps and<br />
still keep to short lead times.<br />
Multi-component machines for rear lights at Proper Group International<br />
Molds used to produce automobile headlights are part of<br />
the core business of Proper Group International, along with injection<br />
molds for textile back injection or glass insert molding for multi-component<br />
parts and also for premium-quality visible parts. The company<br />
also supplies molds for polyurethane processing. After signing<br />
a strategic partnership agreement in 2008, the Proper Group and<br />
KraussMaffei have successfully positioned themselves as system<br />
partners for injection molding technology and polyurethane technology<br />
in the US market. They have been successfully providing complete<br />
ready-for-use solutions ever since. A live demonstration for manufacturing<br />
SkinForm components from thermoplastic substrates with<br />
premium-quality soft-touch surfaces at the NPE 2012 trade show<br />
proved this in an impressive manner.<br />
At Proper’s joint technology center in Warren (Michigan), KraussMaffei<br />
can use injection molding machines with a clamping force of between<br />
80 and 2,700 t for development, testing, and mold trials.<br />
In the course of this cooperation, Proper has recently ordered an<br />
MXZ 1600-12000/3000 multi-component machine that should serve<br />
for mold trials and manufacturing reflector housings for the automotive<br />
industry. MB
KraussMaffei Partners & projects<br />
23<br />
aWaRd-WINNING<br />
“ pUrTrAIN” IS oN TArGET<br />
For THE AUToMoTIvE INDUSTry<br />
although eight partners had to share the JeC Innovation award 2012, none of them was<br />
bothered by it. on the contrary, they were all proud of the award that they had received<br />
collectively for a lightweight construction application for rail vehicles. KraussMaffei was<br />
one of the prizewinners.<br />
Paris, March 2012: At the world’s largest<br />
fiber composites trade show, JEC Composite<br />
Show, Jan Kuppinger from the<br />
Fraunhofer-Institut für Chemische Technologie<br />
(Fraunhofer Institute for Chemical<br />
Technology) (ICT) accepted the JEC Innovation<br />
Award 2012 in the Manufacturing<br />
Process category, as a representative of<br />
the network of eight partners, who collectively<br />
made headway in the field of lightweight<br />
construction. Their “creation” may<br />
not sound interesting at first glance: a selfsupporting<br />
diesel engine housing for rail<br />
vehicles.<br />
Although the length and the width of the<br />
demonstration prototype, based on a polyurethane<br />
sandwich structure, were only<br />
4.50 meters and 2.50 meters, respectively,<br />
it made the engineers’ hearts beat faster.<br />
The part has the same properties, but it is<br />
35 percent lighter than its counterpart made<br />
of steel and aluminum, and comprises fewer<br />
parts.<br />
Together with ICT and Bombardier Transportation,<br />
Werk Hennigsdorf, and with support<br />
from the Federal Ministry of Education<br />
and Research, the partners KraussMaffei,<br />
Bayer MaterialScience, DECS GmbH, the<br />
DLR-Institut für Fahrzeugkonzepte (DLR<br />
Institute for Vehicle Concepts), the Institut<br />
für Flugzeugbau der Universität Stuttgart<br />
(Stuttgart University Institute of Aircraft<br />
Design), and the Karlsruher Institut für<br />
Technologie (Karls ruhe Institute of Technology)<br />
have pooled their expertise to find<br />
a completely new solution in just three and<br />
half years. Josef Renkl, the R&D Director of<br />
KraussMaffei’s Reaction Process Machinery,<br />
emphasized in Paris that it is a solution that<br />
can be “directly applied to other sectors such<br />
as the automotive industry.”<br />
KraussMaffei develops new manufacturing<br />
processes The work for the “PURtrain” project<br />
was anything but trivial. This is because<br />
it was not at all meant to replicate a metallic<br />
engine housing using plastic. The partners<br />
had to work together closely to carry out extensive<br />
development activities along the entire<br />
value-adding chain. The tasks included<br />
developing new manufacturing processes<br />
(for which KraussMaffei was responsible),<br />
