km made by 1 2010 eng

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

“Technology

advances mark the

way forward.”Dr. Dietmar Straub,

KraussMaffei CEO.

EDITORIAL

made by KraussMaffeiPublished by: 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 Responsible: Matthias Andreesen Viegas

PUBLICATION DATA

EDITORIAL | NEWS

Editorial office: mk publishing GmbH, Döllgaststraße 7–9, 86199 Augsburg, Phone +49/821/3 44 57 0, Fax +49/821/3 44 57 19, www.mkpublishing.de Photo credits: Becker Kunststofftechnik, Bikkoplast/Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunst-stofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM

02 MADE BY KRAUSSMAFFEI 1 ¦ 2010

Dear Readers,

Forcing down costs, increasing efficiency and boosting productivity – these

are key concerns right now throughout the plastics industry. It takes new-

generation machines and systems to gain a key competitive edge; technology

advances mark the way forward.

This holds true for KraussMaffei as much as for the rest of our industry. It’s

why we’ve recently invested a substantial amount to boost quality and

productivity in our main production plant in Munich. Our new Surface

Treatment Center opened just a few days ago, replacing our previous paint

shop. All in all, the new facility cost around four million euros – you

couldn’t ask for a stronger sign of our conviction that the economy can and

will recover. Experts tell us that you’d have to look a long way to find the

equal of our new facility anywhere in the world. For example, we now

move parts and modules weighing up to 32 tonnes through the paint line on

an overhead track system synchronized with the rest of the assembly line.

When the system is operating at full capacity, it is handling the equivalent

of the take-off weight of an Airbus. As you see, we never let up in our

pursuit of quality and productivity for our machines and processes. But

your vote is the decisive one – as our customer you have the final say in

whether we’re offering you the right solution at the right time!

If you’re among the customers who currently have no plans for major

investments, we can nonetheless show you affordable options for increasing

the efficiency of your production. Our retrofit packages and upgrades can

significantly improve the productivity and energy efficiency of your installed

machines. You might opt for a higher level of automation with a robot from

our expanded portfolio, or for reduced energy consumption with one of our

efficiency packs. Especially in recent years, KraussMaffei has taken up the

theme of energy efficiency; today “BluePower” stands for the products and

upgrades we offer to help you reduce energy consumption. To add even

more momentum to this strategy, KraussMaffei has now launched the

BluePower Award, which will honour energy- and resource-efficient

production solutions. We’ll be announcing the winners during the world’s

biggest plastics show, the K2010, at the end of October. We’re looking

forward with great interest to your competition entries.

With best regards,

Dr. Dietmar Straub

BluePower is the

concept that bundles

our continuing

endeavours to

promote the

development

of energy- and

resource-efficient

production

solutions. As part

of this effort, KraussMaffei has now launched

the BluePower Award inviting entries from all

the innovative plastics processors among our

customers.

We’re looking for new developments that deliver

a significant increase in energy- and resource-

efficiency. They can be anything from individual

applications and processes to complete concepts

– and they can come from any area of the plastics

processing industry. We’re especially interested in

processes that make sustainable use of synergies

through intelligent combinations of different

technologies, such as injection moulding, reaction

moulding and extrusion. The entries will be

evaluated and the winner selected by an independent

jury panel made up of high-ranking representatives

from science and industry. KraussMaffei employees

will not be eligible to vote on this panel. The winner

of the BluePower Award 2010 will be announced on

October 28, during the world’s biggest plastics show,

the K2010 in Düsseldorf, Germany. Closing date for

entries, which must be in writing, is May 31, 2010.

More information and details of how to enter are

contained in a questionnaire that you can request by

email. p

KraussMaffei sets up a prize for efficiency!

BLUEPOWER AWARD 2010

CONTACT

Dr. Reinhard SchiffersPredevelopment/EnergyPhone +49/89/[email protected]

KraussMaffei Berstorff is now offering complete

systems for continuous production of PU-

insulated pipes. One, or two, plastic media pipes

is encapsulated in an insulating polyurethane

layer plus a protective polyethylene sheath.

