KM_AHEAD_1_12_E.pdf - Netstal

AheAd
the Customer mAgAzine of KrAussmAffei issue 01.2012
GX SerieS
A new dimension
Automotive induStry
mobility for the future

ediToriAl CoNTeNTs
Dear Readers,
I am very excited to present to you our new customer magazine with its new format
and fresh content. And we have given our magazine a new name: AHEAD.
With AHEAD, we have purposefully chosen a strong title that, for one, clearly
expresses our forward-looking approach in all areas, based on our technological
expertise. It also highlights the competitive edge you gain from the high quality of
our machines and our extensive skills and knowledge base.
Our cover story provides the perfect illustration of how we are moving “ahead” with
our strong and innovative performance. We are taking you to a whole new dimension
of injection molding with our new GX series. In our view, this is currently the
best complete machine concept and its innovative features, the GuideX guide shoe
and GearX locking mechanism, provide distinctive production benefits with regard
to energy efficiency, accessibility and performance.
Because our aim is always to offer you greater added value across your value chain.
For this reason, the KraussMaffei group is strengthening its injection molding activities
worldwide. Dr. Hans Ulrich Golz , a proven mechanical engineering specialist,
has now become President of the Injection Molding Machinery division across the
group ; previously, he has successfully made his mark in the company as the Head
of Extrusion Technology and Managing Director of KraussMaffei Berstorff.
As Vice President Technologies, Dr. Karlheinz Bourdon will now take responsibility
for research and development activities across all divisions as well as process development
and product management. In future, I will have sole responsibility for
Sales in Injection Molding Machinery of the KraussMaffei brand as Vice President
Sales KraussMaffei.
In this way, we will continue to help you develop your competitive edge with powerful
products and technologies in the future. For example with our new industrial robot
series and the product innovation “WizardX”. Or with our 45 years of extensive expertise
in traditional polyurethane processing.
Look forward to fresh and innovative ideas as well as proven KraussMaffei quality,
pioneering and integrated technology system and process solutions in injection
molding and reaction technology and automation. Travel with us to tomorrow’s
world. Join us for the journey AHEAD!
Wishing you an enjoyable read,
Frank Peters
Vice President Sales KraussMaffei
Cover Story
4 injection molding in a new dimension
8 success story
New GX machine makes a compelling
case in production use
9 interview
Dr. Karlheinz Bourdon talks about the
new GX series
BrAnd & mArKetS
10 75 years old and young just the same
12 The 1000th polyurethane mold from
harderberg
13 Around the globe – international trade
show appearances
14 Making the old new
14 Global Technology³ Transfer
15 securely connect to an expert at the
touch of a button
ProCeSSeS & ProduCtS
16 The latest from automation technology
PArtnerS & ProjeCtS
18 A window for the washing machine
20 The 100th CX for the shl plant in Taiwan
21 Mobility for the future
22 The biggest of its kind in the
Netherlands
23 The British are getting a move on
KrAuSSmAffei GrouP
24 interview with Ceo Jan siebert
25 New and strong brand presence
26 The latest from KraussMaffei Berstorff
26 The latest from Netstal
27 KraussMaffei Group appoints dr. hans
ulrich Golz as the new “President”
of the injection Molding Machinery
segment
27 imprint

13
Around the globe KraussMaffei again visited exhibitions all
over the world in 2012.
4
Injection molding in a new dimension The GX series, the
latest generation of KraussMaffei injection molding machines.
18
Contents
A window for the washing machine With a fully automated
manufacturing cell from KraussMaffei, Miele is producing
doors for washing machines.
3

4 Cover story
AHEAD Issue 01.2012
The new injecTion molding dimension
GX Series
Powerful by means of
• Very short dry cycle time
• High precision with maximum dynamics
• Very low energy consumption
User-friendly by means of
• Outstanding accessibility
• Intelligent and user-friendly control system
• Fast mold changeover
Value stability by means of
• Robust clamping and injection unit
• Low maintenance costs
• Simple retrofitting

KraussMaffei Cover story
InjEctIon molDIng In A
nEw DImEnsIon
even more efficient and better work with even higher quality – a truly ambitious goal! once
again we have reached our goal using our decades of experience and by looking through our
customer's eyes and making their needs our own. This was also possible thanks to a few
hundred man hours from our innovative developers and, not least, thanks to the ability of our
engineers.The result premiered in munich: The gX series, the newest generation of Kraussmaffei
injection molding machines. The new injection molding dimension.
TeXT: eva münzenmaier PhoTos: harald mehnerT
T
he GX series complements KraussMaffei's product spectrum
in the area of hydro-mechanical twin-platen machines
with medium clamping force. At first, this classification
sounds very plain. But a massive bundle of innovation
is hiding beneath the surface. The two key components
are called “GearX” and “GuideX”. One thing is certain: The innovative
GearX interlock mechanism and the intelligently created GuideX guide
shoe are setting new benchmarks for injection molding machines in
the mid-range segment.
Just flashy words? Not a chance. Here are the facts and special features
behind these new developments.
The powerful team of GuideX and GearX provides for high article
quality and fast locking A real highlight of the GX series is the
GuideX guide shoe, a cleverly integrated fixed bearing joint that we optimized
with the aid of state-of-the-art development tools (FEM). On
one hand, its stable design is the basis for the machine's outstanding
platen parallelism. On the other hand, the innovative technology
makes it possible to direct the forces to the linear guides in greatly attenuated
form. This keeps the guides protected over the long term and
maintains their precise ease of movement. The movements are optimal
in terms of energy usage and the sensitive mold area protection
can realize its full efficiency.
HIgHlIgHts
The fast gearX interlock and the intelligent
guideX guide shoe are the highlights of the new series.
5

6 Cover story
AHEAD Issue 01.2012
GearX ensures fast locking. The positive locking meshing of the locking
nut in the bar grooves requires only a short flow of force inside the
unit. The enclosed locking unit is located behind the moving clamping
platen and is protected continuously. Due to the tidy and optimized design,
the ejector area remains clear and broadly accessible as usual.
Depending on the need, customer-specific ejector drilling patterns,
ejector plates, boring units or rotary distributors can be placed behind
a moving platen as the situation warrants.
Comfort and efficiency for the entire machine The accessibility of
the clamping area, ejector area and nozzle area as well as control
cabinets and the pump chamber are a high priority for the GX series.
Thanks to the accessible design, the operator works efficiently and
very comfortably at all times. Short set-up times and simple maintenance
are advantages that speak for themselves. GX: This is usability
in a new dimension!
PURE UsAbIlIty
The new splitscreen technology in our mc6 control system shows you all important
production processes at a glance. with just a few clicks you always reach
your goal quickly and easily.
injecTion uniT - clamPing uniT maTriX
Injection units
Screw diameter in mm
sP 1400 sP 2000 sP 3000 sP 4300
55 60 70 60 70 75 70 80 90 80 90 100
machine
model
clearance
kN HxV / mm
GX400 920 x 830 • • • • • • • • • • • •
GX450 920 x 830 • • • • • • • • • • • •
GX451 1055 x 925 • • • • • • • • • • • • *
GX500 1040 x 910 • • • • • • • • •
GX550 1040 x 910 • • • • • • • • •
GX551 1130 x 980 • • • • • • • • • *
GX600 1110 x 960 • • • • • • • • •
GX650 1110 x 960 • • • • • • • • •
GX651 1200 x 1020 • • • • • • • • • *
* Starting October 2012