new sandwich-core and top-layer materials,<br />
new fire protection systems, in-house design<br />
principles, and even computation methods.<br />
The result was a sandwich component made<br />
using a glass-fiber-reinforced polyurethane<br />
layer and a paperboard honeycomb core. The<br />
polyurethane (PUR) was initially modified in<br />
such a way that it complied with fire protection<br />
regulations. Then the fiber-spraying process<br />
used to apply PUR layers was optimized.<br />
A new mixing head made it possible to manufacture<br />
even the most complex structures –<br />
which was necessary to reduce the number of<br />
components – in the sizes required.<br />
The demonstration component fulfilled all<br />
requirements stipulated in the requirement<br />
specifications, e.g., puncture strength, which<br />
is an important criterion. This is important<br />
since the engine housing is suspended under<br />
the passenger compartment and above rails.<br />
Its task is to protect the engine from the impacts<br />
of stones, collect any oil that may leak,<br />
and prevent fire from spreading in case of<br />
fire. In the meantime, extensive tests must<br />
be conducted to check whether the jointly developed<br />
product can cope with all of these<br />
challenges.<br />
Erich Fries is visibly proud: “It is an exciting<br />
project, which once again showed that lightweight<br />
construction is not only relevant in the<br />
automotive industry.” JW<br />
JeC euRoPe INNoVaTIoN aWaRd<br />
The development consortium around<br />
Fraunhofer ICT was also able to score<br />
points. The SCS process (Structural<br />
Component Spraying), a manufacturing<br />
process for lightweight structures which<br />
is based on sandwich structures, and<br />
spraying processes for glass-fiber-reinforced<br />
polyurethane resins, was awarded<br />
the JEC Europe Innovation Award 2012 in<br />
the Manufacturing Process category.
24 KraussMaffei Group <strong>AHEAD</strong> Issue 02.2012<br />
KraussMaffei Group<br />
INTeRNaTIoNal TRade faIRS<br />
GroUp prESENcE wITHoUT BorDErS<br />
Through joint brand launches, for example, at leading trade fairs in Italy and the uSa, the<br />
KraussMaffei Group and its strong brands are recognized throughout the world.<br />
TexT: eVa MÜNZeNMaIeR<br />
ALL AroUND THE worLD<br />
The NPe trade fair in orlando and Plast in Milan were just two examples of<br />
successful joint exhibition appearances. The KraussMaffei Group will also be<br />
exhibiting as a complete entity at the fakuma 2012 trade fair.<br />
NPE Orlando<br />
KraussMaffei presented energy-efficient machines from the AX Series,<br />
as well as powerful and integrated manufacturing concepts based on<br />
the CX and MX Series. There were also polyurethane solutions for premium-quality<br />
surface finishes on display, classic foaming processes,<br />
lightweight construction processes, as well as insulation applications<br />
for the white goods sector. One of the highlights, previously unprecedented<br />
in the USA, was the live presentation of the SkinForm process<br />
in one production cell with a CX 200-1400 hybrid injection molding machine<br />
and a RimStar hybrid mixing and metering system for polyurethane<br />
processing.<br />
More efficient production thanks to constant improvements: <strong>Netstal</strong><br />
presented highly efficient production of closures on an ELION 2800<br />
with the new electric form closure with energy recuperation. The<br />
PCO 1881 drinks closures were produced at a cycle rate of 3.5 seconds<br />
using a 72-cavity mold.<br />
The energy-efficient IPC system from KraussMaffei Berstorff was in<br />
great demand. This system cools the pipe in addition to conventional<br />
external cooling, using ambient air from the inside. American customers<br />
are particularly impressed by the significant increase in output of<br />
up to 60 percent, which achieved by this system, especially as resources<br />
and energy consumption is also significantly reduced.<br />
“Two criteria are critical for our American customers in their decision<br />
to buy, namely perfect product quality and extremely high output<br />
