K-NEWS 2020 EN

KautexMaschinenbau

The customer magazine by Kautex Maschinenbau

ISSUE | 14

The customer magazine by Kautex Maschinenbau

Expertise – Communication – Innovation

Three pillars for a successful

customer relationship

Sustainability as guiding principle

Energy efficiency and modern processing

techniques for post consumer regrinds

Reorganization

Optimized processes to generate

added value

www.kautex-group.com


2

04 | Customer Experience

Our guiding principle

06 | Undergoing change

An interview with Andreas Lichtenauer

and Thomas Hartkämper

08 | New heads in the management team

10 | Our commitment to

sustainability From sustainably

grown raw materials to processing

post-consumer regrinds

12 | Our customers and us

2 success stories

16 | WT extrusion heads and

RapidXchange

New technologies for higher production

efficiency

18 | Pre-acceptance runs by video livestream

Satisfied customers and cost savings

Newsflash

19 K-Foam

20 Flash-Event

20 DataCap

21 Modernization instead of replacement

22 | Composite Liner XXL

First blow molded hydrogen liner

made from polyamide

24 | A year of anniversaries

85 – 60 – 25

Three reasons to be proud


ISSUE | 14

EDITORIAL 3

Dear business partners

and friends

Publisher

Kautex Maschinenbau GmbH

Kautexstraße 54

53229 Bonn · Germany

T +49 228 489-0

F +49 228 489-414

info@kautex-group.com

www.kautex-group.com

Responsible

Communication and Marketing

Kautex Maschinenbau GmbH

Date of publication

June 2020

The coronavirus pandemic

is keeping many of us in

suspense. Here at Kautex,

we fortunately reacted early

and introduced comprehensive

safety measures so that we

were able to maintain our

machine production and

continued to deliver without

any restrictions. But these times

also provide opportunities to

try something new. Recently,

we started presenting our latest

technology virtually. The first

virtual Flash Event in April

enabled 130 customers from

across the globe to get to know

our new Kautex KSB10 machine

in continuous test mode and, at

the same time, communicate

directly with our experts.

Independently of the current events, we are continuing to drive

forward the transformation process started in 2019 as well as our

product offensive in the areas of packaging and specialties. In

addition, we have brought further experts on board (see pages

8 – 9). They will provide support for us to realize our ambitious

targets. The fact is, we are an innovation-driven company in blow

molding technology that continues to lead the way as shown by

our recent success in the production of hydrogen liners made of

polyamide plus our K-Foam and RapidXchange technologies.

I hope you enjoy a thought-provoking read and I look forward

to your feedback.

Yours

Andreas Lichtenauer

CSO Kautex Maschinenbau


4


ISSUE | 14

5

Three pillars of successful

customer relations:

Expertise – communication

– innovation

Customer service: Put structures to

the test and form cross-functional

teams to fulfill customer requirements

faster and better.

Markets change. Most companies face worldwide

competition due to globalization. With increasing

speed, we have to react to change to give our own

company an advantage over the competition and secure

our own market position. This requires strong partners who

are in a position to put ideas into practice quickly and flexibly

and to bring them to market. Partners with special know-how

and with appropriate structures. We have been among

the leading experts worldwide in the sector of extrusion blow

molding technology for decades.

However, expertise is not enough on its own. Process

operations and communication must be designed to provide

customers with optimum support and positive experiences.

From a customer perspective, better accessibility, quick reaction

times and expert support come first. The widespread pillar

structure, with each section more or less working for

themselves, no longer fits the bill. Instead, we utilize crossfunctional

teams, which coordinate and control customer

projects across all sections from provision of the offer up to

the installation of the finished machine. This avoids

breakdowns in communication and process handling. That puts

you in a better position to receive products from us quickly,

that best meet your requirements.

olegdudko/123rf.com

Put us to the test. We invite you to take on the competition in

blow molding technology together with us. Let us know what is

on your mind and let us seek innovative solutions together. You

can reach us any time via our hotline – 24/7. Brochures and data

sheets on our machines and service products are available to

download. You can visit our YouTube channel to look at a wide

range of machine applications. And please send us your feedback

– as that is part and parcel of successful customer relations.