The insulated pipes can transport either hot or

cold media. With this single-vendor production

solution, the company, a world leader in

plastics and rubber processing machinery,

once again demonstrates its multitechnology

competence – in this case in pipe extrusion and PU processing – built on

many decades of engineering excellence. This unique know-how enables

us to develop complete production solutions by skilfully integrating

modules from different technologies. p

NEWS

Events through to autumn 2010

TRADE SHOWS

19. – 22.04. Chinaplas Shanghai, China

19. – 23.04. Expoplast Algiers, Algeria

11. – 14.05. RusChem Moscow, Russia

11. – 15.05. Technics Belgrade, Serbia

13. – 16.05. Plastex Cairo, Egypt

25. – 28.05. Plastpol Kielce, Poland

26. – 28.05. PU China Shenzhen, China

14. – 16.09. Composites Essen, Europe Germany

27.10. – 03.11. K 2010 Düsseldorf, Germany

COVER

03

��

��

��

��

� �

��

Perfectly paired off:pipe plus insulation

Bavarian Economics Minister

Martin Zeil (right) and

Dr. Dietmar Straub,

KraussMaffei CEO, at the

opening of the new Surface

Treatment Center.

KraussMaffei has recently completed a future-oriented project in our main

production plant in Munich. Guest of honour at the opening of the new Surface

Treatment Center (STC), on March 5, 2010, was Bavarian Economics Minister

Martin Zeil. The new facility replaces our previous paint shop. In his address,

Martin Zeil commented, “The German plastics machinery sector has been

especially hard hit by the turbulence of the economic crisis. This is why I’m

absolutely delighted with every Bavarian company that has taken the crisis

as a spur to look ahead, modernize and invest. With its new and innovative

paint facility, KraussMaffei is among the leaders in this area too.” Despite the

economic crisis, KraussMaffei invested around four million euros in building and

equipping the STC. As Dr. Dietmar Straub, CEO of KraussMaffei AG, pointed

out, “With the new Surface Treatment Center we’re improving the transparency

of our entire assembly process; it will enable us to work more efficiently and

cut our turnaround times – our customers will benefit significantly.” The STC

was planned and built in a close collaboration between KraussMaffei and

Rippert Anlagentechnik GmbH & Co. KG, from Herzebrock-Clarholz/North

Rhine-Westphalia. Rippert, a systems engineering company with around 300

employees, has almost 40 years’ experience in planning and installing painting

and filtering systems and industrial ventilation units. Complex coating systems

are among its core competences. p

MULTI-MILLION INVESTMENT

New Surface Treatment Center opened

04 MADE BY KRAUSSMAFFEI 1 ¦ 2010

Cleanroom Competence Center in Rosenheim,

opened on January 29, 2010, provides an excellent

environment for researching this field,” emphasizes

Martin Würtele, Manager Predevelopment New

Technologies at KraussMaffei. Under the aegis of

Prof. Peter Karlinger, researchers in Rosenheim

are working on a complex production cell based

on a KraussMaffei all-electric EX 80/380. “Our

cooperation with the university in Rosenheim has

already generated a large number of successful

projects and graduate theses across all three key

technologies – injection moulding, extrusion and

reaction moulding,” says Martin Würtele. Much

of this research is aligned with KraussMaffei’s

“Technology to the Power of Three” strategy. With

the opening of the competence center, Rosenheim

University became part of the PRIMUS Network

for Innovation set up by KraussMaffei (responsible

for the focus area “Life Sciences”).

Focus on energy efficiency

The University of Duisburg-Essen (UDE) is

also a member of the PRIMUS Network. Since

January 15, 2010, there’s been a cooperation

agreement between the university’s Faculty of

KNOW-HOW SHARING DRIVES DEVELOPMENT

Development engineers in mechanical engineering companies are not the only people working on solutions to tough challenges in plastics processing – there’s a lot of academic research going on too. In Germany alone, KraussMaffei supports over 20 universities and other research institutions with machinery and know-how. Life sciences, lightweight structures and energy efficiency are among the key research topics.

One strong trend in

plastics research is

the increased focus on

the life sciences sector

– medical technology,

pharmaceuticals and

cosmetics. There’s

a long-standing

cooperation in

this area between

KraussMaffei and

Munich’s University

of Technology (TU), with ordinarius professor

for medical technology, Prof. Dr. Dr. Erich

Wintermantel. TU researchers and students have

two injection moulding machines, including an

EX 50/55, and a compounder at their disposal for

experiments.

Relatively new, by contrast, is the cooperation

agreement between KraussMaffei and Rosenheim

University of Applied Sciences. It’s also focused

on the life sciences field and especially on

cleanroom technology. “One of the main concerns

in this sector is to develop processes that make

post-mould sterilization unnecessary. The new

FOCUS

Industry and research hand-in-hand

Celebrating another

recent cooperation

agreement: Prof. Dr.

Dieter Schramm and

Prof. Dr. Johannes

Wortberg from the

University of Duisburg-

Essen with Dr. Karlheinz

Bourdon and Georg

Holzinger, from

KraussMaffei (l. to r.).