performance. In this case, we offered first-class solutions at the NPE<br />
trade fair. Customers were really impressed,” explains Paul Caprio,<br />
Head of the American subsidiary.<br />
Plast Milan<br />
Efficiency and resource savings are also increasingly decisive factors<br />
for Italian processors when deciding to invest. The KraussMaffei<br />
Group entered the race on precisely these topics with intelligent solutions<br />
at the Plast Milan 2012 trade fair.<br />
In presenting the AX and EX Series, KraussMaffei exhibited powerful,<br />
all-electric machines for all production requirements. In a live demonstration,<br />
liquid silicone rubber (LSR) was processed under clean-room<br />
conditions and complex, technical formed parts were produced in an<br />
energy-efficient process.<br />
<strong>Netstal</strong> displayed a system solution specially optimized for packaging<br />
tasks, created from the powerful ELION 1200, which included mold,<br />
automation, and other peripherals. During the demonstration of thinwall<br />
injection molding, it was possible to save up to 60 percent in energy<br />
consumption compared with conventional drive systems.<br />
KraussMaffei Berstorff received numerous inquiries from the building<br />
industry, especially in the polyolefin pipe extrusion sector. The<br />
QuickSwitch system in particular generated a great deal of interest,<br />
with which pipe dimensions can be changed at the press of a button<br />
without interrupting the production process. Visitors to the trade fair<br />
were also greatly interested in systems to manufacture technical films<br />
made of ethylene vinyl acetate (EVA).<br />
This is the motto under which the KraussMaffei Group will be<br />
presenting the “best-in-class” solutions for efficient production<br />
with outstanding results at this year’s Fakuma trade fair. You can<br />
experience the new dimension in injection molding for the first<br />
time “live” at stand 7303/7304 in hall A7 – a GX450-3000 Cell-<br />
Form with LRX 250 linear robot as a technology platform with a<br />
thermoplastic lightweight construction application. You can also<br />
look forward to other high-tech exhibits and processes from the<br />
KraussMaffei, KraussMaffei Berstorff, and <strong>Netstal</strong> brands – for<br />
an efficient production process in injection molding, reaction, and<br />
extrusion technology.
KraussMaffei<br />
TRade faIR aNd PRoduCTIoN loCaTIoN IN CHINa<br />
TEcHNIcAL TrEATS For THE FAr EAST<br />
TexT: eVa MÜNZeNMaIeR<br />
KraussMaffei Group 25<br />
The KraussMaffei Group took several important steps towards developing its joint presence in China with<br />
its three brands KraussMaffei, KraussMaffei berstorff, and <strong>Netstal</strong> in China.<br />
IMprESSIvE<br />
according to an old Chinese saying, “a long journey always starts with the first<br />
step.” The KraussMaffei Group took a few great strides forward this year at the<br />
Chinaplas exhibition and in the plant at Haiyan.<br />
Chinaplas 2012<br />
Chinaplas once again confirmed that, for Chinese processors, reliable<br />
and innovative machine technology bearing the “Made in Europe”<br />
stamp is very popular. The KraussMaffei Group offered a good many<br />
technical treats for innovation-hungry plastics processors, with applications<br />
from injection molding, reaction, and extrusion technology.<br />
High on the visitors’ list of interest was the MX swivel plate and embossing<br />
machine from KraussMaffei. This machine has positioned itself<br />
just as successfully in the Chinese market as the CX Multinject for<br />
multicolor and multiple component applications.<br />
Performance and efficiency in the PET sector. <strong>Netstal</strong> presented a<br />
high-quality application on the PET-LINE. This application was based<br />
on a platform with 3,500 kN clamping force and covered the range of<br />
48 to 128-cavity molds with a highly cost-efficient total system. “With<br />
this system, we provide an excellent solution for the growing drinks and<br />
foodstuffs packaging sector in China,” explained Markus DalPian, Head<br />
of the PET business unit at <strong>Netstal</strong>.<br />
KraussMaffei Berstorff scores points with products that are manufactured<br />