6

Change at Kautex

Interview with Andreas Lichtenauer

and Thomas Hartkämper

Our society is changing. CO 2

reduction,

sustainability and the maintenance of our

natural resources are issues that motivate

people worldwide. One sector particularly

affected by that is the plastics industry.

Kautex is part of that. As a machine-building

company, how do you respond to the changed

framework and needs of your customers?

Thomas Hartkämper

As one of the leading manufacturers of

extrusion blow molding machines, here at

Kautex Maschinenbau, we set a new course for

change early on. That particularly includes our

commitment to sustainability. We want to be

pioneers in this area. Today, our systems and

technology are already trend-setting in terms of

efficiency, energy and resource consumption and

our system solutions are already optimized for

the processing of recyclates. For a long time,

we have tested different products and set up a

PCR database that contains all processing

parameters for the blow molding process. In

addition, we are making a massive investment

in understanding article design and functionality

of our customers and products. Through radical

weight reduction, we create verifiable added

value. That has been completely underestimated

up to now by the public, but plastic and

Kautex are making a massive contribution to

saving our planet and resources. Our global

Kautex team will press ahead with even greater

determination in the future.

It‘s not only market conditions that are

changing. Kautex is also currently in a process

of transformation. What are the company‘s

targets with the restructuring?

Andreas Lichtenauer

In the past few months, we have initiated

numerous processes that will contribute to

securing and extending our outstanding position

in the worldwide plastics machine market

over the long term. We are shaping this

transformation process together with our

customers and partners to generate added value.

To do that, we have strengthened our team over

recent months with the addition of more experts

who will drive this process forward, together

with us. With our system solutions, technology

and services, we want to offer our customers the

best possible support and give them decisive

competitive advantages. Here we are not

limiting ourselves to our extrusion blow molding

machines and extrusion heads, but we are also

offering system solutions that cover the whole

production chain. We want to reduce waiting

times and, as a partner for our customers,

offer solutions that are ideally customized to

the requirements of their appropriate target

markets. That begins with the processing of

offers through our newly formed ‘Center of

Competence‘. Here, our customers will receive at

an early stage, a tailored and well designed

offer. For the automotive and packaging areas,

we also have set up a central product application

management (PAM) system that develops

customer-oriented solutions.


ISSUE | 14

7

You have created a new section, ‘Operations‘.

What is the background?

Thomas Hartkämper

The basic idea of our changes go under the

headline ‘Lean‘. In German-speaking countries

lean is unfortunately a negative concept which

is why we have reduced it in our global

communication, vision and mission to the two

core elements of process and leadership

excellence. In recent months, we have carried

out cross-process value stream mapping at the

main production sites in Bonn and Shunde, with

the aim of eliminating all types of waste across

departments and processes. We want to

introduce more fluency to production and

develop from a specialist machine manufacturer,

to a small-series machine manufacturer. That

has led to new and optimized processes and –

derived from that – new forms of organization.

In future, hierarchies will play a secondary role.

Under the Operations section, we bring together

order management, production planning and

control, pre- and final assembly as well as system

start-up. The team have done a fantastic job in

recent months and we have been able to achieve

massive reductions in delivery time for all

products based on the optimized processes.

What impact do the changes have on the

company and how have you been able to deal

with the coronavirus pandemic in the middle

of this process?

Andreas Lichtenauer

The initiated changes are already having a

positive effect on the whole company structure.

We are now in the position to react much

quicker and respond to individual customer

requirements. Fortunately!

That proved to be successful at the start of

the coronavirus pandemic when we effectively

implemented the widest range of measures

with the aim of ”remaining 100% productive“

to remain operational during this time and

be there for our customers.

