������������������������������� 1 ¦ 2007

made by

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A unique pairing

E DI T O R IA L

COMING EVENTS

“In this magazine,

Trade shows 2007/2008

you will find the Dr. Dietmar Straub, CEO, KraussMaffei.

unique expertise of KraussMaffei.”

Dear Reader, 24.–31.10.2007

K2007

14.–16.11.2007

Tyres &

Shanghai,

Welcome to the first edition of our magazine Made by KraussMaffei. In this new customer magazine we aim to provide you with information

Germany

specifically tailored to your interests, which is why the copy you are now reading is one of three parallel editions, one each focussing on

Rubber Tech China

China

15.–17.01.2008

Swiss Plastics Fair

Lucerne,

29.1.–1.2.2008

Interplastica

19.–22.2.2008

Plastex

5.–6.3.2008

Kunststoffe im

Mannheim,

injection moulding, extrusion and reaction processes. This threefold approach reflects the unique expertise of KraussMaffei:

Switzerland

we are the only company in the world which unites these three key technologies for the plastics and rubber industry under the same

Automobilbau

Germany

12.–14.3.2008

PU Tech

New Delhi,

8.–11.4.2008

Plastimagen

17.–20.4.2008

Chinaplas

of extrusion, injection moulding and reaction processes in a single manufacturing cell.

India

You as a customer will profit from faster cycle times, lower space requirements and an innovative concept that is ready for mass

Kiev, Ukraine

for you as a customer. We’ll be the first company worldwide to present a new process concept which integrates the three technologies

Moscow, Russia

corporate umbrella. At the end of October, at the K2007 in Düsseldorf, we’ll be demonstrating that this has enormous advantages

Düsseldorf,

Mexico City, Mexico

production. In short: we can offer you new prospects for deploying

Shanghai, China

manufacturing processes which have hitherto not been feasible! KraussMaffei is currently going through a process of change. We will not be retaining the previous holding structure. In addition we have merged our extrusion activities under one management and a new, single brand, KraussMaffei Berstorff. Across all our core competences

IMPRINT

– in extrusion, injection moulding and reaction processing – we are

Made by KraussMaffei

committed to partnering with you in delivering not merely machinery,

Published by: Krauss Maffei GmbH,

but complete solutions. Our expertise is comprehensive – from raw

Krauss-Maffei-Straße 2, 80997 Munich, Germany

materials conditioning, through all stages of processing, to highly

Phone + 49/89/88 99 0,

automated systems. Our goal is to supply innovative machinery and

Fax + 49/89/88 99 22 06,

systems for an integrated complete solution.

www.kraussmaffei.com

See for yourself what the new KraussMaffei has to offer in products

Responsible: Matthias Andreesen Viegas

and services. And talk to us about what we can do for your business.

Editorial office:

Visit us at the K2007 in Düsseldorf, October 24 –31, 2007.

mk Fachverlag fu ¨r Kundenmagazine GmbH,

Until then, we trust you will find a lot to interest you in our magazine.

Max-von-Laue-Straße 9, 86156 Augsburg, Germany

This first issue, naturally, focuses on the most important event in the

Phone +49/821/34 45 70,

industry calendar, the K2007.

Fax +49/821/34 45 7 19,

I look forward to meeting you in Düsseldorf at the end of October!

www.mk-fachverlag.de Photo credits: ESA, geobra Brandstätter,

02

Best regards

KraussMaffei, Messe Düsseldorf, mk Fachverlag/

Dr. Dietmar Straub

mk Archive, pixelio.de, Petra Wallner

EDITORIAL | NEWS

MADE BY KRAUSSMAFFEI 1 ¦ 2007

CUSTOMER MAGAZIN E

made by KraussMaffei

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A priority for KraussMaffei in communicating its

the magazine will be different for each of

new brand identity is to present the same strong

our three divisions.

identity across all business divisions and in all

The link between the three versions of

relevant target markets and groups. One of the

Made by KraussMaffei will

key communication tools will be the new customer

be the topics relevant

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magazine Made by KraussMaffei, published in

to all three technology

German and English. This is the first issue. It’s

divisions. Although the

unusual in that, while presenting all the important

design of all three versions is

information from the world of KraussMaffei,

similar, it’s easy to tell them

the layout has also been tailored to the special

apart: on the title page the

interests of people active in the fields of injection

managing director

moulding, extrusion and reaction processing.

of the division

The magazine has a dual structure. The first

in question

section of the magazine covers topics relating to

addresses his

KraussMaffei as a whole. In this first issue, the

readers directly

focus of pages 1 to 9 is mainly on the K2007, the

and in person. p

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most important event for us on the autumn trade

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show calendar. The content of the second half of The three versions of ������ ������

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the magazine reflect the core competences of KraussMaffei.

CORPORATE DESIGN

New Corporate Design Since July 1, 2007, KraussMaffei’s new

unified entity, for example on the internet with the

orientation has been reflected in a new corporate

international domain name www.kraussmaffei.

design. The company logo has been given a

com. Important and practical for all concerned:

new look which is both fresh and modern. The

the e-mail addresses of KraussMaffei staff

amalgamation of the extrusion activities of

members now follow a uniform and easy-to-use

KraussMaffei and Berstorff has created the new

pattern: first name.last [email protected].

