E_KM_AHEAD-Magazin_2-12.pdf - Netstal

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8 Brand & markets AHEAD Issue 02.2012 brand & markets wIDE-rANGING ExpErTISE IN THE FIELD oF INjEcTIoN MoLDING „ We want to use our performance capabilities and outstanding machine technology to generate even more value added for our customers along their entire valueadding chain. To this end, we will maintain the separate market presence of the Netstal and KraussMaffei brands with a clearly defined product portfolio and their independently operating sales organizations.“ dr. Hans ulrich Golz, President of the Injection Molding Machinery Segment our motto is: Together, we are stronger. Since 1 July 2012, the KraussMaffei Group has added a comprehensive sector: injection molding machinery. It unites the KraussMaffei and Netstal brands. The company has consciously decided to take this step, to increasingly align its services to its customers’ requirements along the valueadding chain, to utilize the market potentials better, and to use the innovative strengths of both these brands more aggressively by joining them together. The advantage for our customers: both the brands’ strengths are retained with a clearly defined product portfolio. The most important objective is “to offer the customer the best solution, irrespective of the brand and the location.” Dr. Hans Ulrich Golz, President of this sector, is very happy that he “could virtually fill all management positions in the Injection Molding Machinery sector with experienced and highly competent managers from the KraussMaffei Group.” In addition to his task as the head of the sector, Dr. Golz has also assumed the task of leading the sales division for the Netstal brand. Mr. Frank Peters is the Executive Vice President Sales. Dr. Karlheinz Bourdon is responsible for the Technology fields (among others, Research and Development, Processing, and Automation). „ by pooling the excellent knowhow of two strong brands, we can offer our customers the right product of the right brand for them from our wide and powerful product portfolio, as well as the corresponding services tailored to their individual needs. We are also emphasizing our technology leadership on the market. We are highly motivated and are gaining momentum.“ frank Peters, executive Vice President Sales Dr. Bernd Thurat heads the Operations Department and Renzo Davatz heads the Service Department, including the Used Machinery Business. The Injection Molding Machinery sector is presenting itself to customers with a new consolidated distribution channel. The entire injection molding business will be divided into seven business units in the future and these will be oriented towards the target markets: • Automotive, led by Mr. Bengt Schmidt, under the KraussMaffei brand • Technology, led by Mr. Klaus Bange, under KraussMaffei with the KraussMaffei and Netstal brands • Logistics and Packaging (thick-walled), led by Mr. Bengt Schmidt, under the KraussMaffei brand • Packaging (thin-walled), led by Mr. Markus DalPian, under the Netstal brand • Screw-cap closures (CAP), led by Mr. Markus DalPian, under the Netstal brand • PET, also led by Mr. Markus DalPian, under Netstal with the KraussMaffei and Netstal brands • “In the Medicine BU, we will continue with the two-brand strategy under the leadership of Mr. Patrick Blessing,” said Dr. Golz. “This is because we have two complementary product portfolios and excellent expertise in the field medical technology at both locations. Therefore, we believe that we can better tap growth opportunities in this way.” EM
KraussMaffei Brand & markets fIRST TeCHNoloGy-SPaNNING eNeRGy aNalySIS “BLUE powEr” MEETS “THINK BLUE. FAcTory.” It was a first: Together with Siemens, KraussMaffei carried out an extensive, energyrelated machinesystem analysis for Volkswagen. The goal was to evaluate the energy consumption associated with the production of instrument panels. The holistic inspection of the complex process provided the fundamental principles for further optimization of the processes, the drive technology, and the thermal budget. The production lines for instrument panels are highly complex structures. The overall process incorporates several different processing techniques and automation components. In order to be able to work economically and in a way that makes efficient use of resources and energy, the separate process steps must first be aligned with each other in a manner that cuts across different technologies. Concrete measures can be derived from the product-specific total energy consumption. Several analyses of this nature have