But that‘s just the start of a far-reaching product

offensive, in the areas of packaging and

specialties, we are undertaking in the next

months and years. The first results are, for

example, our new WT extrusion heads. They

have been developed for packaging applications

and, in combination with our RapidXchange

technology, enable significantly faster color

and material changes as well as considerably

improved melt qualities and material

throughput.

Thank you very much for this interview.

Andreas Lichtenauer and

Thomas Hartkämper from

the management team


8

New heads

in the management team

We have brought further support on

board to strengthen central regions

and business areas

Jorge Cuevas Martín – Global

Service Manager

A new member of the team since May 2020 is Jorge

Cuevas Martín (51). As Global Service Manager, he

coordinates our service provision with our regional teams

and decentralized parts distribution centers and he will

expand these with a customer-oriented focus.

»We want to offer our customers

the best possible support for

adapting their production to the

current market conditions. Customer

service is our big plus.

Admir Dobraca – CEO North

America

»

The Kautex Group is experiencing

a great development. I‘m glad I

will have the opportunity to

make a personal contribution to the

Admir Dobraca (41) took over as CEO at Kautex

success of this innovative company.

Machines Inc. in the USA in February 2020.

He succeeds Bill Farrant and will strengthen and

extend our presence in the North American market.

Julia Keller – Chief Financial

Officer

Julia Keller (42) took charge of commercial

management in April 2020 in addition to

her role in Human Resources. The business

studies graduate, specialized in finance

and human resources, succeeds Frank Röhrlein,

who has now retired.

»For me, open communication, listening,

inspiring, supporting and challenging are

core factors for successfully implementing

change in the company.


ISSUE | 14

9

Michael Müller – Global Sales

Director Packaging

Mechanical engineer Michael Müller (49)

took over as Global Sales Director Packaging

at the end of April. Müller is a packaging

specialist and knows the international

market inside out. He will make a significant

contribution to guiding and promoting our

packaging sales branch.

»As a system provider, Kautex

has the opportunity to be

a key partner in the customer‘s

value chain from granules to

the finished product.

Dhanny Mulyanto – Head of

Global Supply Chain Management

»Kautex is changing and moving

forward, and is a pioneer in many

areas. I find the opportunity

to work in this kind of environment

extremely exciting and inspiring.

From March 1, 2020, Danny Mulyanto (38) has

strengthened our Change team as the new Head of

Global Supply Chain Management. He will optimize

our supply chain in terms of customer orientation and

ensure the availability and quality of our products.

Follow us on social media

– and stay up to date


Foamed PCR in middle layer

10

Sustainability –

Exemplary processing of

recycling materials

Circular Economy: On the development

for the optimized processing of recyclates

(PCR), measures for cost optimization and

improvement of the carbon footprint.

The use of recyclates is a crucial factor on the way to

a closed-loop economy in the plastics industry. The PCR

materials currently available and used by customers

have highly variable quality and characteristics. In

particular, budget commodity quality can lead to

process fluctuations and loss of quality due to impurities

in the blow molding processes. With premium quality,

which is prepared more intensively, challenges, such as

hose length fluctuations or formation of holes due to

impurities in the material, appear considerably less

often. In addition, plastic processors have a very variable

level of experience in processing these materials. These

findings come from our customer survey on the use

of recycled plastics at the K-Messe 2019 trade fair.

This feedback coincides with our own experiences. As

part of our Replax project (recycling of plastics by

Kautex) for the investigation of new possibilities, we

tested the material characteristics of PCR plastics (Post

Consumer Regrind) before customers go into series

production with it. Visitors to our exhibition at the

Technikum in Bonn can examine examples of the tested

materials from different manufacturers.

dennis.dube@kautex-group.com

SUSTAINABLE

material

FOSSIL

material


ISSUE | 14

11

Fossil raw material

Sustainable raw material

Machine

Process

Cycle time

Top load

Material

Recycable

Weight

KBB60D

ReCo3

13 seconds

220N

HDPE

Yes

48g

Machine

Process

Cycle time

Top load

Material

Recycable

Weight

KBB60D

ReCo3, foamed middle layer

13 seconds

230N

I‘m green TM polyethylene and PCR (Braskem)