KraussMaffei Cover story
7
Overall modular design creates flexibility Innovation does not mean
abandoning tried-and-tested designs, however. For KraussMaffei, the
modular structure of the system is part and parcel of this. No matter
which injection unit, clamping unit or drive is needed, the modular
machine design makes it possible to meet every individual requirement.
Due to the fact the machine center always remains at the same
height, the system is compatible with all clamping and injection unit
combinations.
A high-performance injection unit with a proven plasticizing system
We have also retained the tried-and-tested screw system for the
GX series, which ensures a wide range of applications. Our standard
plasticizing unit assures optimal melting quality and high throughput.
Furthermore, as a specialist for special polymers, we offer our
customers a plethora of material-specific plasticizing solutions –
from PC to PMMA to PET, PC/PBT or screws for long fiberglass. Our
plasticizing unit expertise center offers customers almost unlimited
possibilities.
The perfect symbiosis of machine and automation As our customers
already know, KraussMaffei offers machine and automation in a
fully integrated complete system. Machine and handling form a functional
unit in this combination. A uniform protective housing makes the
perfect symbiosis visible on the outside as well. The shared control
system in particular is a true added value for the customer. It allows
both functional units to be controlled on any control panel: Machine
and automation.
PowERfUl, wItH stAblE vAlUE
all of the important interfaces for the mold can be reached easily (left). The
injection unit is the core of our machines. it ensures precision and the highest
possible process stability (right).
The new MC6 control system with SplitScreen and Eco function
In the MC6 we have developed a control system that accommodates
your needs for usability in every respect. It is clearly laid out and unbelievably
easy to operate. Whether you are working with a KraussMaffei
control system for the first time or you are accustomed to its MC5
predecessor – MC6 technology is so intuitively accessible that you will
hardly notice. In keeping with our overall energy-efficient design, the
MC6 control system has what is known as an Eco button. This allows
you to configure the machine in the most energy-optimized manner at
the touch of a button. The new “SplitScreen technology” shows the operator
all important production processes at a glance. It almost never
takes more than two clicks to get where you want to go quickly and easily.
This is usability in a new dimension as well.
Curious? Get to know a bit more about the GX.
YOUR CONTACT
götz scheibe
Product and Technology management
Kraussmaffei Technologies gmbh
goetz.scheibe@kraussmaffei.com

8 Success story
AHEAD Issue 01.2012
success sTory
nEw gX mAcHInE mAkEs A comPEllIng
cAsE DURIng UsE In PRoDUctIon
waFa Kunststofftechnik field-tests the gX series successfully for several months
Manufacturing components with premium-quality chrome and coated
surfaces is the core area of expertise for WAFA Kunststofftechnik
GmbH in Augsburg. In particular, small process windows during
chrome-plating place very high requirements on consistent, uniform
process and article quality without defects as early as the injection
molding stage. A field test over several months confirmed that the
new GX machine from KraussMaffei fulfilled the stringent requirements
perfectly.
Since 1962, WAFA Kunststofftechnik in Augsburg has been manufacturing
technical parts made from plastic, in addition to surface finishing
and manufacturing glass and metal jewelry. Their core industry
is manufacturing and surface finishing high-quality plastic
parts. At the main plant in Augsburg, the company produces coated
and chrome-plated parts and assemblies at 44 injection molding machines,
predominantly for the automotive industry. “Due to stringent
requirements for the production process and for the component, the
company was deliberately selected for field testing in ongoing production
operation,” said Dr. Daniel Ammer of KraussMaffei. A new
GX 550-4300 was delivered to WAFA in October of 2011. “The high precision,
speed, modularity and high usability completely convinced us,”
enthused Wolfgang K. Müller, Owner and Managing Director of WAFA.
“KraussMaffei once again raised the bar for the high quality of their
injection molding machines with their new GX series.”
gAbRIjEl josIfoskI
manager of the injection molding Technology center at waFa
Chrome-plating requires the highest possible component quality
Even just after delivery, the machine made a compelling case for itself
to the people responsible for production at WAFA. It persuaded them
with its robustness, reliability and easy accessibility. As a result, the
machine was integrated right into daily three-shift production. “The
GX series surpassed our expectations, even during demanding continuous
operation,” said Robert Wengenmayr, Quality Manager at WAFA.
“High product quality with uniform process consistency was evident in
the excellent production numbers and low rejection rates. Dry cycle
time was very low.” For example, trim strips for the automotive industry
made out of ABS and PC/ABS were produced on the machine.
These parts were then chrome-plated right at WAFA. Due to the direct
connection of these in-house processes, the employees at WAFA
very quickly recognized the links between product quality during injection
molding and the possible defects that can result after chromeplating.The
GX machine scored points with above-average product
quality, particularly with very few article defects such as entrapped
air, streaks or other imperfections. Such defects are often not visible
on the injection molding part until they become apparent during the
chrome plating process and the part needs to be discarded. This is all
the more frustrating at that point, since all of the value creation has
already taken place.
Modular design for customized production cells Many of the parts
produced and chrome-plated by WAFA are strips or frames. They are
used as design elements in automobiles and, due to their thin geometry,
are lightweight but have enormous dimensions that require large
molds. Thus WAFA's ideal injection molding machine requires large
mold mounting dimensions and, subsequently, a large clamping unit
combined with a small injection unit for low shot weights. Today, usual
adaptations with smaller barrels only lead to limited success since
the overall system of hydraulics and mechanical parts has been optimized
for other sizes. With additional degrees of freedom for combining
an injection unit, a clamping unit and a module, the expanded
modular design of the GX series allows optimal adaptation to the production
requirements – as the results prove. Furthermore, the machine
is equipped with a type LRX 250 linear robot, the basic component
for economical manufacturing cells. This removes the sensitive
articles, places them on a cooling/conveyor section and separates the
sprues as needed. Furthermore, the robot ensures that conditions regarding
demolding time and cycle time remain consistent and thus
has a positive influence on process conditions. The uniform paneling
system for the machine and robot from one casting is also new. It is
certainly a great visual - as well as functional - addition.
“KraussMaffei has created a top-quality machine in the GX, which literally
opens new dimensions. Modular design, high performance and
outstanding precision combine to form one user-friendly machine –
a great performance!” stated Wolfgang K. Müller in praise of the development
team. MB

KraussMaffei Interview
injecTion molding in a new dimension
fIRst-clAss
mAcHInE DEsIgn –
tHE bEst REsUlts
world premiere in mid-may in munich. Kraussmaffei
presented impressive six machines from its new
gX series. with these, the company is expanding
its product portfolio in the hydro-mechanical twinplaten
machine segment in the mid-range clamping
force segment. dr. Karlheinz Bourdon, vice President
Technologies, talks about the new gX series and
its advantages for customers.
The inTerview was conducTed By marKus BeTsche.
AHEAD: you talk about a new dimension of injection molding. what
makes the new gX series so special?
Dr. bourdon: we talk about a new dimension because customers can
use the machine to get the best results from their production. To me,
the machine represents the best overall design on the market. it offers
the highest injection molding capability in regard to speed, precision
and modular design and it's setting new benchmarks regarding
performance, usability and value stability. it is a cut above due to its
one-of-a-kind and intelligent product innovations, the gearX interlock
mechanism and the guideX guide shoe.
AHEAD: can you explain the benefits of gearX and guideX for our
customers in more detail?
Dr. bourdon: during production use, gearX excels with a fast interlock
and, subsequently, short cycle times. The guideX’s innovative design
reduces friction and isolates force effects and deformation during
movements and clamping force build-up. This results in longer service
life and energy efficiency. we paid special attention to good accessibility
and simple operation for the compact clamping unit in order
to minimize set-up times as much as possible. due to the modular
design, the machine can be combined with all available injection units
individually from an extensive construction set. even the drive module
can be selected according to production requirements. our tried-andtested
plasticizing units and injection units with state-of-the-art control
technology are used for material processing. overall, the gX offers
high efficiency and productivity due to speed and a short cycle time as
well as a maximized number of good parts due to process parameters
that are stable over the long term.
AHEAD: which target groups are the focus of the gX?
Dr. bourdon: in the gX series, we offer an excellent injection molding
machine for all industries and regions. The modular design and its
speed meet the highest customer demands and allow an ideal adaptation
to all production requirements. To start with, machines with 4,000
DR. kARlHEInz boURDon is convinced of the gX series' success.
to 6,500 kn of clamping force in various dimensions are available and
can be combined with screw diameters of 55 to 100 millimeters. The
gX series is outfitted with our excellent twin-platen technology, which
allows a fast closing movement.
AHEAD: what are the advantages for the operator?
Dr. bourdon: with generous bar spacings and mold mounting dimensions,
the readily accessible gX machines enable short set-up times
and thus an increase in production time. with the integrated automation
solution, the customer receives a truly all-in-one production
cell. visually and functionally. in addition, the machine and robot are
operated together using the intuitive mc6 control system. The readily
accessible and visible machine simplifies the operator's work and
the clearly arranged mc6 supports the operator with many helpful
functions. This prevents operating errors, helps during faults and effectively
decreases production interruptions.
AHEAD: How energy-efficient is the gX series?
Dr. bourdon: during development of the gX series, we applied our
experiences from a multitude of energy considerations and designed
the machine components in the best possible way in regard to energy
efficiency. For example, linear guides for the clamping platens reduce
friction during clamping unit movements. control pumps also come
standard on the machines. Furthermore, all of the modules from our
“BluePower” product line are available for the gX as well. and with
the mc6’s eco button, the machine switches into the most energyconserving
production state automatically. Thus the gX series is setting
benchmarks in this regard, too. it's something i can't emphasize
enough: it is the best machine design on the market.
9