KraussMaffei Berstorff brand, with a new logo

KraussMaffei operates successfully on a global

embodying the new name. Injection Moulding

scale, and so it makes sense to use the website

Machinery (IMM) and Reaction Process

www.kraussmaffei.com as the domain for e-mail

Machinery (RPM) will use the KraussMaffei logo

addresses. The advantage of the new system is

with the claim “People for Plastics”. A third logo

that if you know the first and last names of your

variant, with no additions, will be used in any

contact, you automatically know his or her e-mail

situation where the company presents itself as a

address. p

NEWS

03

KRAUSSMAFFEI AT T H E K 2 0 0 7

Lead trade show and a high point for the industry At this year’s K2007, the leading trade show for the plastics and rubber industry, the emphasis is on process optimization and increasing productivity. KraussMaffei presents its wide-ranging portfolio of products and services with a great many impressive innovations in injection moulding, extrusion and reaction processes. to deliver cost benefits. This shifts the spotlight onto identifying new and expanded applications, onto faster and more flexible use of existing process technologies, and onto boosting machine performance and product quality. Enhancedperformance materials

KraussMaffei is

and novel process

the largest single

combinations are also high

exhibitor in Hall 15.

on the agenda. The K2007 covers a total exhibition space The K2007, the traditional lead show for the

of over 250,000 square metres, divided into four

plastics and rubber industry, takes place in

sections: machinery and equipment; raw materials

Düsseldorf from October 24 – 31, 2007. Under

and auxiliaries including semi-finished products;

the motto “Turning Visions into Business”, the K

technical parts and reinforced plastic products;

is set to attract over 3,000 exhibitors from over

and services. The manufacturers of plant and

50 countries with their products and innovations.

machinery traditionally make up the largest group

Once again, world market leaders from Europe

of exhibitors at the K and occupy Halls 1 to 4

and the USA are strongly represented along with

and 9 to 17, that’s around two-thirds of the total

numerous exhibitors from China, India, Korea and

exhibition space.

Taiwan. They will be showcasing their innovations

04

and lead products at this meeting point and

The KraussMaffei booth: breaking records

trendsetter for the entire industry. This year there’s

Our motto for the K2007 is “Our technology

a strong market focus on process optimization

– your advantage – worldwide” and we’ll be

FOCUS

MADE BY KRAUSSMAFFEI 1 ¦ 2007

INFO 17th International Trade Fair

Visit us in

Plastics + Rubber K2007

Hall 15!

Messegelände Düsseldorf October 24- 31, 2007 Hall 15, Booth A23/B24/C24 Opening times: Daily from 10 a.m. until 6.30 p.m. Organized by: Messe Düsseldorf GmbH Infoline +49/211/45 60 900 www.k-online.de

presenting our unique expertise in plastics and rubber processing in Hall 15. Our booth A23/B24/ C24 occupies around 1,800 square metres, making

INFO

KraussMaffei the largest single exhibitor in this

You’ll find more information about KraussMaffei and the K2007 at www.kraussmaffei.com

hall. As the only company offering high-quality machinery for the three key technologies injection moulding, extrusion and reaction processes, KraussMaffei will once again be one of the big draws at the K2007. A very special premiere will be the first joint appearance of KraussMaffei and

KRAUSSMAFFEI EXHIBITS AT THE K2007

Berstorff as the new Extrusion Division. Visitors will gain an overview of their combined strength

Machine

Topic

KraussMaffei’s numerous exhibits include

KM 2300 MX SpinForm

SkinForm door module

the largest machine ever exhibited at the K,

KM 300 CX-IMC

Cross-linked TPU-X roll restrictor

a KM 2300-12000 MX SpinForm injection

KM 240 EX CleanForm

100% quality test, syringe barrels

moulding machine. It’s on the KM booth, in

KM 80 EX SilcoSet

Wire-end ferrules, LSR

the injection moulding section alongside other

KM 80 CX CoverForm

Scratchproof surface, flap

high-performance machines. RPM demonstrates

KM 65 CX ClassiX

Integrating proof-of-origin code

and concentrated expertise.

its strength as an exclusive supplier of complete

KMD 133-32 / KMD 63 K

Twin-screw extruder + coextruder

KME 125-36 B/R

High-performance single-screw extruder

Of course, one focus of attention will be on

KM-RKW 39

Large-diameter pipehead

the future prospects of our Injection Moulding,

Inline dimension change

Extrusion and Reaction Process divisions.

QuickSwitch calibrating basket

More than ever before, KraussMaffei intends

PlanetCalander

Film and sheet production

to exploit synergies generated by combining

Modular system with ZE 50 UTX

Compounding system

GE150 with ZRP

Rubber extruder with gear pump

Tandem Hybrid

Abrasive-filled systems

Twin Comet

Small-volume metering

Routing Star

Automated cutting cell

Scoring system

Airbag scoring

Moulds

Flexible solutions

Mixing heads

Mixing head portfolio

systems for PUR processing with a wide diversity of exhibits and examples.

different processes and materials. A wide-ranging technology presentation on the KraussMaffei booth shows innovative engineering solutions, new materials and sophisticated technology combinations. KraussMaffei bundles the expertise of all divisions in order to supply customers with complete, application-specific solutions from a single partner. p

FOCUS

05

High-quality components are a top priority for the automotive sector.

PRODUCT HIGHLIGH T S A T T H E K 2 0 0 7

A unique pairing Centre of attention on the KraussMaffei booth at the K2007 will be machines which integrate several processes. These machines are capable of producing plastic components that match customer specifications today and tomorrow. This means premium surfaces, different surface combinations, and material pairings, all produced with short cycle times and low unit costs.

Higher quality, lower manufacturing costs The trade show machine demonstrates the serviceability of the SkinForm process for volume production of parts which meet OEM requirements for higher quality and lower manufacturing costs. To achieve this KraussMaffei pooled its expertise in injection moulding, reaction processes, automation and tooling technologies. Together with CADENCE Innovation, an established automotive parts supplier from

“As an automotive industry supplier, we must be able to rely on the innovative strengths of our partners.”