already been carried for individual injection molding machines and extrusion lines. But Volkswagen, Siemens, and KraussMaffei were the first to examine an entire production line. Challenging roles As part of the “Think Blue. Factory.” program, Volks wagen has set clear goals for itself in terms of an ecological installation: based on the annual values for the year 2010, the company is planning to reduce the environmental pollution caused by all of its facilities by 25 percent by the year 2018. This applies to the CO 2 emissions, the amount of waste produced, the energy consumption of each vehicle, and the amount of water consumed by the factories. These goals are being met with the help of KraussMaffei’s “BluePower” initiative, which is aimed at the efficient use of energy and resources. Every journey begins with the first step Each optimization process begins with a detailed analysis of the energy consumption of every single consumer load. The list of the included system components makes clear just how important the holistic approach is. In the case of the production line for instrument panels, the list included, along with the injection molding machine and the facility for the production of the slush skins, a prewarming station, a round table with 12 mold carriers (each with a clamping station and an opening), a mixing machine, a metering machine, three robots, several heating units and heaters, and various pumps. A total of 25 measuring devices had to be installed on the round table, after which they had to be connected to a central PC via a WLAN connection, thus enabling data recording. The measurements were recorded over more than ten days so that the energy-related interaction between the system components during downtimes and over the weekend can be recorded. The power consumption levels of various injection units were measured and counters were used to measure the consumption of compressed air and cooling water. The recorded data was used to determine the specific energy consumption of every component. Process management determines the potential for savings The biggest consumer of the round table was the process of tempering the molds, followed by the vacuum supply, the metering system, and the exhaust system. The detailed analysis of different system statuses provided interesting savings potentials. The results can be applied to other productions as they are, after which they are incorporated into the development of new generations of machines. For example, an optimized operation with individual components of the round table that were designed in accordance with the results opened up savings potential of up to 10 percent. The system control unit plays a decisive role in this process: In this case, it is possible to save intelligent processes that control the operational behavior of the system components, depending on the process requirements. The individual measures alone can save up to 30 MWh of electrical energy per annum. MB TaKING CoMPlex PRoduCTIoN SySTeMS INTo CoNSIdeRaTIoN kWh/cycle 2.0 1.85 1.8 1.76 1.50 1.6 1.33 1.4 1.2 1.0 0.72 0.8 0.6 0.61 0.52 0.4 0.2 0 0.14 0.12 0.15 0.10 0.19 0.18 0.07 0.33 0.23 0.22 0.13 0.06 KM130012000Mx KM270024500Mx KM320017200Mx Power consumption [kW] 0.65 kWh/kg 0.60 0.55 0.50 0.45 12:39:02 Poly Iso Pump P 12:39:46 12:40:29 Puming station 12:41:12 Stirring device Pump disc filter Venting Tempering unit Poly Heat exchanger °C Stirring device Pump disc filter Venting Iso 12:41:55 Timeline Tempering unit Heat exchanger °C Compressed air Compressor cooler Hydraulic power pack Chiller for water supply Pump I Mixing head hydraulic ExTENSIvE MEASUrEMENTS AND EvALUATIoNS provide a thorough understanding of the energy consumption that is required by the process and their correlations. 12:42:38 12:43:22 12:44:05 Specific gas consumption Mean value 12:44:48 12:45:31 0.40 200,000 240,000 280,000 320,000 360,000 400,000 9
Page 1 and 2: ahead The CUSTOMeR Magazine Of KRaU
Page 3 and 4: KraussMaffei Contents 4 Technology
Page 5 and 6: KraussMaffei Cover story INNoVaTIVe
Page 7: KraussMaffei Cover story 7 DEvELopI
Page 11 and 12: KraussMaffei Brand & markets 30-yea
Page 13 and 14: KraussMaffei A powerful team: GearX
Page 15 and 16: KraussMaffei Brand & markets ReaCTI
Page 17 and 18: KraussMaffei Brand & markets ITaly
Page 19 and 20: KraussMaffei Brand & markets rELIAB
Page 21 and 22: KraussMaffei Processes & Products G
Page 23 and 24: KraussMaffei Partners & projects 23
Page 25 and 26: KraussMaffei TRade faIR aNd PRoduCT
Page 27 and 28: KraussMaffei Imprint 27 pROpeRTy Ri

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