locally. “Our customers in Asia attach a lot of importance to locally<br />
manufactured machines, which also satisfy extremely high technological<br />
demands,” informed Fan Kai Jun, General Sales Manager<br />
for Extrusion Technology in China. A rising demand in the PVC, pipe,<br />
and profile extrusion sectors proves him right. And with its proven 36D<br />
single-screw series, KraussMaffei Berstorff is well equipped to cope<br />
with the requirements of the rapidly growing Chinese polyolefin pipe<br />
market.<br />
“Open house” in the plant at Haiyan<br />
During the Chinaplas trade fair, the KraussMaffei Group opened the<br />
gates of its production plant in Haiyan. This gave customers the opportunity<br />
to view machines and systems, which had been specifically<br />
designed for Chinese requirements and locally manufactured, actually<br />
in operation.<br />
KraussMaffei presented a type MX850 injection molding machine,<br />
which is entirely manufactured in Haiyan. Also high on the list of interest<br />
were machines, systems and tooling systems for polyurethane<br />
foam applications, for example refrigerators, insulation applications,<br />
or lightweight components.<br />
KraussMaffei Berstorff showed two pipe extrusion lines which, processed<br />
material of local origin. The high-speed systems produced hotwater<br />
pipes made of PP-R for the supply of fresh water with diameters<br />
ranging from 20 to 63 mm, as well as heating pipes made of PE-RT<br />
from 20 to 32 mm. “Since the initial start-up of our own manufacturing<br />
plant, we have been producing, among other things, the core components<br />
for both systems, the <strong>KM</strong>E 60-36 B/R single-screw extruder and<br />
the <strong>KM</strong>-RKW 32 spiral mandrel distributor pipe heads from the Performance<br />
series,” explained Harald Schweitzer, Head of the Chinese<br />
subsidiary. “As from now, we offer our customers complete pipe extrusion<br />
systems with all downstream units locally manufactured, which<br />
set new standards in terms of quality and performance.”
26 KraussMaffei Group <strong>AHEAD</strong> Issue 02.2012<br />
SMArT pIpES<br />
one of the current global megatrends is “energy efficiency.”<br />
KraussMaffei berstorff is not just following this trend when it<br />
comes to their own products. Their customers can also score<br />
points on the market thanks to their results from increasing<br />
their energy efficiency.<br />
It is becoming increasingly common<br />
to make effective use of heat and cold,<br />
which are often the by-products of<br />
other processes. It is important that these forms of energy can<br />
be transported across both short and long distances with as little<br />
loss as possible. For this reason, KraussMaffei Berstorff has developed<br />
a solution: insulated pipes, in which several plastics have<br />
been integrated to form a highly efficient compound. Their extremely<br />
low thermal conductivity (for experts: at a minimum at 0.02 to<br />
ELIoN 3200: A SUccESSFUL coNcEpT<br />
coNTINUES To Grow<br />
0.03 W per Kelvin and meter) makes them the ideal transport medium<br />
for both heat and cold. These plastic pipes, which usually have<br />
one or two medium pipes on the inside and are surrounded by polyurethane<br />
insulation and have an outer coating of polyethylene, are<br />
not only considerably more compact, more flexible, more leakproof,<br />
and easier to lay. Thanks to a continuous manufacturing procedure<br />
with a high level of automation, they are also significantly<br />
more cost-effective. In short, they really are “smart” – just like the<br />
systems that produce them.<br />
The elIoN Series has successfully established itself on the market. With the new 3200<br />
model, <strong>Netstal</strong> is offering a highly efficient solution to manufacture complex moldings.<br />
In 2003, <strong>Netstal</strong> launched its all-electric ELION<br />
Series. This high-performance injection molding<br />
machine quickly proved itself to be one of the most<br />
efficient and most precise all-electric machines on the market. And<br />
not much has changed since then.<br />