06

One of the most impressive machines at the

Liberec/Czech Republic, who took on

K2007 will be on view at the KraussMaffei

responsibility for product development and mould

stand. It’s a manufacturing cell incorporating a

making, we produced a component which meets

spin-platen machine 21 metres long, nine metres

OEM requirements for this technology. Pavel

wide, and weighing 200 tonnes. KraussMaffei

Neumann, Managing Director of CADENCE

will be demonstrating a SkinForm process where

Innovation, explains the reasons for his company’s

the PUR process is fully integrated in the

ongoing (since 1994) partnership with

injection moulding process. This process is ideal

KraussMaffei: “As an automotive industry

for highly-automated mass production in a

supplier we are operating in a very dynamic

“one-shot” process without manual post-

market. We must be able to rely on the innovative

processing. In the first phase, a complex

strengths of our partners. In KraussMaffei we have

thermoplastic substrate – the interior trim for a car door – is injection moulded. In the second phase, the plastic substrate is enhanced by adding a bi-colour polyurethane skin. The PUR mix is poured via a mixing head which is permanently docked onto the mould. In this application, the PUR skin has sections in different colours. The system on show uses KraussMaffei’s multi-colour mixing head ULKP2KVV+2K; pigment is added in the mixing chamber using a MicroDos pigment metering

Marco Gruber (left) and Frank Peters (right) welcomed

Pavel Neumann,

system. This makes it possible to change the

Pavel Neumann (third from left) and Karl Elsnegg

Managing Director of

colour of the PUR skin sections from shot to

(second from left) of CADENCE Innovation at the

CADENCE Innovation.

shot.

KraussMaffei plant in Munich.

FOCUS

MADE BY KRAUSSMAFFEI 1 ¦ 2007

KraussMaffei’s spin-

such a partner.” Other cooperation partners are

via a heated runner and an injection piston into

platen machine is one

Rühl Puromer, ISL Chemie, Bayer Material

the mould. Both parts of the process –

of the most impressive

Science, Bomix, Synventive, Eschmann, Kistler,

compounding and injection moulding – are highly

exhibits at the entire

Robot Technology and Skoda, the OEM.

repeatable. This means constant quality

K2007.

throughout the whole production run, and the

“All in one”: the X-Form process

tight tolerances familiar in injection moulding.

The X-Form is a triumph

A concept machine from KraussMaffei integrates

With a thermoplastic process, it becomes possible

of teamwork: combining

three processes – extrusion, injection moulding and

to use modern tooling and hot runner systems and

an injection moulding

reaction processing – in a single manufacturing cell

to deliver a high-quality, sprueless and flashfree

compounder, a CX injec-

and thus achieves considerably shortened cycle

product. The mould comes from Mues.

tion moulding machine

times. “All in one” achieves the elastic properties

Dr. Erwin Bürkle, Manager Research and

and PUR know-how.

and high resilience of natural rubber and other

Development Process Engineering

elastomers through an innovative curing step.

(Injection Moulding Machinery) at

KraussMaffei will demonstrate that this machine is

KraussMaffei, describes the

ready for mass production with the fully

particular problems which had to be

automated manufacture of a typical 2C component

solved in the development of the

with integrated vibration damping, similar to a roll

process. “The thick walls of the

restrictor. The substrate and the load-bearing

injection moulding component

collar, made of Ultramid CR (PA66-GF35) from

require a relatively long cooling

BASF, are joined together in the mould, in a 2C

period. In order achieve a short cycle

process, by an injected damping element with

time, we decided to apply the TPU-X

adhesive properties.

in two layers.” Despite the thickness of the TPU-X element,

A trailblazing process

manufacturing the part in stages in a

The damping element is made of Elastollan

rotary table mould made it possible

(TPU-X) from Elastogran; it is integrated during

to cut cycle time to 60 seconds

the cooling process following the moulding

instead of 900 seconds using other

process. The crosslinking agent is added to the

processes. As Dr. Bürkle pointed out,

TPU melt as a liquid prepolymer and the two

“This material combination and the

substances are mixed on a KraussMaffei injection

new manufacturing process

moulding compounder (IMC). IMC machines

developed by KraussMaffei and

successfully yoke continuous extrusion and

Elastogran opens up completely new

discontinuous injection in one machine. Because

prospects for applications which were

the extruder operates continuously, it ensures that

previously restricted to rubber-metal

the crosslinking agent is metered continuously

pairings. With this process we can

into the TPU melt and thoroughly mixed to

make a huge difference to production

produce a homogenous compound. The

times. We think we’re right to call it

plasticized and homogenized material is injected

a trailblazing process.” p

CONTACT Marco Gruber Technology Manager SkinForm Phone +49/89/8899 4872 [email protected] Ludwig Jung Product Manager Reaction Process Machinery Phone +49/89/8899 3373 [email protected] Jochen Mitzler Technology Manager Phone +49/89/8899 4410 [email protected]

FOCUS

07

COVERFORM PROCESS

One-step scratchproofing KraussMaffei has perfected the one-step CoverForm process to apply functional surface coatings under cleanroom conditions in the mould right after injection moulding. The simple process cuts the cost of applying a protective, scratchproof layer to plastic parts. used to pour the liquid, acrylic-based reaction mix – produced by Degussa GmbH, Düsseldorf – into the mould cavity. The low viscosity of the reaction system lends itself to long flow paths. The compression moulding stage spreads the coating evenly over the PMMA surface. This process produces a very thin coating layer – under 50 µm. The coating cures in two stages – it cures in the mould until the parts can be demoulded without damage; curing then completes under UV light in a post-mould process.