Yes

39g

Ahead of K-show 2019, we also carried

out tests with our partner Braskem within

the scope of these trials. The aim was to

produce a plastic bottle as sustainable as

possible. The result is a triple-layered bottle

that uses a renewable raw material in

the external and internal layers, with the

middle layer made of a premium recycling

material. In order to reduce the

consumption of materials and to lower the

costs of the expensive recycling material,

the middle layer was foamed using our

K-Foam process. By maintaining the cycle

time and all mechanical characteristics, it

was possible to reduce the amount of

material in the bottle by 18%.

This example shows that it is possible

now to achieve a financially interesting

use of PCR materials using Kautex

technology. From a technical point of

view, all Kautex blow molding machines

are capable of processing such materials.

We will be happy to advise interested

customers.


12

KBB machines meet stringent

requirements of the pharmaceutical

industry

Röchling Medical, a division in the

Röchling Group, is installing two new

KBB machines at its site in Neuhaus

am Rennweg, Germany. The allelectric

blow molding machines meet

the exacting GMP C class clean room

requirements and ensure the complete

transfer of operating data from

production. The new high-performance

machines will make an important

contribution to increasing the revenues

generated by the Medical division

in the group as a whole.

We selected the Kautex

machines because they

provide us with the highest standards

and required production reliability at

all times. Kautex has unparalleled

technical expertise that encompasses

the entire extrusion process and has

actively supported us effectively also

at short notice. The new machines are

not just helping us achieve our

commercial targets. They are also

supporting our sustainability aims.

Alexander Stauch,

Managing Director BU

Medical Europe


ISSUE | 14

13

The Röchling Group, headquartered

in Mannheim, Germany, is one

of the world‘s leading plastics

processing companies. The

Röchling Medical division offers

its customers a wide range of

high quality components and

assemblies through to complete

OEM products. Röchling Medical

has a global workforce of around

1,200 employees at six locations.

Its product portfolio also includes

standard plastic products with

special expertise in the areas of

diagnostics, fluid management,

pharmaceuticals and surgery

& interventional. These skills are

complemented by extended

services for Development and

Regulatory Affairs through

to the approval of a complete

medical product.

At the Neuhaus site, hollow plastic

bodies of all sizes, consisting of

up to 6 layers, are manufactured,

using standard manufacturing

Pharmaceutical

packaging from

Röchling Medical

processes, combinations of

different plastics and multi-layer

processes. Everything, from

development to series production,

takes place there.

Safe, reliable production processes

are especially important for

pharmaceutical products. Errors

in the production process,

variations in product quality and

microbial contamination can have

direct consequences for the

health of people and animals.

For this reason, Röchling Medical

manufactures, processes and

packs all its products under

controlled clean room conditions.

As part of the modernization

and expansion strategy at the

Neuhaus site, the company has

now brought two KBB extrusion

blow molding machines into

operation. These are the latest

generation of the all-electric high

performance machines. They

operate at high speeds, with

outstanding precision, and are

highly energy-efficient. These

machines supplied to Röchling

Medical have been fitted with

digital industrial features,

including sensors for transferring

vital operating data.

Protecting the environment and

improving living and environmental

conditions are at the heart of

Röchling‘s company goals. When

planning production processes, the

issues how plastic waste can be

reduced and its reuse be increased is

always considered . It‘s therefore

hardly surprising that KBB machine

operators at Röchling are being

trained on the digital twins of the

KBB series: the virtual machines.

Kautex developed these simulators

so that customers can be trained

without using materials or energy

unnecessarily. One of Kautex‘s goals

is to reduce granulate loss in its

actual processes to zero percent.

The machines are already designed

for low-waste production. Despite,

the company is striving to further

reduce the amount of flashing

generated in the production

process. Producers such as Röchling

Medical are currently unable

to process recycled material.