05

Engineering and KraussMaffei with the specific

goal of improving the energy efficiency of plastics

processing machinery. The strategic cooperation

partner on the university side is the chair of

Engineering and Plastics Machinery headed by

Prof. Dr.-Ing. Johannes Wortberg. The cooperation

partners have agreed on regular information

exchange and supporting engineering students and

researchers. One specific area of cooperation will

be developing and optimizing alternative drive

technologies for plastics processing machinery. The

remit for this project includes energy consumption,

energy recovery, precision and efficiency.

KraussMaffei is mainly concerned with developing

and optimizing components, in particular with the

practical implementation and with application-

related process engineering.

Combined process for function-integrated

lightweight systems

The cooperation between KraussMaffei and the

Institute for Lightweight Structures and Plastics

Technology at Dresden University of Technology,

headed by Prof. Dr. Werner Hufenbach, dates

back to 2008. One important area of research

here is fiber-composite lightweight elements and

the development of new resource-efficient process

chains for manufacturing them. The researchers

in Dresden have at their disposal an innovative

LFI (Long Fiber Injection) system, including a

shuttle mould carrier, supplied by KraussMaffei’s

Reaction Process Machinery division. The research

encompasses multitechnology and multiprocess

solutions.

The Center for Integrative Lightweight

Technologies (ZIL) at the Chemnitz University

of Technology is working in related fields. For

example on the development of a new combined

process for reinforcing plastics with long fiber

materials and fabric intermediates in injection

moulding. These types of lightweight composites

are used in making anything from aircraft to

rolling stock and road vehicles, because their

lighter weight reduces fuel consumption and

carbon dioxide emissions. The ZIL, headed

by Prof. Dr. Lothar Kroll, operates a total

of six KraussMaffei machines, including a

multicomponent spin-platen machine, a RIM

polyurethane system and an IMC injection

moulding compounder. A new addition to the

center’s machine park is a ZE 40 A x 50 D UTXi

twin-screw extruder from KraussMaffei Berstorff

engineered for high-performance compounding

tasks. “Basic research is very important for us

as a mechanical engineering company, because

it paves the way for adapting our extruders

to market requirements and to continuously

developing them,” points out Prof. Dr. Bernd

Poltersdorf, head of Foam, Film and Sheet

Extrusion at KraussMaffei Berstorff. p

FOCUS

CONTACT

Martin WürteleManager PredevelopmentNew Technologies/Process EngineeringPhone +49/89/[email protected]

Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]

Prof. Dr. Bernd PoltersdorfManager Foam, Film and Sheet ExtrusionPhone +49/511/[email protected]

Prof. Dr. Lothar Kroll,

Dr. Wolfgang Kempt and

Dr. Wolfgang Nendel

(from left) of the TU

Chemnitz with the ZE

40 A x 50 D UTXi twin-

screw extruder from

KraussMaffei Berstorff,

Hanover, which offers

new scope for research.

06 MADE BY KRAUSSMAFFEI 1 ¦ 2010 FEATURE

– adding up to around 14 in total. “Thanks to our

joint project with Evonik, we can now offer our

customers a far more cost-effective process,” says

Dr. Karlheinz Bourdon, head of KraussMaffei’s

Injection Moulding Machinery division. And Josef

Renkl, R&D Manager for the company’s Reaction

Process Machinery division adds, “Thanks to our

multitechnology know-how – in this case injection

moulding and PU processing – we’ve been able to

develop the process to market readiness. It will

dramatically shorten the process chain. The new

CoverForm process has just four steps: incoming

check, injection moulding and coating in the same

mould, quality control, final assembly. All these

steps are performed in one and the same machine.

The process saves time, costs and production space.

In addition, the surfaces produced in this way are

often more scratch-resistant than those that are

COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK

Display panels in mobile phones, appliances,

consumer electronics and automotive instrument

panels are made of transparent polymers.

The displays must remain transparent despite

exposure to mechanical and chemical impact, for

example, through cleaning agents or handcreams,

otherwise they are not fit for purpose. The

material most used for these applications is

polymethyl methacrylate (PMMA) often known

by the tradename Plexiglass. The PMMA must

be specially coated to protect the surface from

scratches and chemical damage. In conventional

production, this coating is applied in a post-

mould paint process.

A far shorter process chain

A conventional process comprises multiple steps

including quality controls, storage and transport

Joint project in surface treatment technology

Dr. Karlheinz

Bourdon, member of

KraussMaffei’s Board of

Management (left) and

Gregor Hetzke, head of

Performance Polymers

at Evonik, at the opening

of the CoverForm

Competence Center.