10 Brand & markets
AHEAD Issue 01.2012
Brand & markets
PolyureThane (Pur)
75 yEARs olD AnD
yoUng jUst tHE sAmE
Kraussmaffei has process and machine expertise from 45 years of experience.
TeXT: marKus BeTsche PhoTos: harald mehnerT
HP-Rtm systEm
laboratory production system for the hP-rTm process
consisting of a rimstar thermal metering unit, a hP-rTm
mixing head and an sFT-mX600 mold carrier

KraussMaffei Brand & markets
P
roducts made from polyurethane, commonly just referred
to as PU or PUR, are a part of our daily plasticbased
lives that can no longer be ignored. There are literally
thousands of different types of polyurethane. All of
which are fundamentally derived from an additional polymerization
reaction between isocyanate and polyols. In the process,
the multi-faceted chemistry allows almost unlimited property
profiles for the finished components, from soft foams like auto mobile
seat cushions to extremely light, high-strength carbon fiber composites.
Polyurethane finds use in almost every industry and application
area. It is a little-known fact that polyurethane actually
represents a very young class of materials. Polyurethane's “birth
certificate” is German Imperial Patent DRP 728,981 with priority dated
November 13th, 1937. Inventor Otto Bayer was, one could say, the father
of all types of polyurethane, which saw the light of day for the first time
75 years ago. PUR has been unlocking more and more new applications
ever since and the end of this development is not in sight.
KraussMaffei starts machine production at record pace
KraussMaffei has been working with polyurethane chemistry and the
necessary associated machines and systems for 45 years. And this
makes KraussMaffei a pioneer in regard to the use of this material
for plastics production. The starting gun went off in 1967 and just one
year later, KraussMaffei was active on the market as a machine supplier.
In the process, KraussMaffei focused on high pressure processing
of PUR from the beginning. In close cooperation with raw material
manu facturers and processors, new fields of application, machines
and methods were being developed constantly – in rapid succession.
You can find more information about some important events regarding
our performance and innovation strengths in the adjacent list.
Show of expertise at the NPE 2012 trade show Just in time for the
anniversary, the trade show location in Orlando made possible a live
demonstration of polyurethane processing at NPE 2012. For the audience
of American professionals, KraussMaffei demonstrated the
manufacture of an armrest using the SkinForm method. In one machine,
the injection-molded carrier was flow-coated with a foamed
aliphatic type of polyurethane from Bayer MaterialScience with pleasant
surface characteristics and outstanding UV resistance. “Krauss-
Maffei's extensive Technology 3 expertise across the entire process
chain was apparent at this machine” said Nicolas Beyl, Head of the
Reaction Process Machinery Division at KraussMaffei. “The machines,
automation, mold technology, and custom solutions were all
from our company and unified our expertise.” In the USA, KraussMaffei
Corporation and Proper Group International of Warren, Michigan have
been cooperating since 2010 as part of a strategic partnership for
turnkey solutions for processing polyurethane.
YOUR CONTACT
nicolas Beyl
head of reaction Process machinery division
Kraussmaffei Technologies gmbh
nicolas.beyl@kraussmaffei.com
nIcolAs bEyl has been the division head of reaction Process machinery
since 1 February, 2012.
45 years oF Pur aT KraussmaFFei
1967 First developments and trials for manufacturing
polyurethane furniture
1968 First special clamping unit with two rotating axes,
called “moon-swing”
1970 Presentation of the first Kraussmaffei mixing head
in successful production use
1972 First self-cleaning mixing head in the world with a recirculation groove
1973 export of the first Pur bumper system for an
automotive industry customer in the usa
1974 delivery of the 100th Pur metering machine
1981 delivery of the 2,000th mixing head
1982 First transfer mixing head in the world and first twin-piston
metering machine
1984 First dual hardness soft foam system
1985 delivery of the 50 KK machine with metering outputs
of up to 8,000 cm³ per second
1989 largest piston metering machine in the world with up to 16,000 g/s
1991 development of the Pur recycling process; unveiling
of continuous gas charging
1992 The in-mold coating process for an undercoat
in a foam mold is presented at the K trade show
1993 systems for cFc-free foams
1995 initial presentation of the lFi Pur process unit at K
1996 start of lightweight design activities, first system for grP components
1999 lFi production system for the smart roof
2002 Founding of the “white goods” expertise center in abbiategrasso, italy
2005 First skin spray head in production use
2004 The skinForm method is presented at K for the first time
2005 start of mold-building activities for Pur,
milling and custom solutions
2006 development and presentation of the first small-quantity, high-pressure
mixing head
2007 skinForm large system for manufacturing interior door panel sections at K
2010 Presentation of the colorForm process at K
2011 complete hP-rTm system for manufacturing cFrP components;
opening of the largest Techcenter for fiber composite technology (lightweight
construction) in the world in munich
2012 45 years of Kraussmaffei reaction process machinery; First
live demonstration of Pur processing at nPe in the usa
11

12 Brand & markets
AHEAD Issue 01.2012
Tool and mold consTrucTion
onE-tHoUsAnDtH PUR molD fRom HARDERbERg
in april of this year, the one-thousandth mold was produced in harderberg and delivered to the
eppendorf company, a loyal customer from germany. The mold was for foaming the steel vessel
interior and exterior for centrifuges.
The business relationship with Eppendorf Zentrifugen GmbH in Leipzig
has been in place since 2008. The company is part of Hamburg-based
Eppendorf Group, which employs more than 2,500 employees world
wide. The biotechnology company was founded in 1945 and deve lops,
produces and sells systems for life science research in laboratories.
The product selection includes pipettes, dispensers and centrifuges
along with consumables such as reaction vessels and pipette tips.
Eppendorf's mission also includes providing high-quality support. In
the sample handling product area, the company deals with heating
and cooling, freezing and mixing and with instruments for photometry.
Eppendorf's high-quality centrifuges are well-known. With their performance
and with the help of a proprietary “epGreen” concept, these
centrifuges have set a new laboratory standard - including in terms of
energy consumption.
Partnership due to quality Up to this point a total of 15 molds have
been delivered to Eppendorf for a wide variety of foaming applications.
This loyalty confirms our customer orientation and the excellent high
quality of the delivered molds. Requirements from laboratories designing
the centrifuges were taken into account in close coordination
with experienced process optimization staff at the heart of production
at Eppendorf. Appropriate production solutions were developed for the
requirements together with the mold specialists from Harderberg.
“We can completely depend on the quality of the molds produced by
KraussMaffei,” confirmed Dr. Matthias Schmidt, Production Manager
of Eppendorf Leipzig. “The molds are delivered as scheduled and they
can always be put right into production, where their longevity and dependability
shine through.” But Eppendorf does not just rely on molds
from KraussMaffei, they also rely on mixing and metering machines
and mixing heads for processing polyurethane.
Successful balance In just the past seven years, tool and mold making
in Harderberg has developed impressively. After starting with
three employees expansion has been constant. By 2010, the production
space had already doubled to 2,700 square meters in order to
meet skyrocketing demand. “The decision for the Harderberg location
due to the specialist expertise available there was the right one
and has proven itself to this day,” confirmed Rainer Janotta, Factory
Director in Harderberg. Today, about 70 employees work at the location
in Harderberg and produce molds for processing polyurethane,
predominantly for the automotive industry. But, as the “anniversary
mold” shows, approximately one-third of the molds go to other industries
such as construction, electrical and medicine.In the process,
two completely separate project rooms in the TechCenter allow
for simultaneous mold proving for different projects with absolute
secrecy. MB
sElEctED EXAmPlEs of tHE PRoDUcts DElIvERED to EPPEnDoRf
• “Anniversary” mold for foaming centrifugal vessels (interior and
exterior wall made of steel)
• Foaming tool for IMC (in-mold coating) semi-rigid structural foam
component with steel insert
• RimStar Compact 16/16 mixing and metering system with outrigger,
barrel station for rigid foam products
• RimStar Compact 40/16 mixing and metering system with outrigger,
barrel station and modular minidos color-metering unit for semi-rigid
structural foam applications
YOUR CONTACT
rainer janotta
harderberg Plant manager
Kraussmaffei Technologies gmbh
rainer.janotta@kraussmaffei.com