A dustfree environment A laminar-flow box above the KM 80-180 CX

KraussMaffei CX series machine.

PMMA is the material of choice whenever

clamp unit creates a dustfree environment.

transparency is high priority, for example, in

Operating under cleanroom conditions inside the

displays or cockpit instruments. PMMA produces

machine safety housing, a KraussMaffei IR 50F

the hardest surfaces of any thermoplastic

industrial robot picks the coated part from the

material, but for some applications which demand

mould, presents it for sprue-removal and deposits

a super-hard surface the PMMA is given an

it on a conveyor belt where curing completes

extra scratchproof coating. This coating used

under UV radiation.

to be applied in a relatively complicated post-

The system on show also integrates an

mould process. This has all changed now that

electroluminescent film in the PMMA part.

KraussMaffei and Degussa have jointly developed

Electroluminescent film, which lights up when an

the CoverForm process. The coating is applied

electric current is applied, is increasingly popular

under cleanroom conditions to the PMMA

in lighting systems and displays. p

substrate in the mould immediately following injection moulding. It’s a simple and reliable process that cuts costs dramatically.

Thin coating layer

CONTACT

KraussMaffei is demonstrating this process for

Martin Eichlseder Process Development Phone +49 /89/8899 2542 [email protected]

the first time at the K2007. A specially developed small-volume mixing and metering system is

08

FOCUS

MADE BY KRAUSSMAFFEI 1 ¦ 2007

SUR FACES AT THE K 2 0 0 7

Diversity for the senses Surface look&feel determines whether plastics products look expensive or cheap. High-quality surfaces can only be achieved with suitable processes. There’s a huge diversity of plastic surfaces

like leather, it also shares many of the properties

out there. And look&feel strongly influences

of the natural material.

our intuitive response to a product – which is why the design of the surface is such an

Films and sheet for many tasks

important factor product design. At the K2007

Optically clear films and sheet are used where

KraussMaffei shows its expertise in this field

high levels of transparency, scratch and impact

with a wall of surfaces showing some of the

resistance, UV durability and thermoforming

wide variety of surface finishes available.

ability are required. Films reinforced with fibre insulate houses, swimming pools and

PUR spray skins

rubbish depots. Technical films with a variety

PUR spray skins are a cost-effective way of

of surfaces are used in the automotive and

producing high-quality PUR skins for complex

furniture industries and in civil engineering.

components such as instrument panels, centre

XPS insulating panels are a favourite with

consoles and door trim for vehicles. This

home builders, because they are highly pressure

technology offers, above all, wide freedom in

resistant, non-rotting, a good heat insulator

component design. Complex geometries, such as

and virtually non-

undercuts, can be designed as required. Sprayed

flammable.

material is very evenly distributed, guaranteeing

KraussMaffei

uniform layer thickness. The result is surfaces

Berstorff offers a

that look and feel expensive.

very wide range of machine concepts

More colour with SkinForm

for innovative end

The combination of the SkinForm process and

products. p

the spin-platen technology makes it possible to coat a thermoplastic substrate with a polyurethane skin, which can combine varying thickness and colours. The process is ideal for highly-automated mass production without

Neoprene – water

post-processing. The new spin-platen machine,

sportsmen love this

which KraussMaffei is showcasing at the K2007

material.

(see page 6), will be producing this type of part. The complex thermoplastic substrate is injection

CONTACT

moulded and then, in the second process stage,

Markus Betsche Product and Marketing Manager Phone +49/89/8899 4712 [email protected]

the polyurethane surface – in varying colours – is added. The resulting surface not only looks

FOCUS

09

KE YN O T E

“Above and beyond innovative engineering, Manfred Reichel, Member of the Management Board, Injection Moulding Machinery.

TRAINING COURSES

Step by step to solid expertise

we deliver complete

Every year, KraussMaffei trains hundreds of customer

system solutions,

and maintenance mechanics. The current training

employees as machine operators, set-up specialists

closely matched to the

programme, available on our website, covers our

requirements of our

revised options. The programme is structured to turn

customers.”

full range of training courses, including new and participants into experts step by step. This year there’s an increased offering of special courses and customized training concepts. Multimedia training tools,

Dear Reader,

simulators at every workplace, training in small groups (maximum 12 people) and individual support from our

Welcome to our new company magazine Made by KraussMaffei.

experienced trainers add up to high-calibre training

It covers some of the huge range of concepts, products and

with good outcomes. You can view and download the

applications that go to make up our business spectrum. We

current training programme at www.kraussmaffei.com.

trust it will give you an idea of how committed we are to

Click on Service/Training. p

using our engineering and process expertise, and our grasp of market needs, to develop solutions that help you meet market challenges.

INJECTION MOULDING MACHINERY SALES

Among other topics, there’s an article on the electric EX

Hans Stadler is the new head of IMM sales

range and one on a pioneering natural gas heating system for plasticizing units. We also look at some interesting applications, like fittings manufacture at the Swiss sanitary ware supplier Geberit. There’s an article on cleanroom solutions for medical and pharmaceutical products – an area where we are acknowledged experts – and one on R&D projects we undertake with universities. In the last analysis, we believe these

Effective mid-September, Hans Stadler is the new head

cooperations benefit our customers, as we incorporate the latest

of worldwide sales of the Injection Moulding Machinery

research findings in our machines.