The CoverForm process, developed by KraussMaffei, as machine supplier, and Evonik, as material supplier, substantially shortens the process chain for the production of transparent, scratch- and chemical-resistant parts. Processors save transport effort, time and production floor space – in the last analysis they save costs. The quality is often better than can be achieved in a conventional painting process.

COVERFORM PROCESS STEPS Inl ine scratch-resistant coating of PMMA

Inject PMMA

Compression/cooling

Open cavity & inject coating

Compression & heating 100%

Compression & cooling

Compression & start heating

FEATURE 07

conventionally painted. It couldn’t be simpler. This

is how CoverForm works – after injection of the

special PMMA, a mould stroke forms the surface

to be coated. The part cools in the mould. The

cavity is then enlarged slightly, creating a space for

the surface coating layer. This gap is flooded with

a liquid reactive system, ideally matched to the

PMMA material, and the mould closes in a second

compression stroke. The high-performance Dynamic

Temperature Control (DTC) ensures that the

temperature profile in the mould, required for the

different process stages, is exactly repeated in each

cycle. The only post-mould process is UV curing

which takes place immediately after demoulding.

The parts are then ready for assembly.

Competence center

for award-winning process

In November 2009, a CoverForm Competence

Center was opened at the Evonik plant in

Darmstadt – it’s the ideal

place to demonstrate

the new process. The

center was opened by

Gregor Hetzke, head of

Performance Polymers at

Evonik and Dr. Karlheinz

Bourdon. Evonik is using

the new center both for demonstrations and for

further development of reactive systems. Among

the possible candidates are new anti-reflective or

electrically conducting coatings. In addition, the

center is the ideal training environment for the

technicians in Evonik’s worldwide service teams.

despite its relatively short time on the market,

CoverForm has already won an award. At the

Materialica trade show, last autumn in Munich,

it won “Best of” award in the category Surface

and Technology. In its review, the jury noted

that CoverForm is a forward-looking,

market-ready process which is the

result of productive interaction between

materials, engineering expertise and design.

CoverForm is a system solution available

exclusively from the joint partners Evonik

and KraussMaffei. It’s yet another example

of the sustained increase in productivity

that can be achieved by joining up

processing technologies, as advocated by

KraussMaffei’s “Technology to the Power

of Three” strategy. p

KraussMaffei injection

moulding machines are

at the heart of CoverForm

production cells.

CONTACT

Marco GruberManager Application Engineering,Process Development IMMPhone +49/89/[email protected]

Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]

Sven Schröbel, Evonik

Industries, Martin

Eichlseder, KraussMaffei,

and Arne Schmidt, Evonik

Industries (from left),

showing off the “Best of”

award at the Materialica.

Demoulding Final curing (UV curing)

08 MADE BY KRAUSSMAFFEI 1 ¦ 2010FEATURE

LIFE CYCLE SERVICE

Technologies change over time. Part of KraussMaffei’s full-service offering is our commitment to maintaining and upgrading plastics processing machinery over the whole life cycle, so that it is always fit for purpose in fast-changing markets.

Multitechnology processes – such as CoverForm

(see page 6/7), nanoskin (see page 9) or inline

compounding – are an important way forward

for plastics processors. Production cells for these

processes are all based on a KraussMaffei injection

moulding machine. Our customers know they can

count on our many decades of experience with

injection moulding machines, which are one of

our core businesses. Our expertise goes beyond

developing and supplying highly productive ma-

chines; we also have the engineering skills to make

sure they stay that way over long service lives and

in the face of changing products and markets. “A

processor buying a machine today generally has

only the vaguest idea of what he’ll be producing in

five or ten years’ time. He would be well advised

to invest in KraussMaffei machinery, because we

can make sure that his production solution will

grow with his changing applications – even for

decades ahead,” says Josef Hammerschmid from

Service Marketing at KraussMaffei.

Retrofit, overhaul, move

A production cell may undergo many changes over

the years. The experts in our Service teams can

help our customers cope with them all. A pro-

cessor might come to us with a request to adapt

an existing machine for a new application, perhaps

with a MuCell package for physical foaming at low

unit cost. Or he might want to expand into multi-

component moulding. This upgrade can be achieved

relatively simply with a bolt-on unit. Hydraulic and

electric bolt-on units are completely self-sufficient,

so only minor changes, if any, need be made to the

machine.

Combining an upgrade with a planned machine

move saves production time. “We’re professionals in

moving and transporting machines – we do it all the

time,” points out Josef Hammerschmid. “Our com-

mitment to our customers is to move any machine

any distance, on time and within budget. And to see

the job through from start to finish.” Occasionally,

the machines make a detour to the KraussMaffei

plant in Munich for a general overhaul. We also op-

erate a practical trade in used machines. In our skilled

hands machines get a new lease on life. p

CONTACT

Josef HammerschmidService SalesPhone +49/89/[email protected]

Always fit for purpose

KraussMaffei Service

professionals have

the expertise to make

a complete success of

any task, however big.