KraussMaffei Brand & markets
eXhiBiTions
ARoUnD tHE
globE
Kraussmaffei again visited exhibitions
all over the world in 2012.
PLASTINDIA
Strong presence in growth markets
Injection molding machines for customers
from the packaging industry were the focus
of the trade show appearance in India. The
state-of-the art CX 110-380 ClassiX made
its debut at PlastIndia with the proven twinplaten
clamping system as the visitor magnet.
In live operation, it produced caps for yogurt
bottles at the booth. Injection molding
technology was also the focus for trade fair
visitors as part of Interplastica in Moscow as
well. There, customers from pharmaceutical
companies in particular were the target audience
for the all-electric EX 150-750 Clean-
Form model. At the trade show stand, twistoff
bodies made from polypropylene were
produced in a 24-cavity mold.
NPE2012
Conquest of the North American
packaging industry
At the NPE2012, KraussMaffei presented
highly productive injection molding cells
consisting of hydraulic or all-electric machines
of the CX, EX and MX series in conjunction
with fast robots. Great customer
interest was attracted by the live operation
of the MX 650+, which is compliant with the
specific requirements of American packaging
customers in packaging production technology.
In the injection molding technology
area, an MX SpinForm reversing plate machine
with integrated assembly technology
attracted the interest of the specialist audience.
It enthused visitors to the trade show
stand with production of ready-to-use threepart
plastic closures. KraussMaffei presented
the all-electric EX series especially for
the pharmaceutical industry and illustrated
the implementation of the stringent requirements
for clean-room production.
CHINAPLAS
“Open house” and cooperation with the
industry of the future in China
At the Chinaplas trade show in Shanghai, the
focus was on special solutions for injection
molding customers. KraussMaffei proved to
be a highly skilled technological partner for
the profile extrusion and C-PVC processing
industries. In the scope of an “Open House”
in the nearby KraussMaffei Group production
factory in Haiyan, KraussMaffei demonstrated
the assembly of an MX series injection
molding machine to its customers at the
Chinaplas. The opening of the “KraussMaffei
Technology Center,” in cooperation with
Chinese company Foxconn from Shenzhen,
also contributed to expansion of our presence
on the Chinese market. Working with the
Apple supplier, technology for the electric and
electronics industries was developed on four
machines of the CX and MX series here.
PLAST MILAN
More market share in the highly
competitive Italian market
Efficiency and resource conservation are increasingly
the focus for Italian processors
when making their investment decisions.
KraussMaffei is ideally equipped to meet
these demands, and presented its customers
at Plast Milan with exciting AX and EX series
machine technology in all-electric design
and various products dealing with technological
expertise for premium quality surfaces
and lightweight solutions. “Of particular
interest in this regard is the design of the
MX600 mold carrier with injection molding
technology components,” explained Frank
Peters, Managing Director of the Reaction
Process Machinery Business Unit at Krauss-
Maffei. “Its modular concept makes use of
proven components and the advantages of
injection molding machine series production
to create application-specific solutions.” EM
13

14 Brand & markets
AHEAD Issue 01.2012
mAkIng tHE olD nEw!
Even the injection molding machines with the longest service life
eventually get old and lose performance due to wear and tear. In addition,
an older technology can sometimes no longer hold up against
state-of-the-art machines. For processors, the question arises here:
should they invest in a new machine or overhaul and modernize their
machine park? In the latter case, the colleagues at KraussMaffei Service
help with their competence and expertise in older machines as
part of life cycle management. The modernization of existing machines
is an economically interesting alternative, particularly for existing
production facilities with extensive infrastructure. Planning is
everything in this. The service team not only advises companies during
repairs, but also develops a solution for how this can be done during
running production without impeding utilization and quality. The
lower costs in comparison to a new acquisition are not the only feature
that makes a modernization attractive for the customer. Because
mechanical measurements and interfaces remain unchanged, no new
peripheral devices have to be purchased. The present logistics also
remain intact and identical. Good reasons to decide in favor of a modernization.
We are happy to advise you! MB
jocHEn mItzlER
director of Product and Technology
management at Kraussmaffei munich
comPleTe renovaTion oF injecTion molding machines
• Low downtime for modernization
• Good planning security in production
• Logistics in the plant remain intact
• Peripherals can remain completely intact
• Low costs in comparison to a new acquisition
YOUR CONTACT
ralph lindner
manager, used machines and refurbishing
Kraussmaffei Technologies gmbh
ralph.lindner@kraussmaffei.com
globAl
tEcHnology³
tRAnsfER
Premium quality surfaces, functional integration,
production and energy efficiency are becoming
increasingly important. But what does this mean
for processors, and how can Technology³ solutions
from Kraussmaffei contribute to optimization?
interview with jochen mitzler, director of Product
and Techno logy management for injection molding.
inTerview conducTed By marKus BeTsche.

KraussMaffei Brand & markets
sEcUREly connEct
to An EXPERt At tHE
toUcH of A bUtton
Highly integrated manufacturing cells bundle
process steps and make use of synergies,
yet the demands on service support increase
with the complexity of the systems. Krauss-
Maffei's teleservice concept shows how simple
the solution to this can be: A simple click
on the control panel of the machine control
system, and the connection to one of our
product specialists is already established.
sERvIcE
Kraussmaffei teleservice is an
all-in-one solution consisting
of technology and support with
which our experts have direct
access to all system components.
AHEAD: How can processors achieve a higher efficiency in the
production process?
mitzler: in order to improve production efficiency for the long term,
three major levers are available: material efficiency – resource efficiency
– energy efficiency. Behind them stands our approach: to
manufacture a maximum of premium-quality good parts with lower
material consumption at smaller production equipment capacities and
with low energy consumption. if the articles produced also possess
excellent properties that for example are not possible with classical
methods, this vastly raises the production efficiency.
AHEAD: with which methods can efficiency be increased?
mitzler: i have a good, current example for this: with the Kraussmaffei
spinForm injection molding machine, for example, three-part
plastic closures are produced in a single machine and brought
together in the mold area by means of the integrated Tim-stack installation
equipment. ready-to-use closures come from the machine
and are directed to further production. Together with moldmaking
company zahoransky, we have designed the entire system for
maximum productivity. For maximum energy efficiency, we use our
“BluePower” servo pump drive and an electric sliding and rotary unit.
advantages for the customer are a low production space requirement,
better part quality through a combination of identical cavities with the
same process values and the omission of buffer storage.
KraussMaffei
INJECTION
MOLDING
TECHNOLOGy
elecTrical
sysTem
Thanks to fast and secure data connections,
our experts are quickly and directly available
to help you with your concern and can access
all system components individually. From
the time the service request is received, our
service technicians automatically have all
machine-specific technical documents available.
During machining, service technicians
have access to the machine control system
asks service
questions
KraussMaffei
AUTOMATION
customer
kraussmaffei
teleservice
offers
global service
via vPn and
internet
service aPPlicaTion
soFTware
and all remote-capable peripherals in order
to carry out diagnostics and provide support
with process and machine settings. If absolute
expert knowledge is needed, the departments
are involved in machining via the secure
internal factory network. Unbeatable
advantages of teleservice: Fast and efficient
help, with the entire KraussMaffei expert
team if needed – globally. MB
AHEAD: How can our customers in far-off regions
take advantage of this technology?
mitzler: Kraussmaffei is represented worldwide by its extensive sales
and service network. we push the technology transfer from the development
centers into all regions and present the new developments locally
to the customers and processors in trade shows, conventions and
conferences on site. also with our own technology events, such as our
successful “competence tour” in Korea or our “competence forum” in
munich with live demonstrations. of course, as the project progresses,
our experts also come directly to the processors in order to discuss the
possibilities and advantages of these procedures in detail on the physical
product.
6. congress on PlasTics in e&e aPPlicaTions
KraussMaffei
REACTION
PROCESS
MACHINERy
KraussMaffei, with other partners including the SKZ, a South German
plastics trade association, is organizing the comprehensive trade meeting
“Fuse box meets dryer” being held on June 14 and 15, 2012. The
venue is the Tageszentrum Festung Marienberg conference center in
Würzburg. The convention is taking place for the sixth time.
This year, the trends in new materials, innovative procedures and prod-
uct design will be discussed. Topics will also include the most impor-
tant future technologies in the E&E industry, e-mobility and renewable
energy.
15

16 Processes & products
AHEAD Issue 01.2012
Processes & products
oPTimizaTion
tHE lAtEst fRom
AUtomAtIon tEcHnology
since the company was founded by josef neureder in 1982, Kraussmaffei has
planned, designed and manufactured automation solutions for the injection molding
processing industry based on linear and industrial robots, and the prospects
continue to be rosy.
TeXT: marKus BeTsche
Efficient
Faster production starts and shorter
delivery periods. customers get these
advantages from our optimized manufacturing
concept.