At the Fakuma 2012 trade fair, <strong>Netstal</strong> is presenting the latest newcomer<br />
to the series: the ELION 3200. Together with Müller Fabriques<br />
SA, <strong>Netstal</strong> is displaying a complete system for manufacturing<br />
thin-walled covers for cream cheese packaging. The<br />
pLANT ExpANSIoN IN SLovAKIA<br />
The expansion of the KraussMaffei Group production plant in<br />
Sučany (Slovakia) is making very good progress. “Production in<br />
the second assembly hall is expected to be able to start as early<br />
as the end of 2012, rather than in the first quarter of 2013, as originally<br />
planned,” said Plant Manager Vladimir Boda. The intention<br />
in the future is to use the production plant in Sučany, which covers<br />
a production surface area of around 13,000 m 2 , to additionally<br />
manufacture robots, injection molding machines from the EX Series,<br />
and machines and systems for reaction process machinery,<br />
as well as trimming components of the KraussMaffei brand.<br />
pLANT ExpANSIoN IN cHINA<br />
pIpES FULL oF INTELLIGENcE<br />
energyefficient transportation in<br />
polyurethaneinsulated pipes<br />
polypropylene molding has been developed with a total cycle time of<br />
less than 3.5 seconds on a 4+4-cavity multi-daylight mold. A completely<br />
automated system inserts the labels, removes the finished<br />
parts, and stacks these parts. The maximum output is 8,230 pieces<br />
per hour. The electrically driven clamping unit can be combined with<br />
the hydraulic high-performance injection unit from the EVOS Series.<br />
The energy-saving potential of this hybrid technology with innovative<br />
Eco Powerunit drive unit has been put to full use. When compared to<br />
a conventional hydraulically driven toggle-lever machine, the ELION<br />
hybrid can save energy by up to 50 percent.<br />
+++ NEwS TIcKEr +++ NEwS TIcKEr +++ NEwS TIcKEr +++<br />
The extension of the production capacities at the production plant<br />
of the KraussMaffei Group in Haiyan (China) is going according to<br />
plan. By spring 2013, it is intended to double the production surface<br />
area to around 22,000 m 2 . In future, injection molding machines<br />
for PET applications of the <strong>Netstal</strong> brand will be manufactured<br />
here, in addition to machines and systems for reaction<br />
and extrusion technology. The MX 850-6100 injection molding machine<br />
from the KraussMaffei brand with a clamping force ranging<br />
from 8,500 to 40,000 kN will also be produced for the Chinese and<br />
Asian markets.
KraussMaffei Imprint 27<br />
pROpeRTy RighTS SeCURe<br />
TeChnOLOgiCaL advanTageS fOR<br />
The BenefiT Of The CUSTOMeR<br />
systematic patent protection at Kraussmaffei,<br />
Kraussmaffei Berstorff, and netstal<br />
The protectors of intellectual property in the<br />
KraussMaffei Group have their hands full. For<br />
they have approximately 1,450 patents – which<br />
include patents that have been granted and<br />
registered as well as utility models – that need<br />
to be managed and regularly reviewed. And<br />
between 30 and 50 new inventions are added<br />
to these each year. This is a considerable<br />
added value, above all for our customers who<br />
benefit from these innovations.<br />
Property rights – as international as our<br />
business Since the KraussMaffei Group with<br />
its worldwide branches numbers among technological<br />
leaders, many patents are also registered<br />
beyond Europe, above all in the USA,<br />
China, and Japan. And this innovation lead is<br />
consistently secured: The company uses legal<br />
means to prosecute patent infringements –<br />
whether they concern machines or processes.<br />
A strong competitor The high value of our research<br />
achievements for the customerʼs benefit<br />
can be seen from three examples: Inventions<br />
that were made ready for series<br />
production with passion and ambition and<br />
make us a strong competitor. It is hardly<br />
tRade shoW calendaR (octoBeR 2012 – maRch 2013)<br />
possible to imagine KraussMaffei now without<br />
reversing plate technology, which is used, for<br />
example, in SpinForm technology. As a substitute<br />