LIFE CYCLE

SERVICE FROM

KRAUSSMAFFEI

• Plasticizing units

• Refurbishing

• Functionality upgrades

Moving machinery •

Technology upgrades •

Consulting and advice •

Bolt-on units are a

fast, sure route into

multicomponent

moulding.

Teleservice •

• Robots, handling systems, automation

09FEATURE

NANOSKIN PROCESS

Integrated multitechnology processes are often the answer to the challenge of producing polymer parts with durable, functional surfaces at a competitive cost. The new CoverForm process (see page 6/7) is an example of this type of integrated process. Another new process – nanoskin – is approaching market readiness. Again teaming injection moulding with PU processing, the nanoskin process is being developed by KraussMaffei and a number of project partners.

Functionalizing materials by generating a finely

structured surface – a nanostructure – is among the

dominant trends in process engineering. There are

well-known examples of nanostructures with useful

properties in nature, like the self-cleaning leaves of

the lotus flower or the anti-reflective surface layer

of moths’ eyes. The quest is on to develop a process

for transferring the moth’s-eye effect to transparent

polymer parts so as to make them inherently anti-

reflective – in other words to eliminate the need

for a post-mould anti-reflective coating. The part

would also need to be resistant to mechanical and

chemical damage. Possible applications include

covers for dashboard instruments and displays.

The nanoskin process supplies the answer.

Injection moulding and RIM

The nanoskin project partners set themselves

the task of developing a cost-effective technical

solution for a one-step multicomponent moulding

process which would combine thermoplastic and

chemically crosslinking polymer materials. The

core of the part can be produced in a conventional

injection moulding process. Only the nanostruc-

ture surface is generated in a parallel RIM process,

using a chemically crosslinking polymer which also

guarantees the necessary mechanical and chemical

resistance. The nanoskin research and development

project received funding from the German Federal

Ministry of Economics

and Technology as part

of the government’s

InnoNet concept, which

aims to promote and

support networks for

innovation. It was carried

out with organizational

and technical support

from the project sponsor,

the VDI/VDE. “Now,

well ahead of the planned

project end in autumn

2010, we can already say

that KraussMaffei and

our partners are writing

the first chapter of a suc-

cess story. Together we

have taken the nanoskin

process to a point where we’ll be able to offer it to

our customers for concrete production applications,”

says Martin Eichlseder, who is leading KraussMaffei’s

contribution to the nanoskin project. p

CONTACT

Martin EichlsederProcess DevelopmentSystems & SolutionsPhone +49/89/[email protected]

Finely structured

The nanoskin process

generates transparent

parts with finely

structured surfaces.

NANOSKIN PARTNERS

• Plasmatreat GmbH and Fraunhofer IWM:

Regenerative hybrid layer systems and process-

integrated atmospheric plasma treatment

• Hochschule Heilbronn: Process integration

• Mast Kunststoffe GmbH & Co KG:

Durable, functional components, tested under

production conditions

• FHR Anlagenbau GmbH:

Mould coating and surface structuring

• Krallmann Holding & Verwaltungs GmbH:

Moulds with highest precision and rigidity

• RÜHL PUROMER GmbH and KraussMaffei:

Tough, transparent polyurethane systems

for surface functionalization and technology

development – flow moulding

One of the stations for the VBM’s mobile information

center was the KraussMaffei plant in Munich-Allach

(March 10-16, 2010). School classes and teenage

children of KraussMaffei employees were keen to

find out what’s on offer in the way of vocational

training for careers in the metal processing and

electrical industries. The truck was fitted out to bring

the world of technology closer to the young people

and to provide a window onto all sorts of interesting

fields – from physics to CNC machining. At the same

time, we also offered the visitors a chance to find out

more about an apprenticeship at KraussMaffei. Our

in-house trainers and some of our current apprentices

were on hand to talk individually with the young

people. Richard Schmidt, Director of Vocational and

Advanced Training and Personnel Development at

KraussMaffei, pointed out, “In the 2009 training

year, 40 young people began an apprenticeship or

a sandwich degree in our Munich plant. We offer

training in various trades and in commercial fields. We

take a proactive role in ensuring that we can draw on

a pool of well-trained candidates for future jobs.” p

10 KEYNOTE | NEWS INJECTION

“With KraussMaffei

you cut your operating

costs and increase your

productivity.”