Division (IMM). Hans Stadler (52) is an engineering

I hope you will find a lot to interest you in the magazine. If

graduate with many years’ experience in sales and

you would like more information, you are assured of a warm

management and a record of

welcome at our booth in Hall 15 at the K2007. We trust that

solid success in key account

what always comes across is our commitment to putting our

management. In his new post,

immense know-how in the field of injection moulding machinery

he will have the support of

to work to deliver not only innovative machinery, but also

a restructured management

complete, application-specific solutions for our customers.

team of experienced players. Among them is Hans-Jürgen

With best regards

Schulze (40), who returns to KraussMaffei after a brief absence to lead the Systems

Manfred Reichel

and Solutions team. Michael Skerat will be responsible

Member of the Management Board,

for sales activities in Germany, Holger Tumat focuses on

Injection Moulding Machinery

international sales and Bengt Schmidt heads up the team working on key accounts. p

10

KEYNOTE | NEWS INJECTION

MADE BY KRAUSSMAFFEI 1 ¦ 2007

COMPLETE SOLUTIO N F O R F I T T I N G S

Automation in a tight space Among the items manufactured at the Geberit production plant in Jona, Switzerland are injection moulded fittings for the company’s low-noise Silent drainage system. The new KraussMaffei manufacturing cell that went into operation recently demonstrates just how much automation and performance can be packed into a very small space. With its mature technology and innovative drive,

control cabinet normally stands. The control

the Geberit Group is European market leader in

cabinet itself has been relocated to the machine bed

sanitary technology. Over the years, the company

beside the injection unit. The control system for the

has pioneered solutions that count as milestones in

LR 300 robot is fully integrated in the machine

the progress of sanitary engineering. At its

control system for extra ease of use. KraussMaffei’s

production plant in Jona, Geberit runs an injection

competence and experience in both injection

moulding operation producing elements for its

moulding and automation has generated a

Silent building drainage system. As the name

customized, high-performance manufacturing

suggests, Silent is a pipe and fittings solution

solution for Geberit. It completely meets the

designed to minimize the noise of flushing toilets

company’s specifications for reliability, high

and emptying baths. It’s targeted at buildings where

product quality, low labour costs and minimla

sound insulation is high priority. The pipes and

space requirements. p

fittings are made of a specially developed, high-

A Silent acoustic drainage system (above)

density polyethylene. The filler content increases

cuts noise levels in

the density of the material to around 1.7 g/cm3 to

CONTACT

buildings. Geberit’s

dampen vibrations and reduce noise levels.

Manuela Kneidinger Robots and Automation Systems Phone +49/89/8899 4105 [email protected]

new manufacturing

Geberit now produces fittings for the Silent range – bends and branches – in a fully automated manufacturing cell supplied by KraussMaffei. At

cell packs a maximum of automation into a minimum of space.

the heart of the cell is a KM 800-1200 MX injection moulding machine fitted with an LR 300 linear robot. Part of the design brief for the system was to achieve a very high level of automation in a very tight space. The KraussMaffei MX machine with its compact 2-platen clamp is ideal for this task. The plasticizing unit was adapted to handle the abrasive material – with a special screw geometry, armour-plating on the screw and wear protection for the barrel.

A custom solution Space in the production halls is in short supply and the system demonstrates how KraussMaffei engineers tackled the problem. For example, you’ll find the sprue waste conveying chute where the

APPLICATION

11

SERVICE INJECTION M O U L D I N G M A C H I N E R Y

Engineering and support go hand-in-hand The Service team from KraussMaffei’s Injection Moulding Machinery division promises to exceed your expectations – with reliable spare parts logistics and a high quality of service. Our customers know they can rely on us 24/7, year in, year out.

the factory’s power supply lines by temporarily storing reactive current. Remote service, or teleservice, is an on-going topic. At the K2007, KraussMaffei will be launching a new teleservice concept. It’s a combined hardware/ software solution that generates a Virtual Private Network (VPN), a secure zone exclusive to communication between the customer’s machine and the KraussMaffei service centre.

All-round service package for a machine move Correctly maintained, KraussMaffei injection moulding machines have a service life of 20 years

Proactive service for your injection

One aspect of our service is energy management,

and more. During this time, it can happen that a

moulding machines

which will be a focus at the K2007. After an on-site

machine has to be moved from one production

is one of Krauss-

analysis of the machine’s power consumption, our

plant to another. KraussMaffei can handle all the

Maffei’s great

service engineers use their expertise to recommend

planning and effort that such a move entails. We’ll

strengths.

measures for optimizing power consumption and

inspect the proposed new location, draw up a

the heating system. The aim is to ensure that the

dismantling protocol, dismantle your machine,

machine continues to produce the same product

organize the transport, install the machine at the

quality, but makes more effective use of energy.

new site, commission it and, if necessary, train your

We have a suite of engineering solutions on offer,

operating and maintenance staff. We offer a

including the KraussMaffei Economiser, the new

complete package and highest service quality.

gas heating system, electric screw drives, and our

12

energy analysis software package for the control

Training from the experts

system. The KraussMaffei Economiser is a technical

The 2008 training programme for KraussMaffei’s

The KraussMaffei

solution for saving energy on injection moulding

Injection Moulding Machinery division will be

Economiser: con-

machines. Its integrated motor management can

published to coincide with the K2007. Two new

serves resources

achieve power savings of up to 20%. With the

thematic areas have been added: “Expert

and saves costs.