KraussMaffei Processes & products
o
nly a short time after the completion
and start of production in the
new assembly hall at the Schwaig
location in December 2011, it is
already working at full capacity.
The steady, high demand for premium-quality
automation solutions confirms the added
value of efficient manufacturing cells that result
from the consistent convergence of robots
and injection molding machines. The expansion
of the production area came at just
the right time. In only six months, the floor
space was more than doubled. “This achievement
was only possible with the professional
project management and the high level of
dedication of the employees in Schwaig,” said
Thomas Marufke, Head of Sales and Finance
at KrausMaffei Automation. “I am pleased
that our customers also honor our timely and
goal-oriented working methods with professional
project management.” With the move
into the new hall, the manufacturing concept
was also optimized. With standardized processes
and the compilation of pre-checked
components in the final assembly, the goals
and expectations set were vastly exceeded.
First-class service from a single source
Along with optimizing the production processes
and continuously refining the automation
products, KraussMaffei works continuously
on further expanding the already
excellent service network for robots and automation
products. For this purpose, the
first-level support provided by the national
organizations at the user's location is being
strengthened. These are the “first responders,”
the first after-sales service technicians
at the customer's location, who provide
support for the machines and robots and usually
resolve the situation for the owner/operator
quickly and successfully. The on-site colleagues
get assistance from second-level
support, made up of the specialists and experts
for automation technology at the factories.
They support the on-site service people
“This excellent result could only
be achieved through the outstanding
dedication and effort by
the automation employees.”
Thomas marufke
with expert advice, remote diagnostics and,
if needed, also with their presence on site. In
the scope of the increasing internationalization
of the projects and orders, the service,
consulting and project engineering in the regional
offices is also being expanded. For example,
the KrausMaffei Corporation (KMC)
project engineering experience will be available
at the beginning of the NPE trade show.
The front-end salespeople from Florence, Ky
will be supported on the project level by an
experienced automation specialist.
Further growth is anticipated The great
order situation was not only evident in the
main automation factory. The Schwerin location
also had one of its best years ever
in 2011. The high number of incoming orders
for large linear robots was extreme for
the space-limited plant. “Our colleagues in
Schwerin handled these challenges masterfully,”
said Marufke, “and once again I would
like to thank all the employees at this location.”
Due to the high utilization and the great
and stable project situation, an additional expansion
of the production capacity and facilities
is planned.
The new IR series with easy-to use user interface
The market introduction of the new IR
series is happening at the same time as the
presentation of the GX injection molding machines.
This IR series offers a convincing new
mechanic and kinematic system that is ideally
adapted to the needs of the plastics processing
industry, particularly for clamping forces
over roughly 5000 kN. Additionally, the type
family was expanded from 10 to 20 basic units
in order to better satisfy demand for customer-specific
production solutions. The now
doubled range of offerings of standard combinations
makes possible an even more exact
match to the optimal working point of the production
cell with regard to robot range, working
range, payload and installation area. In
conjunction with the new GX series, machines
and robots have the new MC6 control system,
a fully integrated, optimized user interface for
both devices. Customers and operators alike
benefit from a simple and user-friendly user
interface for machines and robots with a typical
KraussMaffei look and feel.
No wizardry required – the programming
assistant “WizardX” For the KrausMaffei
linear robots with MC6, there is a supplement
to the proven offline programming tool:
a new online programming assistant called
“WizardX.” It makes programming the robots
enchantingly simple. The system recognizes
programming mistakes and provides effective
help for program creation with intuitive
operator guidance and visual representation
– quickly and easily. After the end of the
first development step, the programming assistant
is ready in function-tested form. The
second phase, detail optimization in production
operation, is currently underway. This
step is being carried out in close cooperation
with select customers and partners. WizardX
is expected to be available in the final version
in the middle of this year. The steadily growing
number of standard industrial robot (IR)
applications also leads to increased demand
for simplified programming. As a result, the
next step planned is the introduction of the
WizardX for the IR series.
YOUR CONTACT
Thomas marufke
head of sales and Finance
Kraussmaffei automation ag
thomas.marufke@kraussmaffei.com
17

18 Partners & projects
AHEAD Issue 01.2012
Partners & projects
A wInDow foR tHE
wAsHIng mAcHInE
with a fully automated manufacturing cell, miele is making doors for automatic washing
machines in the warendorf, germany plastics plant. The doors are in premium quality
and correct plastics design, without visible bolts. while doing so, the company relies on
the process consistency and reliability of the cX series from Kraussmaffei.
TeXT: marKus BeTsche
Precision
The finished, installed washing
machine door from miele

KraussMaffei Partners & projects
miele has over 40 years of experience
in the manufacturing of
plastic parts in their own production,
which since 1974 has been
located at the plant in Warendorf,
Germany with a production area of approximately
10,000 square meters. Here, about
three million parts are built per month by
220 employees; this corresponds to about
70 percent of the company’s total demand. Of
the 44 total injection molding machines in the
clamping force range of 800 to 10,000 kN, over
two thirds are from KraussMaffei. All machines
are equipped with robots that simultaneously
do tasks like imprinting, packing
and buffering. From the final device assembly
comes the demand to get more finished function
components delivered, which leads to a
trend of further assembly directly at the injection
molding machine. With function groups
such as dryer floor assembly modules, the filter,
cover, and other metal and plastic parts
are, in some cases, assembled automatically
and delivered to the final assembly as a complete
module.
High-gloss finish in one piece The “Sophia”
washing machine door, which is available
in various appliance series,
is an example of how appealing plastic parts
with a good design can be. High-gloss finish
with depth effect and closed surfaces without
visible bolts are the outstanding features of
the entire line. In addition, the door is superior
in strength to its predecessors, which were
made of metal. The complete door consists
altogether of 11 parts made of plastic, metal,
glass, and rubber and is easily assembled in
a complex but very compact manufacturing
cell made of three injection molding machines
with automation based on modular manufacturing
sections. “The high surface demands
on the visible parts and the very low intermediate
buffer with 10 to 14 parts in the system
require the injection molding machine to be
highly reliable with high article quality. In this
respect, KraussMaffei machines have performed
outstandingly through the whole line,”
said Dr. Jürgen Jahn, Plant Manager at Miele.
Reliable and precise Everything begins
with the injection molding of the front panel
ring on a SpinForm CX 650-2700/2700 reversing
plate machine, which is later visible
on the outside of the washing machine. This
consists of an approximately 3 mm thick
polycarbonate part which is over-molded
with gray ABS after opening and rotating
the middle plate. This results in a scratchresistant
component with an enormous
depth effect that has an impressive design.
The electric-powered sliding and turning
unit makes fast and precise movements
for short cycle times and a pronounced
high positioning accuracy, which has a positive
effect on the access point. After a short
cooling/conveyor section, the sprue is removed
automatically by milling, the edges
are rounded with hot air in order to eliminate
the possibility of injuries, and subsequently
a film is applied to protect against
scratching.
In the meantime, a CX 420-3000 injects what
is called the basic carrier made of glass-fiberreinforced
polypropylene, which is responsible
for mechanical stability and fixes the
fastening elements and the inspection glass.
After the injection molding process is done,
it is followed by installation of hinges, bushing
and axes and the fitting of the inspection
glass, which is fixed and bonded with a clamping
ring, also in an automatic process. On the
third machine, the high-gloss ABS inner trim
panels are finished and are also routed to the
final installation step.
Three become one In the central assembly
cell, the pre-assembled parts from the
three injection molding machines come together.
The basic carrier and front panel
ring are glued with polyurethane and locked
additionally. For quality control and traceability,
a designation is applied and at the
end, the inner trim is equipped with a closure
and closing piston. A complete washing
machine door is finished. This peak
achievement with regard to design engineering,
production engineering and using
the correct plastics for the job was recognized
by the Verband Technische Kunststoff-
Produkte e.V with the TecPart Innovation
prize in 2010. At Miele, they are particularly
proud, as the entire assembly concept
and the higher-level control system were
devised in-house. This demonstrates the
Warendorf plastics specialists' extensive
automation expertise and longtime experience
in factory automation.
Simple solutions with large effects All three
injection molding machines are equipped
with cylinder and pipe insulation in order to
prevent unnecessary heat emission where
logical and feasible in terms of process technology.
The BluePower set of electric drives
for selected functions, such as an electric
plasticizing unit drive, increase the precision
and energy efficiency of the machines even
more.
Flexibility as a challenge Another core business
in Warendorf is manufacturing premium
quality vacuum cleaner housings. For
this, the surface quality in particular is the
focus. Additionally, various variants and colors
are needed for the housings. Each day,
approximately 18 mold and material changes
take place in addition to the color changes
for similar components. A fast flushing of the
plasticizing unit is mandatory in these processes.
Therefore, the newer KraussMaffei
HPS-AT machine screws without mixing and
shearing parts are used to allow fast material
change, and they simultaneously ensure
an excellent coloring and material homogeneity
in production.
KraussmaFFei services
• SpinForm reversing plate injection molding
machine CX 650-2700/2700
• Injection molding machine CX 420-3000
• Linear robot LR 300 in cantilever arm version
• BluePower cylinder isolation
19