Dr. Karlheinz Bourdon,

General Manager,

Injection Moulding Machinery.

KEYNOTE

Dear Readers,

We’re now some way into 2010 and I hope that you too are

noticing more positive economic signals than were evident a

year ago. For us at KraussMaffei, the turning point was the very

encouraging reaction at the Fakuma 2009. Since then we’ve seen

a slow upward trend. And even when the economy enters a

stronger recovery phase – we’re definitely talking about the

future here – I’m certain that one trend is irreversible. This is

the accelerating pace of technological change. Around the

world, plastics processors are looking to counter intense

pressure on prices with efficiency gains. They need to see fast

returns on every investment. The return you get on new

production machinery depends on two factors – operating costs

and productivity. Processors installing injection moulding

machinery from KraussMaffei score on both points – especially

if they chose a complete production cell with integrated

automation. One very important advantage of these integrated

production cells concerns the changed safety requirements

contained in the new European Machinery Directive – which

came into force without a transition period at the end of

December. Every KraussMaffei machine satisfies these

requirements. We supply complete solutions that meet all

standards, where the customer has absolutely no documentation

or certification effort. And lastly, even with the lower investment

in new machinery, KraussMaffei is still strongly focused on

optimizing your operating costs and productivity. Our

automation retrofit programme is just one striking example.

You can find out more between the covers of made by

KraussMaffei. I trust you enjoy reading this edition of our

company magazine!

Dr. Karlheinz Bourdon,

General Manager,

Injection Moulding Machinery

Technology roadshow: KraussMaffei and the VBM

Info-truck provided information for young people about

careers in the metal processing and electrical industries.

MADE BY KRAUSSMAFFEI 1 ¦ 2010

TRAINING AT KRAUSSMAFFEI

A truckload of information

KraussMaffei has always put the highest priority on in-

company training for our future technicians and on giving

young people a good start on the career ladder through

first class vocational training. We’re far from alone in this

endeavour; the Association of the Bavarian Metal and

Electrical Industry (VBM) operates an “Info-truck” to

give young people an insight into their career options.

11

INTERPLASTICA IN MOSCOW

NEWS INJECTION

KraussMaffei’s specialized teams build switching

cabinets not only for plastics machinery. The

cabinets are engineered and manufactured to

international, European and German standards

– and now they are UL-certified for the North

American market.

KraussMaffei is world market leader in machines

and systems for plastics and rubber processing. We

also supply specific high-tech production solutions

– such as switching cabinets – to other mechanical

engineering companies. Our specialized electrical

engineering teams are experts in the whole task

spectrum, from integrating small automation

PRODUCTS AND SERVICES FOR INDUSTRY

Switching cabinets with UL certification

modules to the highly

complex connection

of large machines.

Their intensive daily

experience means

they’re familiar with the

statutory requirements

and conditions in all parts of the world.

KraussMaffei engineering and manufacturing

meets international and regional standards.

Our production is certified to DIN ISO 9001,

DIN EN ISO/IEC 17025/2005 and VDMA 24470.

We recently qualified for the Underwriters

Laboratories (UL) certification essential for

selling our switching cabinets into the US market.

Our engineering and manufacturing operations

are now certified to UL 508A (Safety Standard

for Industrial Control Panels) and NFPA 79

(Industrial Standard for Electrical Machinery). p

Focus on standard applications

At the Interplastica in Moscow (January 26 to

29, 2010), KraussMaffei’s Injection Moulding

Machinery division demonstrated what it takes

to make a successful production cell for standard

applications – highest energy efficiency and

repeatability, plus very short cycle times.

The Russian market for plastics processing

machinery has not been untouched by the

economic crisis. But it

is still a market where

KraussMaffei has a

strong presence. This is

important, because the

market is changing. The

Russian economy used

to be dominated by the

export of raw materials,

while large quantities

of consumer goods

KraussMaffei’s switching

cabinet manufacture now

has the UL certification

essential for selling into

the US market.

Engineering “Made in

Germany” as cost-effi-

cient standard solutions

for the Russian market –

this was KraussMaffei’s

focus at the Interplastica

in Moscow.

were imported. Now more and more consumer

goods are being produced in Russia. And

Russian processors are increasingly demanding

premium quality and efficiency for their

machine park. KraussMaffei’s booth at the

Interplastica demonstrated how competently

we respond to these expectations. The booth

showcased an all-electric AX 100-380 injection

moulding machine. It was in action producing

grip shells for mobile phones with a cycle time

of 8.5 seconds. The innovative production cell

was completed by an integrated parts removal

robot. The all-electric AX series machines

generally slash electricity consumption by

over 50%, often by as much as 60%. Water

consumption is cut by up to 70% compared

with hydraulic machines. Highly dynamic drive

systems and servo motors contribute to faster

cycles, while precision controlled machine

movements ensure high repeatability. p


IML packaging made in

a single-step, injection

moulding process is

spreading throughout

the food industry.