for the usual rotary table technique, the<br />
reversing plate offers the advantage of working<br />
in parallel with optimum use of space.<br />
Consequently, the cycle times become substantially<br />
shorter; the installation effort and use<br />
of molds, on the other hand, decrease rapidly.<br />
Almost self-evidently, the patented QuickSwitch<br />
from KraussMaffei Berstorff is a technology<br />
that is used in polyolefin pipe production and<br />
in PVC processing. Using it, the producer can<br />
change the pipe dimension at the touch of a<br />
button in mere minutes. The centerpiece is the<br />
calibration basket, with which the complete<br />
system can be set quickly to the desired pipe<br />
in just one step. Calitec is another industrial<br />
property right that <strong>Netstal</strong> has patented. This<br />
innovative cooling system supports preform<br />
cooling by means of compressed air. With this<br />
system, the PET preforms are cooled again<br />
optimally and without interruption after demolding.<br />
Consequently, the cycle time in production<br />
is shortened and the article quality is<br />
sustainably improved. CS<br />
Fakuma, Friedrichshafen 16.10.2012 – 20.10.2012 KraussMaffei Group<br />
Materialica, Munich 23.10.2012 – 25.10.2012 KraussMaffei<br />
ITHEC, Bremen 29.10.2012 – 30.10.2012 KraussMaffei<br />
Feipur, São Paulo 06.11.2012 – 08.11.2012 KraussMaffei<br />
JEC Americas, Boston 07.11.2012 – 09.11.2012 KraussMaffei<br />
Brau Beviale, Nuremberg 13.11.2012 – 15.11.2012 <strong>Netstal</strong><br />
Tyres & RubberTec, Shanghai 14.11.2012 – 16.11.2012 KraussMaffei Berstorff<br />
Euromold, Frankfurt 27.11.2012 – 30.11.2012 KraussMaffei<br />
Plast Eurasia, Istanbul 29.11.2012 – 02.12.2012 KraussMaffei<br />
Arabplast, Dubai 07.01.2013 – 10.01.2013 KraussMaffei, <strong>Netstal</strong><br />
ACMA, Orlando/Florida 29.01.2013 – 31.01.2013 KraussMaffei<br />
Interplastica, Moscow 29.01.2013 – 01.02.2013 KraussMaffei Group<br />
Tire Technology Expo, Cologne 05.02.2013 – 07.02.2013 KraussMaffei Berstorff<br />
Medtec, Stuttgart 26.02.2013 – 28.02.2013 <strong>Netstal</strong><br />
JEC, Paris 12.03.2013 – 14.03.2013 KraussMaffei<br />
iMpRinT<br />
Publisher:<br />
Kraussmaffei technologies gmbh<br />
Krauss-maffei-strasse 2<br />
80997 munich<br />
germany<br />
Phone + 49/89/88 99-0<br />
fax + 49/89/88 99-2206<br />
www.kraussmaffei.com<br />
Person responsible:<br />
Imre szerdahelyi (responsible for content<br />
according to german media law)<br />
editor-in-chief: eva münzenmaier<br />
Editorial team:<br />
markus Betsche (mB), eva münzenmaier (em),<br />
claudia stadler (cs), Imre szerdahelyi (Is),<br />
joachim Weber (jW)<br />
Photo credits:<br />
harald mehnert, stefan Kruppa,<br />
group-internal pictures, plainpicture, corbis<br />
Concept and design:<br />
Kirchhoff consult ag, hamburg, germany<br />
www.kirchhoff.de<br />
Press:<br />
Weber offset gmbh, munich, germany<br />
the customer magazine is published twice a year in<br />
german and english. the magazine may only be reprinted<br />
with the written permission of the publisher.
The KraussMaffei<br />
Group has a global<br />
presence. Countries<br />
with subsidiaries are<br />
marked in blue.<br />
In the white-colored<br />
regions, the Group is<br />
represented by over<br />
570 sales and service<br />
partners.<br />
netstal<br />
KraussMaffei group<br />
KraussMaffei<br />
Injection Molding Machinery Injection Molding Machinery<br />
Reaction Process Machinery<br />
KraussMaffei<br />
Berstorff<br />
Extrusion Technology<br />
KraussMaffei group<br />
wide-reaching expertise with Technology 3<br />
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies<br />
for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff, and <strong>Netstal</strong> brands:<br />
Injection Molding Machinery, Automation, Extrusion Technology and Reaction Process Machinery.<br />
The group is represented internationally with more than 30 subsidiaries and over ten production<br />
plants as well as about 570 commercial and service partners. This is what makes us your<br />
highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry.<br />
Further information available at:<br />
www.kraussmaffeigroup.com