At present, the recycled materials

recuperated from mechanical

recycling processes are not pure

enough to be used for pharmaceutical

products. However, research into

chemical recycling processes which

would make this possible is currently

being conducted world-wide.


14

Dynapack Asia – Production

quality and sustainability

as key factors for customer

decision-making

Dynapack Asia is one of the major players in the packaging

market in South-East Asia. The company operates 35

production sites in China, Indonesia, Malaysia, Singapore,

Thailand and Vietnam. The majority of its customers are

large multinational brand owners such as Beiersdorf, Coca

Cola, Exxon Mobil, Procter & Gamble, Shell and Unilever.

Some of its relationships with these businesses extend back

more than 30 years. The company is currently experiencing

extremely dynamic growth. In 2022, it wants to break

through the billion dollar sales barrier.

Dynapack Asia produces high

quality plastic products for

packaging items as diverse as

foodstuffs, drinks, cosmetics,

pharmaceuticals, chemicals and

lubricants. The company also

produces precision injection

molded products for use in the

automotive industry, electrical

appliances, consumer goods and

the electronics industry. The

company uses the very latest

production standards and

processes and is continually

developing them, with the focus

on innovation, operating

excellence, product quality and

sustainability. Being close to its

multinational customers, thanks to

the company‘s presence in six

countries in Asia, is also a key

factor for Dynapack Asia.

The company has successfully

worked together with Kautex

Maschinenbau for many years.

After a pilot project with a

KBB60D machine, which Kautex

built on the basis of a standard

specification, the two companies

have already developed numerous

extrusion blow molders specially

tailored to the specific production

conditions of Dynapack Asia.

At present, Dynapack operates 24

Kautex machines of different sizes,

21 KBB and 3 KCC machines.

The fully electric KBB blow molders

are not only very economical in

their use of power and resources,

but also have big data-capability.

By adding intelligent downstream

modules, they can also easily

be extended to create an entire

production system. Their

renowned quick change systems

means customers can make

significant product cost savings

in the long term.

Packaging from

Dynapack Asia‘s

portfolio


ISSUE | 14

15

Kautex Maschinenbau is an

important partner for us. Working

together, we can reliably achieve our

customers‘ stringent and growing demands

for quality, accuracy, reliability of supply and

cost-effectiveness. Our customers think the

same as we dvo: they view our decision to

work together with Kautex as an indicator of

production quality and reliability.

As a company that focuses on sustainability,

we work hard to reduce the amount of

material and energy we use, and our

C0 2

emissions. Kautex machines are ideally

suited to this. These machines are already

able to process recycled plastics reliably and

effectively, and this is something we will be

more intensively involved with in future.



Tony Hambali, CEO

of Dynapack Asia


16

New WT heads reduce color changeover

times by up to 75%

New Kautex extrusion heads in the WT series

enable a complete color changeover – mainly

in 30 to 60 minutes.

Short changeover times – the high productivity. The new WT extrusion

heads from Kautex Maschinenbau reduce the change over time in

comparison to a traditional extrusion head by up to 75%. Combined with

RapidXchange technology, you can significantly reduce the downtime of

your machines for changes of color and material. That not only increases

productivity but also reduces energy and raw material consumption.

The extrusion heads in the WT series have been developed for packaging

applications. Modular construction enables subsequent retrofitting on

view stripes, thus making it easier to plan investment. Heads are available

both for mono, two-layer DeCo as well as for three-layer ReCo applications

with variable die diameters between 25 and 600mm. Further applications

on request.

leon.walinski@kautex-group.com

Spiral mandrel

for optimized

melt flow


ISSUE | 14

17

Higher production efficiency

with RapidXchange

RapidXchange technology saves significant

time with color and material changeovers

with extrusion blow molding machines.

That reduces manufacturing costs, ensures

the quality of the products and makes

production processes considerably more

sustainable.

RapidXchange is

available for

Kautex extrusion

heads

In production processes with blow molding machines, the color

and material changeovers on extrusion heads primarily take up

a lot of time. That is caused by the time-consuming purging of

color and material deposits that are formed in the extrusion

head flow channels during extrusion.