20 Partners & projects
AHEAD Issue 01.2012
modern & synchronized assemBly Forms The Basis
For ProducTion involving TighT Tolerances
tHE 100tH cX foR tHE sHl PlAnt
In tAIwAn
shl (scandinavian health ltd.), with over 1,800 employees globally, is the world’s largest privately-owned designer, developer
and manufacturer of advanced drug delivery devices for the biopharmaceutical industry, such as auto injectors, pen injectors
and inhalers. The company was established in 1989 with the goal of combining world-class manufacturing in asia with international
management practices. There are more than 100 injection molding machines at shl’s facilities in asia, with a clamping
force range of 50 to 420 tons. all machines are equipped with either 6-axis or linear robots. machine types range from hydraulic
to hybrid and fully electrical machines, as well as multi-component machines with turntable and indexing technology.
High precision, high capacity When manufacturing single-use disposable
injection systems, such as auto injectors, the quality of all
components must be absolutely identical. Thus, verifiable compliance
with the most stringent quality standards must be guaranteed when
running production 24/7. KraussMaffei’s CX machines, with different
clamping forces, have been certified for their designated scope of
delivery and performance characteristics. The quality requirements
were configured according to the types of components installed and
set within the maximum permissible noise emissions and maximum
tolerances of the shot weight. “With the CX series of machines, we
have further enhanced reliability and continue to produce consistent
high quality components”, emphasizes Roger Samuelsson, CEO and
Founder of the SHL Group, “this has always been a hallmark of SHL”.
High degree of transparency With one of the most modern & synchronized
assemblies with comprehensive documentation, KraussMaffei
has established a transparent basis for manufacturing within tight
tolerances. This allows us to build a machine optimized for producing
molded parts. Where necessary, the machines can also be designed
and qualified according to Good Manufacturing Practice guidelines
which include required documentation. When it comes to producing
molded parts, quality can be distinguished by process reliability and
the exact repeatability of the single components, and this is where
synchronized assembly plays a crucial role. The synchronized assembly
of injection molding machines with clamping forces of 35 to 350
tons means both the assembly and commissioning of each machine
are synchronized in twelve cycle steps. Introduced in 2005, synchronized
assembly has continuously improved thanks to employees’ flexibility
and willingness to work together. This can be seen, in particular,
in the high quality of deliveries and the short throughput times.
We now use KAIZEN, a well-established system, as a general concept
for continuous improvement processes. “Our goal is to achieve the
highest possible customer satisfaction”, explains Michael Müller, Vice
President of KraussMaffei in China, “and an example of our success in
achieving such a goal can be demonstrated by looking at our relationship
with one of our longstanding customers, SHL, where we just delivered
the 100th KraussMaffei machine last December, to their facilities
in Taoyuan, Taiwan”. MB
“ as a global manufacturer of drug delivery
devices for the biopharmaceutical
industry, the key to our company’s success
has been the high quality of our
products. we utilize precise manufacturing
that is proven and reproducible.
and our goal is zero error tolerance, a
goal that our partners must share with
us. Kraussmaffei is a good example of
such a partner.”
roger samuelsson, ceo and founder of shl group

mobIlIty foR
tHE fUtURE
with a large-scale order from Bmw, Kraussmaffei makes
a leap forward as a partner for solutions in the automotive industry
“We are delighted to receive the order from
BMW. We see this as recognition for our longtime,
trust-filled cooperation and our expertise
as an innovative systems and solutions
partner for the automotive industry,” said
Frank Peters, Managing Director of Reaction
Technology at KraussMaffei, expressing his
satisfaction. The order includes the delivery
of numerous injection molding, reaction technology,
and automation machines and systems.
These machines serve to support series
production and the development of innovative
and turnkey process solutions to substitute
conventional materials with plastic.
The machines will be used, for example, to
produce and finish components made of
thermoplastics and reactive resins in the interior
and exterior, as well as for load-bearing
structures. Parts for the vehicle body
will be produced on a total of 9 high pressure
resin-transfer molding machines at the
BMW plants in Landshut and Leipzig. The
main characteristics of the machines are
constant and reproducible process guidance,
as well as high filling pressures for maximum
fiber wetting.
Stable mold carriers In the scope of this
order, the BMW plant in Wackersdorf also
receives new technology from KraussMaffei.
This location gets a large injection molding
machine of the MX 4000-24500 type for
manufacturing stable molded carriers for
the dashboard of the 1 and 3 Series. Here,
what is known as the injection molding
structural foam procedure is used. Components
with compact outer shell and an interior
foam structure are made by this procedure.
Two integrated industrial robots from
KraussMaffei perform the necessary assembly
and follow-up steps. At the BMW
plant in Leipzig, two 4000-ton MX 4000-
17200/12000/750 WL double swivel-plate
machines will produce components with an
outer skin and a thermoplastic substructure.
In this case the outer skin and substructure
will each first be separately injection molded,
joined together as the two swivel plates rotate
and tightly connected with a third plastic
component. A ready-to-use component
is therefore produced at every mold opening.
The machine is fully automated with two
IR industrial robots. Intelligent mold heat-
balancing with impulse cooling is used for
energy-efficient management of the mold's
heat balance.
Convincing expertise that impresses on a
global scale The engineers at KraussMaffei
were able to impress more than just the
Munich-based auto manufacturer with its
technical expertise in injection molding and
reaction technology. As early as the beginning
of last year, internationally renowned
automobile supplier IAC Group from Krefeld,
Germany commissioned KraussMaffei as a
system supplier for equipping their newest
production plant in Bals, Romania. MB

22 Partners & projects
AHEAD Issue 01.2012
hsv Technical molded ParTs (hsv)
tHE bIggEst of Its kInD
In tHE nEtHERlAnDs
everyone in the plastics industry knows that the netherlands have a whole lot more to offer than tulips and cheese.
numerous plastics manufacturers and processors are located there. as in all of europe, the energy debate is in the
focus of the public eye here and regenerative energy sources are gaining increasing significance. in conjunction with this,
the demand for innovative photovoltaic solutions is also rising. Kraussmaffei stood out in this area thanks to its size.
For decades already, HSV Technical Molded Parts (HSV) in the Netherlands
has been the specialist for the development and manufacturing
of large plastic housings for technical devices in the injection
molding process for small to medium series. Moreover, HSV develops
and produces products from recycled plastics that are used in road
construction and hydraulic engineering. One great advantage is the
fact that HSV makes intensive use of not only injection molding technology,
but also thermoplastic foam casting and processing of reaction
injection molding polyurethane (RIM-PUR). This way customers
can be offered the most suitable technology when comparing quality,
investment, and unit price. The production sites in the Netherlands
are in Ede and Leeuwarden.
Large machine with large capacity In Autumn last year HSV expanded
its machine park with the largest (in terms of clamping force) injection
molding machine ever installed in the Netherlands, Type
MX 4000-33000. The technical data alone are impressive: Clamping
force of 40,000 kN – 3,400 x 3,100 mm clamping platens – injection
volume of up to 29 liters. Even more interesting, however, is the
product which is produced on the machine. This concerns what are
called base plates for new photovoltaic modules, which are particularly
suited for industrial buildings with low roof loads. The polypropylene
base plates have a size of 2,100 by 1,430 mm and a weight of
DIMENSIONS
menno Krommenhoek (hsv, right) and mark verveer
(Kraussmaffei) with a photovoltaic base plate in front
of the new install mX 4000-33000.
only 15 kg. The innovative design decreases the roof load and includes
integrated cable ducts and maintenance steps. The stackable base
plates can be transported easily and compactly, which means they reduce
the energy requirements even in transport. An all-around clean
solution for clean power.
“The MX injection molding machines have impressed us in recent
years with their reliability and production consistency,” explains
Menno Krommenhoek, Managing Director of HSV TMP. “It was only
logical for us to again choose KraussMaffei when making the new
investment.”
Plastic makes life more fun By means of the structural foam molding
process, a foam casting technique with low pressure for thermoplastic
plastics, which is excellently suited for manufacturing large
technical structural parts and housings, HSV also manufactures
playground slides for our little ones. In recent years HSV TMP has
gathered a lot of experience with this technique and knows how to use
its extensive possibilities like no other. Thermoplastic foam casting
is particularly suited for medium series and wherever high requirements
are placed on the product's rigidity and surface quality, since
the surface can be easily painted with single or multi-layer high-gloss
paint systems. MB