Packaging is a very

attractive field for plastics

processors, especially

since this market has

so far proved to be

relatively immune to the

crisis. IK, the German

Industrial Association

for Plastics Packaging

and Films, announced

in December that its

member companies had

suffered a 14% drop in

sales in the first three

quarters of 2009, but that fall was relatively low

compared with 21% drop experienced by German

industry as a whole. The reason is obvious: the bulk of

plastic packaging is accounted for by food, beverages

and other basic necessities – such as detergents and

personal care products – where consumers are loath

to make economies, even as they cut back in other

areas. Plastic is still the most widespread packaging

material, according to the Joint Committee of German

Packaging Manufacturers (GADV). And the industry

processes more plastics to make packaging than to

make products for the construction or automotive

sectors.

IML for dynamic results

In-mould labelling (IML) is a packaging solution

which typifies how several process steps can be

combined on a single injection moulding machine.

It is the method by which thin-wall polypropylene

tubs for margarine, salads and many other foods are

made. The decor film label, which will eventually

be visible on the outside of the packaging, is placed

in the mould and the container is injection moulded

behind it. No post-mould printing or labelling is

necessary. KraussMaffei’s EX series of all-electric

injection moulding machines are ideal for this type

of application. A production cell comprising an

Ultra-injection unit and an SR side-entry robot

makes a very dynamic system. Fast injection coupled

with rapid robotic label insertion and tub removal

cut cycle times to under four seconds. Engineered

for the production of food packaging, all EX drives

and the robot are encapsulated, thereby ensuring

clean production. A dry-air system prevents moisture

condensing in the mould, helping to create the

constant ambient conditions that boost the reliability

of the label insertion process.

Solutions along the supply chain

The beverage industry benefits widely from plastic

packaging. Here, again, injection moulding

demonstrates its versatility in producing the full

range from PET bottle preforms, to closures, bottle

crates and pallets. KraussMaffei supplies machinery

and production cells for almost the entire supply

chain, from CX series machines in PET preform

production cells, through to the large MX machines,

delivering the high shot weights needed for making

12 FOCUS INJECTION

SOLUTIONS FOR THE PACKAGING INDUSTRY

No other sector processes as much plastic as the packaging industry. KraussMaffei’s injection moulding division offers powerful production solutions– especially our in-mould labelling process and PETForm production cells – for this market, which is proving to be particularly resilient in the current economic crisis.

Innovative in packaging

13FOCUS INJECTION

require any regular mould overhauls. They’ve easily

chalked up some 15 million production cycles and

they’re still going strong. Compared with competing

systems, they deliver substantial savings on mould

maintenance costs for years on end. And this in turn

reduces manufacturing costs. p

PETForm systems

produce quality

preforms for the

beverage industry.

CONTACT

Markus Betsche Product and Marketing ManagerPhone +49/89/[email protected]

bottle crates, and the IMC injection moulding

compounders for producing pallets. We’ve got the

beverage industry’s logistics chain almost completely

bottled up.

Every PET bottle starts life as a preform. With hotfill

preforms, the threaded section of the future bottle is

crystallized in a separate downstream step. Because

shrinkage occurs during crystallizing, very narrow

tolerances are applied to the threaded section, this

puts huge demands on the production process.

The tried-and-tested PETForm system devised by

KraussMaffei for preform production features

a vertical clamp that produces perfect preforms

without the need for complex temperature control,

even running moulds with a high cavity count.

Extremely long mould life and dependable preform

production to narrow tolerances are assured, thanks

to excellent platen parallelism. PETForm systems that

dispense with separate needle-valve control have long

been successfully used in hotfill applications. Thanks

to high-precision clamp movements, they don’t

MADE BY KRAUSSMAFFEI 1 ¦ 201014 FEATURE

MULTINJECT PROCESS

In this particular application, plastic has two clear

advantages over metal. On the one hand there is

greater design scope, on the other hand there is the

optimal combination of stiffness with a premium

surface and lighter weight. The multipart handles are

made in a four-cavity mould.

Bikkoplast’s Multinject system runs an absolutely

stable, smoothly efficient process thanks to high-

performance engineering and a package deal from

KraussMaffei and Hofmann, one of the leading

suppliers of sophisticated mould technology.