We have developed a solution for this problem with our

RapidXchange technology. RapidXchange drastically reduces

the time required for color changeovers. To that end, the

technology optimizes flow characteristics of the flow channels.

Those zones of the flow channels, where low flow speeds

occur with classic distribution systems during the purging

process, can be eliminated using RapidXchange. This prevents

deposits and smaller deposit build-ups are completely purged

out of the system immediately.

RapidXchange is currently available for

extrusion heads in the WT series

specifically for packaging applications.

Thanks to the accelerated color change

over, you can achieve significantly lower

material consumption through the

shorter changeover times. At the same

time, RapidXchange produces a uniform

all-round distribution that enables you to

achieve an even better quality of

production. Non-productive times are

thereby significantly reduced, which

makes your production use significantly

less resources and thereby become more

sustainable.

Comparison of a mono layer application

90 min | Conventional head

40 min | Conventional head with coating

75% SAVINGS

20 min | Head with RapidXchange


18

Kautex introduces virtual

acceptance procedures

New opportunities for digital

customer service with virtual

pre-acceptance tests via video

live stream.

Customers can associate acceptance processes with long

travel times and high travel costs. Kautex Maschinenbau

have recently introduced the possibility of completing

acceptance processes via the Internet. For a first virtual

pre-acceptance check with our customer Logoplaste, five

web cams were installed on a all-electric KBB60D blow

Despite the difficulties that

COVID-19 brought in terms of

movement of people to support trials,

homologations and Equipment

Acceptance, we were able to maintain all

activities that were planned and follow

them Remotely. The high Level of

connectivity has enabled us to keep

activities, perform tasks and achieve all

our activities with success.

molding machine. The cameras, positioned on five

important points of the production process, transmitted

video in real-time to Logoplaste. The customer has the

opportunity to review and assess all stages of production

without being on-site.

With these modern acceptance processes, we are able to

achieve significant savings in time and cost while also

remaining as close to our customers as possible at every

point, even in these times of contact bans and travel

restrictions.

Paulo Correia,

R&D Director

Logoplaste

Innovation Lab


ISSUE | 14

19

Up to 20% less material used

thanks to K-Foam

Sustainable: The use of K-Foam not

only saves material. The foam structure

improves rigidity and insulation in

products.

Webcams transmit

each production

step directly to the

customer

It sounds easy and can actually be incorporated into all

extrusion blow molding machines: the new Kautex foam

technology K-Foam. Behind the name there is a unique

technology that offers crucial advantages in the production

of blow molded products. It was primarily developed to

reduce consumption of materials.

At the same time, during the plastification process, gas – in

high-precision amounts – is injected into the polymer melt of

the extruder. The fine-celled foam structures, that are

produced, lead to an increased volume of the melt and thus

significantly reduce the amount of plastic required. The

foamed-up material also has outstanding product rigidity and

a significantly higher insulation effect.

As a customer, you benefit in a number of ways. The innovative

manufacturing process cannot only reduce your plastic

requirement by up to 20%, which in turn cuts the unit cost.

The innovative process also reliably reduces production-related

emissions by up to 20%. Therefore, the integration of foam

technology brings both economic and significant environmental

benefits.

K-Foam is ideally suited to Kautex machines and incorporated

into the Kautex–HMI. Operation and process management is

controlled via the central operating unit on the machine. New

blow molding machines can immediately be fitted with K-Foam.

You can also upgrade your old machines.

K-Foam

operating panel

Schematic view of inserting

the gas during the

plastification process


20

Innovations and machines live

in operation

Flash events mark the start of a new and virtual customer

information format. Even in difficult times, this brings

customer service closer, as selected customer groups can

be invited to exclusive presentations and demonstrations

whenever particular technology solutions can be

demonstrated live.

This provides the opportunity to experience machine

solutions live, via the Internet. Every virtual visitor has

the opportunity to ask individual questions to their host

during the demonstration.