Economiser, our customers also reduce the load on

programming for LR and LR-S linear robots” and

FOCUS INJECTION

MADE BY KRAUSSMAFFEI 1 ¦ 2007

SOME OF KRAUSSMA F F E I ’ S C U R R E N T S E R V I C E P R O D U C T S Spare parts and retrofit

Service

• Plasticizing unit:

• Installation, commissioning, repairs

• Programming LR/LR-S robots

• Modular maintenance packages

• Cleaning the machine

– performance upgrade – quality improvement – loan, test and exchange scheme

(Calibration, Standard, Full-service) • Preventive maintenance:

• 24-hour hotline • KraussMaffei training courses:

– thermal camera inspection

– machine operation

• GSM radio element

– endoscopic inspection

– process engineering

• Software packages

– ultrasonic examination

– quality assurance

– refurbishing and retrofit

• Robots (also for non-KM machines)

• Measurement and calibration

– maintenance

• KraussMaffei Economiser

• Repositioning machines or moving

– programming • Energy management

factories

“Maintenance and troubleshooting for linear

and other centres in major market regions. You

robots”. In 2008 in response to customer requests,

can be sure that our technicians can reach you

KraussMaffei will again be offering combined

quickly. We also hold local workshops on special

training courses for operators, maintenance

topics. With a strong regional focus, we pride

technicians and robot specialists.

ourselves on our local knowledge of the different regions in which we operate. p

Worldwide service The complete Injection Moulding Machinery service offering is available anywhere in the world. And customers have the assurance of knowing they always contact one and the same partner at KraussMaffei for information and action on any part of this wide service offering. We operate a

CONTACT Jürgen Meiser Product Manager Service Injection Moulding Machinery Phone +49/89/8899 3121 [email protected]

Our service offering includes modernizing and marketing used machines.

close-meshed network of service centres – three alone in Germany

FOCUS INJECTION

13

PARTNERSHIPS WIT H U N I V E R S I T I E S

Working together to push the pace of progress For many of its development projects, KraussMaffei often works in close partnership with university faculties. The advantages are mutual: the universities can offer their students training in new technologies on advanced machinery, while KraussMaffei is frequently able to put the results of joint research into practice immediately. The starting point for any

Another example of a cooperation is our research

partnership between an

partnership with the Institut für Kunststoffverar-

industrial concern and a uni-

beitung (IKV) at the RWTH Aachen in the special

versity is always a common

research field of optics. Here the topic is manu-

interest. “We look for con-

facturing complex lens systems – very sensitive,

vergences between projects

high-quality products – using injection moulding

on which potential partners

technology.

are currently working and our in-house development

Mutual advantage

projects,” explains Dr.

On the one hand, KraussMaffei and our customers

Erwin Bürkle, the Manager

profit from the fact that the latest research results

Research and Development

flow into the development of machines and pro-

Process Engineering in

cesses. On the other hand, the universities benefit

KraussMaffei’s Injection

from access to innovative machine technology for

Moulding Machinery Divi-

teaching and research. Dr. Erwin Bürkle mentions

sion. “It is often a matter

yet another aspect, “When students are doing

of working out the basic

project and thesis work on our premises, or at the

processing or mechanical

university, within the framework of a research

principles for an on-going in-

partnership, it’s an opportunity for us to get to

house development project.

know each other. They may be potential candidates

Dr.-Ing. Erwin Bürkle,

If we’re working on a joint project, we’ll usually

to join the KraussMaffei team on a long-term basis.

Manager Research and

provide the university faculty with an appropriate

Moreover, during these research partnerships, the

Development Process

laboratory machine for the research work.”

young people gain a wide basic knowledge which

Engineering (Injection

One of our current research partnerships is with

equips them for later tasks in development, applica-

Mounlding Machinery).

the Institut für Kunststofftechnik (IKT) at the

tion engineering, project planning or in technical

University of Stuttgart developing techniques for

sales departments.”p

reactive processing directly on the injection moulding machine. One example of this type of process is the continuous crosslinking of thermoplastic polyurethanes. In fact, all the basic engineering for the IMC compounder was done in partnership with the specialists for process engineering at the IKT in Stuttgart.

14

APPLICATION

CONTACT Dr.-Ing. Erwin Bürkle Manager Research and Development Process Engineering (Injection Mounlding Machinery) Phone +49/89/8899 2799 [email protected]

MADE BY KRAUSSMAFFEI 1 ¦ 2007

ERWES REIFENBERG A N D K R A U S S M A F F E I

A tradition of partnership Mouldmaker Erwes Reifenberg GmbH & Co. KG, Finnentrop, Germany, has added a KraussMaffei C3-AP injection moulding machine to its test lab equipment. The decision continues a long and successful cooperation.

The cooperation partners and the new KM 140-1000 C3-AP injection moulding machine in Erwes Reifenberg’s development lab (from left): Rudolf Erwes (Erwes Reifenberg), Andreas Hanschke, Frank Englert, Peter Bruckbauer (KraussMaffei), Jan Hock (Erwes Reifenberg), Jochen Mitzler, Markus Schinabeck

Founded in 1976, Erwes Reifenberg has always

(KraussMaffei), Oliver Drefs, Bernhard Schneider (Erwes Reifenberg), Martin

specialized in precision moulds for plastic clo-

Schima (KraussMaffei).

sures. This includes closure systems for beverage and edible oil bottles, flip tops, child-proof closures, single-handed closures, snap caps and

combined with fast clamp movements, give C3 AP

screw caps, and special closures for medical pack-

machines extremely fast cycle times.

aging. Thanks to the long-term specialization,

The Erwes Reifenberg lab is now populated with

Erwes Reifenberg has built up extensive know-

five injection moulding machines, with clamp

how in precision moulds. The company has the

forces between 22 and 250 tonnes. The machines

resources and know-how to support its customers

are used to test moulds under production condi-

in developing innovative closure systems.

tions and to define the process parameters for volume production. By optimizing system and