KraussMaffei Partners & projects
23
sTrong demand For elecTrical and hydraulic machines
tHE bRItIsH ARE gEttIng A movE on
recently, the inactive plastics industry in the uK was referred to as a problem child and was again confirmed as
dead – but as is often the case there’s life in the old dog yet. new life has been breathed into it again by the reinvigorated
automotive industry. classic British traditional brands and internationally successful high sales-volume
models are being manufactured in the uK and are leading to a real boom for manufacturers (oems) and suppliers.
“we are also benefiting as a plastic machine manufacturer”, states mike Bate, head of KmuK, “our high quality
machines are in high demand and we are looking ahead to one of our best years yet“. however, classic growth
sectors such as medical devices are also assisting in a recovery in plastic production. companies are relying on
the competence Kraussmaffei has in machines.
A big player in small batch production ARRK Europe, a big player
in small/medium batch production, ordered and recently began
production on a new injection molding machine type MX 3200-
33000 for manufacturing bumpers and larger moldings at their
toolmaking and injection molding plant in Petersfield, Hampshire.
This step is a clear commitment to further growth, and is based
on steadily increasing customer demand, particularly in the spare
parts business and more technically demanding products. “The
MX 3200-33000 is one of the most innovative large-scale injection
molding machines on the market and offers the best cycle times
available today”, according to Peter Kite, Plant Operations Manager
at ARRK’s Technical Centre Petersfield. “This machine puts us in a
good position to meet the wishes of our customers, now and even
more so in the future”. The machine is fully automated with an industrial
robot IR 2100-100 S/K from KraussMaffei. Royden Morgan,
General Manager at ARRK adds, “We are overjoyed to have one of
the best injection molding machines on the market in our production
facilities, because it is perfectly in line with our strategy of offering
our customers high quality, efficiency and reliability”.
Large-scale plans put into action Unusually high product quality
and customer service are the basis with which the BioPure
In DEmAnD
machines in the mX series are designed
especially for hard continuous use and
win over buyers with their short cycle
times and high product quality.
Technology Ltd., founded in 1998, has managed to achieve sustainable
profitability. In February of this year, the gates at the plant in
Horndean were opened. Thanks to optimized processes, customer
requirements are able to be met even better, at the same time as allowing
for space for further planned expansion. The new plant has
also meant a new step for BioPure – the first steps into in-house
production of innovative bio-pharmaceutical devices, known as “bioprocessing
flow path components” using the most modern of production
equipment. To do this, the company ordered injection molding
machines from KraussMaffei that began production in March.
The machines of type EX 80-380 and EX 160-750 are each equipped
with various CleanForm modules and produce devices in a class 7
cleanroom in accordance with ISO, whereby extensive international
regulations are adhered to. At the same time, the knowledge about
component requirements on the part of BioPure and many years of
experience at KraussMaffei in injection molding in cleanrooms complement
each other perfectly. In addition to equipping the machines
for use in cleanrooms, they are also equipped with “BluePower” cylinder
insulation, which improves the already very energy-efficient,
fully automatic machines even further. With the in-house test laboratory,
BioPure is able to offer its customers additional support with
the validation of its products. MB

24 KraussMaffei Group AHEAD Issue 01.2012
Kraussmaffei group
inTerview
cHAngIng tEcHnology
lEADERsHIP Into
globAl mARkEt
lEADERsHIP
jan siebert has been ceo of Kraussmaffei ag since
january 1, 2012. in an interview with ahead's editor, the
aerospace engineering graduate talked about the potential
of the Kraussmaffei group.
The inTerview was conducTed By imre szerdahelyi.
AHEAD: mr. siebert, for a little more than four months now you have
been at the top of the kraussmaffei group. How would you summarize
the first months?
siebert: The first months have been very positive for me. i have visited
many locations and purposely focused on entering into personal
conversations with employees at all levels. By doing so, i gained a very
good overview of current projects and processes. additionally, i spoke
with numerous customers and business partners worldwide, who have
given me a good sense of their interests. This provided me with a wellfounded
overview of the requirements of the markets and customers.
AHEAD: what made a particular impression on you?
siebert: my customer visits assured me of the great acceptance for
the high quality and performance of the machines and systems of
our Kraussmaffei, Kraussmaffei Berstorff, and netstal brands. This
made a particular impression on me at the chinaplas trade show
in shanghai. i was also impressed by the high level of specialized
expertise of our employees in regard to technologies, procedures, and
applications. That makes us the most treasured partner worldwide at
the side of our customers. additionally, i perceived strong motivation
in the company, passionate commitment, and unconditional striving to
develop the best possible solution for the customer at all times.
AHEAD: now you have the “typical” 100 days in the company behind
you. Are you already able to make some statements about the future
strategy of the kraussmaffei group?
siebert: our strategy for the Kraussmaffei group is in place and we
will now implement it in the company, so i would like to give just a
rough outline here. in principle i see us as very well positioned worldwide.
we will consistently work to strengthen business in the core
markets as well as to expand our presence in the worldwide growth
markets, especially in the Bric countries and asia. an essential
foundation for improving delivery capability is the expansion of our
international production capacities, particularly in china. in addition,
we will concentrate more consistently on being market-oriented
and providing our customers with a range of products and services
that is high-quality and requirements-based, but also affordable. we
jAn sIEbERt, cEo (*1966)
as an aerospace engineering graduate, jan siebert has more than 18 years
of experience in leading management positions with esteemed industrial companies
in the areas of strategy, research and development as well as sales
and marketing.
will stand by our customers with this range of products and services
across their entire value chain and offer them significant added value
with respect to efficiency and productivity.
AHEAD: the kraussmaffei group has distinguished itself with its leadership
in technology and innovation. where do you see potential here?
siebert: here we have a clear competitive advantage and we will
continue to push this forward. as a technology leader, in the future we
will continue to invest in the consistent further development of our
machine and systems engineering as well as in our leading application
knowledge. i see future potential for our technology portfolio particularly
due to processors' efforts toward sustainable and economical
management. This includes resource conservation and material
savings as well as improved energy, process, and product efficiency. in
the future we will continue to develop new trendsetting processes with
which we will make a significant contribution to the economic success
of our customers. along with this, however, i have the task of developing
our technological leadership into a global market leadership.
AHEAD: where do you see the greatest growth potential overall?
siebert: i see numerous global market trends that lead to an increased
demand for high-quality machines and systems for producing
and processing plastic and rubber. along with the described trend
towards sustainability, i see the greatest growth potential in aspects
such as the continuously growing world population and an increasing
rise in the standard of living in growing and emerging countries.
This presents numerous business opportunities for us, including in
the areas of medicine, infrastructure, and the packaging industry for
foodstuffs and consumer goods. The Kraussmaffei group is positioned
very well technologically with its product and service portfolio – and
we want to take advantage of that.