The first virtual events on the machine series KSB and KSH

have already been held with great success.

Customer relations in spite of distance:

Virtual flash events offer immediate

opportunities to experience technology

live in operation.

DataCap

With DataCap, Kautex Maschinenbau offers data acquisition packages that

you can use to set up a central data acquisition system for your Kautex

machines. Not only does this make your production processes more transparent,

it also increases the efficiency and quality of your output.

Central data acquisition system for all Kautex machines

DataCap uses a standardized data acquisition system that allows you to analyze

your Kautex machines easily and from one central location. For example, smart

monitoring lets you keep a constant eye on your production and make your

manufacturing processes more efficient. All new Kautex machines are already

compatible with DataCap, while old systems can be retrofitted on request. The

data acquisition system can be installed in shortest time and with minimum outlay.

Thanks to the international communications standard OPC-UA, the packages on

offer are easy to integrate into existing production systems.

Available packages

packages

All packages on offer are built around the basic DataCap package.

Package 1 /

Basic

Purpose of the package:

to provide an overview of the

machine’s status and ongoing

production

Contents of the package:

piece counter, cycle time, extruder

status, temperatures

Package 4 /

Process monitoring

Purpose of the package:

to monitor all data relevant to the

process or item (quality assurance)

Contents of the package:

process times, motion profiles, blowing

air control, mold cooling water

www.kautex-group.com

Package 2 /

WDS profile

Purpose of the package:

to monitor the quality of the

wall thickness distribution in the

preform

Contents of the package:

target and actual value curve, maximum

deviation, quality indicator

Package 5 /

Machine monitoring

Purpose of the package:

to monitor the machine

Contents of the package:

motor torques and temperatures,

motion energy and times; closing

force

felix.bittner@kautex-group.com

More transparency for

Centralized

your Central production

monitoring and

Package 3 /

Energy

analysis of production

processes

Transparent

Clear increase in efficiency

and quality

Compatible

Simple integration across

the entire line thanks to

the OPC UA standard

Easy installation

New Kautex machines

are readily compatible,

while old models can be

retrofitted

Standardized

Identical design for all

Kautex machines

Purpose of the package:

to monitor the fed-in energy (electrical,

cooling water, air)

Contents of the package:

electrical energy consumption,

cooling water consumption including

pressure and temperature;

air consumption and pressure

Package 6 /

Condition monitoring

Purpose of the package:

to promptly detect and prevent

system failures

Contents of the package:

vibration analysis of extruder motor

and gearbox

Product Info

2019-072

DataCap enables central

data collection for all Kautex

machines.

In times of digitalization, intelligent monitoring creates new

opportunities to reliably oversee and target development of

manufacturing processes. Thanks to standardized data

collection with DataCap, customers can monitor and analyze all

machine and production processes at any time via a central

unit. New Kautex machines are immediately compatible with

the standardized system and older units can be upgraded at

reasonable cost.

We offer a total of six different packages under DataCap. As

required, customers have a flexible choice of which sections of

their production are to be digitally recorded and monitored.

For effective quality assurance, process data, machine details or

energy flows can be clearly presented. This enables production

processes to be optimized and potential outages identified and

avoided. Kautex Maschinenbau guarantee integration of

DataCap into existing production systems via the international

communication standard OPCUA.


ISSUE | 14

21

Modernization instead of replacement.

There‘s life left in your machines.

With modern controls

and new components,

older blow molding

equipment can be

brought up to current

production standards.

Kautex machines are designed to be

durable and can be adapted to current

requirements relating to productivity,

energy efficiency and operating

comfort at any time. Outdated

components such as controls, extrusion

heads, extruders and closing devices

are replaced as required by modern

modules. In this way, older machines

can be incorporated in the modern

service tools such as Kautex Remote

Service, which enables fast remote

diagnostics when necessary.