High-performance for packaging

mould technology, the company can be confident

Erwes Reifenberg recently invested in a Krauss-

of meeting the escalating requirements of custom-

Maffei KM 140-1000 C3 AP injection moulding

ers and markets. The close collaboration between

machine. This is a high performance machine

Erwes Reifenberg and KraussMaffei benefits

for the packaging sector with enhanced injection

customers, who can call on the joint support of

performance and a high-powered ejector. The

the two companies to take their project through to

2-platen design guarantees very easy access to

successful series production. p

the mould and to the ejector zone. The compact design gives the machine a relatively small footprint. The HPX high-performance plasticizing unit can be relied on to produce a homogenous, high-quality melt. The C3 AP has an electrically driven plasticizing unit, so that plasticizing can take place while the

CONTACT

mould is opening or closing, which is hydrauli-

Stefan Bayer Project Planning Phone +49/89/8899 2545 [email protected]

cally driven. The high-performance twist-out unit allows the closures to be demoulded simultaneously with mould movements. These features,

APPLICATION

15

PROCESSES FOR MEDICAL TECHNOLOGY AND PHARMACEUTICALS

Achieving top cleanliness classes Escalating competition makes continuous improvement and the development of new, innovative processes essential in many sectors – for example, in medical technology and pharmaceuticals. Processors supplying these sectors know that their products must satisfy the highest criteria for cleanliness and quality. KraussMaffei has many years’ experience with injection moulding machines and peripheral equipment for plastics processing under cleanroom conditions.

Ideal for cleanroom production: machines from the CX Hybrid series.

When KraussMaffei experts and their customer

US Fed. Std. 209 class 100 or EG GMP class A).

embark on a new medical technology project, they

The company has thus proved that its manufactur-

start by analysing the entire process – from the

ing systems are in full compliance with the relevant

pellets to the packaged plastic product. Logistics

cleanroom standards. An important cost benefit of

issues are of prime importance for cleanroom

cleanroom production is eliminating the need for a

production. How do the raw materials get into the

downstream sterilization step.

cleanroom? How does the finished product come out of it? How to locate the machinery and periph-

Pioneering new solutions

erals for the smallest and most compact cleanroom?

Almost all cleanroom applications today use stan-

The outcome of all their work must be a produc-

dard processes running on conventional machines,

tion system which manufactures the product in

sometimes with slight adaptations. New materials

question without waste and in perfect quality. A

are likely to offer exciting new properties, but they

high degree of automation is also desirable, because

can’t be processed using conventional techniques.

people are the biggest source of particles, not to

Processes like injection moulding will have to be

mention bacteria and viruses. The use of robots is

yoked with other technologies and undergo further

also a guarantee for consistent processes, a high

development. Today, KraussMaffei is working with

degree of repeatability and constant quality. With

manufacturers of medical and pharmaceutical plas-

different access rights for operators with differing

tic products to pioneer new solutions. p

levels of training, and extensive documentation, a KraussMaffei system ensures 100% traceability for any changes to the settings. To date, KraussMaffei is the only manufacturer of injection moulding machinery which has on several occasions successfully complied with cleanroom class 5 as per DIN EN ISO 14644 (corresponds to

16

FEATURE

CONTACT Thomas Hörl Project Planning Phone +49/89/8899 3805 [email protected]

MADE BY KRAUSSMAFFEI 1 ¦ 2007

THE ELECTRIC EX SERIES

No compromises KraussMaffei’s EX all-electric injection moulding machines are engineered for high precision and fast cycles. They are ideal for high-performance mass production of packaging, medical and electronics products under cleanroom conditions. There’s no room for compromise when even

fast signal processing makes for rapid responses in

minimal contamination or shot weight deviations

multitasking operation.

can result in high reject rates and the associated costs. KraussMaffei’s EX machines are the answer.

Quality for high-spec products

Key to their high performance is the patented Z

EX machines are ideal for cleanroom production.

toggle clamp with its almost optimal clamping

Encapsulated pivot points eliminate contamination

profile and electric drives. Fast movements cut

risks and efficient water cooling reduces the

clamp force build-up and release times to a

machine’s impact on cleanroom air-conditioning

minimum for very short dry run times.

systems. High-resolution electric drives ensure

The patented Z toggle is a new clamping system

outstanding repeatability. Extremely consistent shot

that deliberately reduces the number of moving

weights, with variation under 0.07%, guarantee

The patented Z

parts to eight pivot points. One obvious effect is

premium products and make it possible to control

toggle stands for

to minimize downtime and simplify service and

material consumption very tightly.

high precision and

maintenance.

Flexibility is another key feature of EX machines.

fastest dry cycle

The direct drive transmits the force of the high-

They are ready for easy upgrading to automated

times.

torque motors directly to the screw in the same

manufacturing cells and can be teamed with other

axis for maximum performance, reduced power

units for special processes.

consumption and low heat generation. The

At the K2007, KraussMaffei is showcasing a 240 t

outcome is higher efficiency and lower energy

EX machine, the KM 240-1000 EX, producing

consumption – as much as 50% lower than a

barrels for disposable syringes in a cleanroom unit.

comparable hydraulic machine. The proven and

A side-entry robot removes the parts, performs

super-efficient MC 5 microprocessor control is

a 100% quality check, and drops them on a

standard on EX machines. Operator-friendliness

synchronized buffering conveyor belt. p

and easy, intuitive use help to avoid input errors; EX machines guarantee speed and precision for high-volume mass production under cleanroom conditions.