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

26 KraussMaffei Group AHEAD Issue 01.2012
eva Film recycling wiThouT qualiTy ProBlems
EvA fIlms foR solAR moDUlEs
with the new, patented technology of a special flat-film extrusion line, Kraussmaffei Berstorff
offers an exciting solution from an ecological and economical perspective for manufacturing
eva films.
TeXT: Toni niPPe, holger schaarschmidT, ProF. dr. Bernd PolTersdorF
With the new flat-film extrusion system
from KraussMaffei Berstorff, ethylene
vinyl acetate (EVA) films can be produced
at high speeds with a width of up to 3.2 m while featuring optimum
visual property pattern and low shrinkage – even when recycling the
edge trimming.
The fields of application include the rapidly growing photovoltaic industry
where, in 95 percent of applications, EVA films are now used
as standard as encapsulation films for silicon cells in solar modules.
The application in laminated safety glass panes is also interesting
since EVA films are more cost-effective than the polyvinyl butyral
(PVB) that are used today and can be produced more easily.
Tests carried out by the Fraunhofer Center for Silicon Photo voltaics
(CSP) in Halle have proved that EVA films that are manufactured on
the new extrusion system are highly transparent. They feature transmission
in a glass-EVA-glass test sample in the spectral range
PeT acTiviTies
bUnDlED EXPERtIsE In tHE PEt AREA
in 2011 the Kraussmaffei group brought together all of its PeT activities under the umbrella of netstal.
customers benefit from a larger product range.
TeXT: chrisTine groB PhoTo: grouP-inTernal sTocK PhoTo
Both Netstal and KraussMaffei have been working
successfully for years in the global PET market
(PET: polyethylene terephthalate, a plastic for beverage
bottles). We consolidated Sales and Marketing
for the PET-LINE series of the Netstal brand and the PETForm series of
the KraussMaffei brand under one roof. This step was greeted by skepticism
from the industry. “However, our customers quickly realized the
advantages – as shown by the number of orders received,” emphasizes
Thomas Anderegg, Marketing Manager, Sales and Application Technology
at Netstal.
mARkEt lEADERs
in the beverage industry,
approxi mately 80 percent of the
PeT packagings worldwide are
used for carbonated soft drinks
(csd) or non-carbonated water
and juices.
between 420 and 1100 nm of 99 percent. At the same time, the shrinkage
that now occurs has been reduced by up to 45 percent so that it
is now lower than 5 percent. And the highlight of these results is that
they were determined for both a commercial formula for a new product
and for a sample that had been recycled three times.
vERsAtIlE
zeuTX twin-screw
extruder gently prepares
the eva material
Clearly, the larger product portfolio from a single source is convincing.
This way we can configure a system for each customer that is perfectly
tailored to its individual needs. PET-LINE from Netstal is a state-ofthe-art
production system on a platform basis for PET preforms. A wide
variety of mold and cavity sizes can be combined on the basis of three
clamping force sizes: 2000 kN, 4000 kN, and 6000 kN. The advantage is
minimum production costs at maximum output.
The PETForm series of the KraussMaffei brand is also an efficient module
platform for manufacturing PET bottle preforms. With their vertical
clamping unit design and an electric plasticizing unit, the machines
distinguish themselves above all by their high efficiency and excellent
uptime. The low production costs and long mold service life make PET-
Form systems a reliable solution for the beverage industry.

KraussMaffei Imprint
27
KrAussMAffei GrouP APPoiNTs dr. hANs
ulriCh Golz As The NeW “PresideNT” of The
iNJeCTioN MoldiNG MAChiNery seGMeNT
the Kraussmaffei Group has appointed dr. hans ulrich Golz as
“President” of a common Group-wide injection molding machinery
Segment. Bernhard merki, Ceo of netstal maschinen AG, is leaving
the company. dr. Karlheinz Bourdon and frank Peters, previously
responsible for the injection molding machinery and reaction Process
machinery business at Kraussmaffei, will take up new posts
within the segment.
Generating additional value add for customers
The KraussMaffei Group will continue
to strengthen its position on key markets
and purposefully extend its presence on
growth markets. “We want to provide even
more benefits for our customers along their
entire value-adding chain. For this purpose,
we will increase our injection molding activities
throughout the Group. We will therefore
maintain the independent market presence
of the Netstal and KraussMaffei brands with
a clearly defined product portfolio and separately
operating sales organizations for both
brands”, said Jan Olaf Siebert, Chairman of
the Board of Management of KraussMaffei
AG. The “President” of the Group-wide Injection
Molding Machinery Segment will be Dr.
Hans Ulrich Golz, a well-known expert in the
field of mechanical engineering, who has served
the company to date successfully as President
of the Extrusion Technology Segment
and Chairman of the Management Board of
KraussMaffei Berstorff. Bernhard Merki, CEO
of Netstal Maschinen AG, decided to step
down from his position and to leave the company.
“Mr. Merki has worked for Netstal in various
functions since 1988. We would like to
trAde Show CAlendAr 2012 (mAy – oCtoBer)
thank him for all his work and wish him all the
best for the future”, said Siebert.
Dr. Karlheinz Bourdon and Frank Peters,
previously responsible for Injection Molding
Machinery and Reaction Process Machinery at
KraussMaffei, will take up new posts as part
of the reorganization measures at the Injection
Molding Machinery Segment. Dr. Karlheinz
Bourdon will take up the post of “Vice President
Technologies” and will be amongst others responsible
for the common segment activities
in Research and Development, Product Management
and Process Engineering Development.
As “Vice President Sales KraussMaffei”
Frank Peters will have sole responsibility for
sales of injection molding machinery bearing
the KraussMaffei brand. “I am very pleased that
both managers have decided to actively support
this process in a responsible position for
the benefit of the company”, said Siebert. As
the suc cessor to Frank Peters, Nicolas Beyl
will manage the Reaction Process Machinery
Segment of KraussMaffei in future. Succession
arrange ments in respect of Dr. Golz as Managing
Director of KraussMaffei Berstorff and
President of the Extrusion Technology Segment
are currently being made.
Technics, Belgrade, Serbia 2012-05-14 – 2012-05-18 KraussMaffei
International Engineering Fair, Nitra, Slovakia 2012-05-22 – 2012-05-25 KraussMaffei
Plastpol, Kielce, Poland 2012-05-29 – 2012-06-01 KraussMaffei Group
6th Congress on plastics in E&E applications, Würzburg 2012-06-14 – 2012-06-15 KraussMaffei
KraussMaffei Japan in-house exhibition 2012-06-26 – 2012-06-29 KraussMaffei
DKT (German Rubber Conference), Nuremberg, Germany
International Energy-saving & Advanced Building
2012-07-02 – 2012-07-05 KraussMaffei Berstorff
Materials Exhibition, Shanghai, China (PRC) 2012-08-15 – 2012-08-17 KraussMaffei
Interplast, Joinville, Brazil 2012-08-20 – 2012-08-24 KraussMaffei Group
China Int. Exhibition on Engineering Plastics 2012-09-05 – 2012-09-08 KraussMaffei Berstorff
MSV, Brno, Czech Republic 2012-09-10 – 2012-09-14 KraussMaffei
Expoplasticos, Guadalajara, Mexico 2012-09-12 – 2012-09-14 KraussMaffei
PU China, Shenzhen, China (PRC) 2012-09-18 – 2012-09-20 KraussMaffei
Taipeiplas, Taipei, Taiwan (ROC) 2012-09-21 – 2012-09-25 KraussMaffei
Composites Europe, Düsseldorf, Germany 2012-10-09 – 2012-10-11 KraussMaffei
Colombiaplast, Bogotà, Colombia 2012-10-01 – 2012-10-05 KraussMaffei
Fakuma, Friedrichshafen, Germany 2012-10-16 – 2012-10-20 KraussMaffei Group
iMPriNT
Publisher:
Kraussmaffei technologies Gmbh
Krauss-maffei-Strasse 2
80997 munich
Germany
Phone + 49/89/88 99-0
fax + 49/89/88 99-2206
www.kraussmaffei.com
Person responsible:
imre Szerdahelyi (responsible for content
according to German media law)
editor-in-chief: eva münzenmaier
Editorial team:
markus Betsche (mB), Christine Grob,
Susanne maxheim, eva münzenmaier (em),
Claudia Stadler (CS), imre Szerdahelyi,
joachim weber
Photo credits:
harald mehnert, eberhard franke,
Stefan Kruppa, customer photo collection,
Group-internal photo collection
Concept and design:
Kirchhoff Consult AG, hamburg, Germany
www.kirchhoff.de
Press:
druckerei Kriechbaumer, taufkirchen,
Germany
the customer magazine is published twice a year in
German and english. the magazine may only be reprinted
with the written permission of the publisher.

The KraussMaffei
Group has a global
presence. Countries
with subsidiaries are
marked in blue.
In the white-coloured
regions, the Group is
represented by over
570 sales and service
partners.
Netstal
KraussMaffei Group
KraussMaffei
Injection Molding Machinery Injection Molding Machinery
Reaction Process Machinery
KraussMaffei
Berstorff
Extrusion Technology
KraussMaffei Group
Wide-reaching expertise with Technology 3
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies
for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands:
Injection Molding Machinery, Automation, Extrusion Technology and Reaction Process Machinery.
The group is represented internationally with more than 30 subsidiaries and over ten production
plants as well as about 570 commercial and service partners. This is what makes us your
highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry.
Further information available at:
www.kraussmaffei.com