In addition, production lines can be retrospectively automated and

expanded via our modernization program. Completely new procedures

can also incorporated in production. We also offer individual

modernization and upgrading solutions for machines from SIG-

Blowtec, Voith Fischer, Battenfeld Fischer and Fischer W. Müller as well

as products from other blow molding machine manufacturers

Blow Command Eco – Virtual set-up saves

time and costs

We now offer a virtual setup of our new control tool

Blow Command Eco (BC Eco) for our KEB machine

series. As with our virtual training sessions, the initial setup does not

happen on site, but instead virtually in-house with us. This enables a

significant reduction in the time used for onsite setup. For you that

means quicker setup, shorter downtimes and significantly lower costs.


22

The work we are doing here is truly

pioneering. The liner size we have now

achieved is just the start. We are confident that,

in future, we will also be able to use this method

to produce considerably larger liners for

hydrogen pressure vessels.

Abdellah El Bouchfrati,

Head of Composite

Business Development at

Kautex, sees great

potential for the new

technology


ISSUE | 14

23

320-liter hydrogen liner made

of polyamide

Innovative procedure opens up

new possibilities for hydrogen

technology for the production

of thermoplastic composite

pressure vessels (CPVs)

Kautex Maschinenbau blow molding experts have successfully

produced a large-volume polyamide liner for hydrogen pressure

vessels, using extrusion blow molding technology. The liner is over

2 meters long, with a diameter of approximately 500 mm and a

volume of 320 L. This is the first time a liner for a hydrogen

container has been produced in this size using blow molding

technology.

Hydrogen presents particularly significant challenges in relation

to the line and materials permeability. As the smallest molecule in

the periodic table, the gas can defuse through nearly all plastic

materials. Special polyamides (PAs) have the best barrier properties.

However, due to their low melt rigidity and complexity, they have

previously been difficult to process on this scale by blow molding

The process developed by Kautex in partnership with a plastics

manufacturer has made it possible for the first time, to produce

a hydrogen liner through a blow molding process on a scale

interesting to the industry.

This opens up new possibilities for hydrogen technology to be used

to produce thermoplastic composite pressure vessels (CPVs) used

for example, in fuel tanks for commercial vehicles, buses, trains and

ships as well as for the transportation and storage of hydrogen.

Plastic pressure vessels are not only significantly lighter than steel

tanks but also completely resistant to corrosion.

The Kautex offer covers the development and production of

prototypes and low-volume production through to the construction

of complete production facilities for the manufacture of composite

pressure vessels.

Abdellah.El-bouchfrati@kautex-group.com


24

Three anniversaries

in a year

2020 marked a special year in

the company history of Kautex

Maschinenbau. In addition to

the 85th anniversary of the foundation

of the company, this year also

marks the 60th birthday of our

subsidiary in the USA and 25 years of

machine manufacturing in China.

Advertising for

innovative plastic

bottles

Our foundation goes back to the year 1935 and the plastics

pioneer Reinhold Hagen. His passion for experimenting

and entrepreneurial skill, saw him succeed in developing

the world‘s first standard production plant for

manufacturing plastic containers, as early as 1949. Thanks

to huge success, Kautex was able to expand beyond

Germany for the first time in 1960 with the establishment

of the first international subsidiary in New Jersey, USA.

The foundation of the first German Chinese joint venture

in Shunde in southern China followed in 1995 and the

Chinese KCC series is now in its third generation.

Today we count as one of the leading manufacturers worldwide of hightechnology

extrusion blow molders and shape the plastics sector with efficient and

sustainable solutions. Issues like recycling and efficiency stimulate our research and

development work as does the introduction of new technologies and services in

the age of digitalization. That includes technology to continue to improve the

carbon footprint in the production of hollow parts. We are convinced of one thing:

If we continue to actively contribute to associate the positive characteristics of

these products with worldwide functioning recycling loops, then that will be a

significant step for everybody towards a sustainable future.

First Kautex extrusion blow

molding machine, 1956

Branch office in Linden,

New Jersey, USA, 1960

Production site in

Shunde, China, 2020

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