CONTACT Dejan Hense Application Engineering Phone +49/89/8899 2969 [email protected]

FEATURE

17

EXTRA-LARGE INJEC T I O N U N I T S F O R B I G I N J E C T I O N M O U L D I N G M A C H I N E S

Gigantic in every way MX machines are engineered to deliver sustained performance – with the right injection unit for the job. Successful moulding of very large products demands huge plasticizing performance; this is where our extralarge injection units come into their own.

either when it comes to injection performance. Even at its highest injection speed, the injection unit achieves and holds the maximum injection pressure – over the whole injection stroke. This extraordinary injection performance makes it feasible to consider reducing the product’s wall thicknesses. With material costs accounting for on average 80% of total manufacturing cost, this is an important consideration. MX machines can also cut cycle times significantly. For the pump systems, we offer pumps with ratings from 250 to 500 kW. The oil-cooled pump drives guarantee top efficiency. Parallel movements can be taken for granted. In addition, gearless, Extra-large

Producing very large parts means processing a

electric screw drives up to 440 kW are available.

injection units,

large volume of polymer in a very short time. To

Force is transmitted to the screw directly via a

here an SP 75000

achieve consistently high product quality, melt

rotary-type injection piston. The result is a highly

with an SP 17200

quality must remain constant even at these very

dynamic system and very low frictional losses.

piggybacked above

high throughput rates. Typical products in this

Operating under closed-loop control, the extra-

it, plus the fastest

category are pallets, box pallets, rubbish bins, and

large injection units achieve constant shot weights,

big machines on

fittings and tank elements for the construction

together with stable and repeatable processes.

the market and

industry. KraussMaffei’s extra-large injection

Reject rates are reduced to a minimum. p

smart automation

units (SP 33.000, SP 55.000, SP 75.000 and SP

solutions make an

101.000) are the answer. It’s also feasible to use

unbeatable team.

two injection units side by side, if an application requires even higher shot weights.

Highly stable process Hallmarks of the big injection units in the MX series are big screw diameters, high shot weights, optimized wear protection and outstanding plasticizing performance (up to 1000 g/s for polyolefins). Advanced barrier screws ensure excellent melt quality, even at top throughput rates and short dwell times. No trade-offs are necessary

18

FEATURE

CONTACT Peter Bruckbauer Manager Application Engineering Phone +49/89/8899 2268 [email protected]

MADE BY KRAUSSMAFFEI 1 ¦ 2007

HEATING PLASTICIZ I N G U N I T S W I T H N A T U R A L G A S

Clear savings on energy costs In the near future, natural gas heating systems for plasticizing units will conquer the market as the economic alternative to electric heating elements. A natural gas barrel heating system developed in partnership with KraussMaffei achieves a marked improvement in the energy efficiency of the injection moulding process.

The first installations – here for the production of

The first prototype natural gas barrel heating

of the flame are certified components in use for

automobile body

system has been in operation for almost 12 months

many years in gas systems and completely safe.

sections – are already

in regular production at the Reinsdorf factory of

Furthermore, the gas heating elements require no

being tested.

Plastal GmbH. A KM 4000-24500 MC, a 4000 t

service and do not use an open flame. Using gas

injection moulding machine with a screw diameter

heating instead of conventional systems can deliver

of 150 mm was modified to use the new heating

annual savings of over 10,000 euros. The extra

The new natural

system. Plastal uses the machine to produce

investment can thus be recouped within a very

gas barrel heating

bumpers in a three-shift operation. Before the green

short time. A further important aspect is the benefit

elements deliver

light was given for mass production, a preliminary

to the environment of using natural gas. As a

a significant

series was subjected to a detailed and very

primary energy source, gas can be used in a heating

improvement in the

comprehensive quality control. No differences were

system without transformation losses. This makes

energy efficiency of

found between this series and parts produced using

it a much more efficient source of energy, which

an injection moulding

an electrically heated plasticizing unit.

helps to reduce CO2 emissions. p

process.

Economic and environmental advantages A gas heating element consists of two semi-circular heating pads which are mounted directly on the barrel of the injection moulding machine using quick-release catches. Together the two halves form a complete, sealed unit. Their modular design makes it easy to add or remove individual heating elements. It is also simple to modify machines that are already in operation. The counter-current principle employed and the combination of convection and radiant heat transfer produces a very even temperature distribution. The design also prevents local overheating and the risk of thermal damage to the melt. The gas heating system is fully integrated into the machine control system, so for the operator there is no difference to an electrically heated machine. Heating elements powered by natural gas are just as safe as the familiar electric heating elements. The components used for mixing, performance regulation, ignition and electronic monitoring

CONTACT Thomas Hungerkamp Plasticizing Unit Development Phone +49/89/8899 2321 [email protected]

FEATURE

19

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INJECTION MOULDING TECHNOLOGY

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www.kraussmaffei.com

Injection Moulding Technology Division Injection Moulding Machinery is KraussMaffei‘s biggest division. The CX, EX and MX Series, KraussMaffei’s three injection moulding machinery ranges, offer solutions for almost all injection moulding tasks, from standard to special processes. KraussMaffei holds a strong position in the market for big machines and as a machine and systems supplier to the automotive industry. Other industry focuses include packaging, electrical/ electronics and medical technology. With its expanding knowledge base in robotic systems and automation, the division is rapidly building a significant position as a full-system supplier of complete manufacturing cells.

At your service woldwide Team America/Spain Injection Moulding Service Team E-mail: [email protected] Injection Moulding Spare Parts Team E-mail: [email protected] Team Europe Injection Moulding Service Team E-mail: [email protected] Injection Moulding Spare Parts Team E-mail: [email protected] Team Asia/ Near East Injection Moulding Service Team E-mail: [email protected] Injection Moulding Spare Parts Team E-mail: [email protected]

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