Bikkoplast, founded in 1983, today employs around

90 people under the management of Katarzyna

Wnek. Bikkoplast has installed 18 KraussMaffei

machines, using them mainly for its core business,

which is components for the white goods industry.

The precision of the machines’ settings and their

high repeatability deliver the highest possible part

quality. This consistent quality was a decisive factor

in Bikkoplast’s decision to invest in KraussMaffei

machinery. Managing director Katarzyna Wnek

also welcomes the expert advice and fast service she

gets from Dopak, KraussMaffei’s channel partner

in Poland. Dopak, also based in Wroclaw, is one of

oldest and most successful sales and service partners

of KraussMaffei’s Injection Moulding Machinery

division. p

Today, multicomponent injection

moulding is as popular as ever.

KraussMaffei has almost 50 years’

experience in the development

of system solutions to produce a

huge diversity of composite parts

using thermoplasts, polyurethanes

or elastomers. The comprehensive

portfolio includes package solutions

– with tooling technology and

process know-how – and a complete

spectrum of system combinations.

KraussMaffei will also engineer space-saving

solutions with the injection units optimally

positioned with regard to space constraints,

mould technology and existing infrastructure.

Far better than metal

One of the many plastics processing enterprises

using Multinject technology for large-volume

orders is Bikkoplast, located in Wroclaw in

western Poland. Bikkoplast manufactures around

150,000 refrigerator handles a year on a 2C

system configured on KraussMaffei’s CX modular

platform, mounting a mould with indexing

technology. The first component, glassfiber-

reinforced ABS, is injected from the main

processing unit. The reinforced material gives the

inner handle element the stiffness it needs. The

second component, injected from the co-injection

unit, is non-reinforced ABS which forms the

handle’s outer layer. ABS is the material of choice

for these refrigerator handles, because it combines

excellent optics with outstanding wear resistance.

Multicomponent technology – always up-to-date

Production with

KraussMaffei machines

at Bikkoplast in

Wroclaw.

“Multinject” stands for KraussMaffei’s almost inexhaustible range of solutions for multicomponent injection moulding. Customers – like Bikkoplast in Poland – profit from the company’s extensive know-how, built up over decades of experience.

CONTACT

Andreas HandschkeTechnology Manager Multinject/ SpinForm/TwinForm/MuCellPhone +49/89/[email protected]

Hans Arnold GmbH specializes in 2K and 3K moulding. This second-generation, family-run business always insists on KraussMaffei machines, not only because of our engineering competence but also for our customer service.

Experts in multicomponent injection moulding

15

In Germany, where production costs are relatively

high, any family-run SME seeking to survive in the

plastics processing business must first identify a

niche for itself and then strive to become the

undisputed expert in that field. Hans Arnold

quickly realized this when he founded his company

in Mühlhausen im Täle, Baden-Wurttemberg, some

35 years ago. He decided to concentrate on

multicomponent injection moulding. Now, the

company has 30 employees and an impressive – and

highly automated – machine park. In fact, the ratio

of employees to machines is more or less one to

one. The parts produced range in weight from 0.5

to 850 grams. Central to this production operation,

and representing the top end of the clamp force

range, are four machines which are fully-equipped

for multicomponent injection moulding. Each one

has been sourced exclusively from KraussMaffei,

including the top model from the CX range, a 650-

tonne Multinject machine.

Short distances are crucial

Among the products which Hans Arnold GmbH

can manufacture with the multicomponent

technology at its disposal are power-tool housings

comprising up to three thermoplastic components,

automotive gear sticks and automotive aftermarket

parts. Not only must the component materials

have different properties, but they are often

combined in various colours to meet design

specifications. This presents a challenge for

mould makers and machine technology alike.

And for the latter, the company banks on

KraussMaffei’s engineering capability and service-

oriented approach. As Petra Arnold-Herpertz,

managing director and daughter of company

founder and current senior boss Hans Arnold,

puts it: “Quality products, fast response and a

‘can do’ company culture are what our customers

expect from us – and that is precisely what we get

from KraussMaffei. The machines are totally

dependable and have absolutely no problems

coping with complex processes. The company has

a local presence, not only physically in the form

of its distribution and service center in nearby

Zell unter Aichelberg, but also figuratively in that

its decision lines are short and we have direct

lines to all contacts.” p

HANS ARNOLD GMBH KUNSTSTOFFTECHNIK, MÜHLHAUSEN IM TÄLE

CONTACT

Jochen MitzlerDirector Product and Technology Management IMMPhone +49/89/[email protected]

Arnold uses four

KraussMaffei Multinject

machines for multicomponent

injection moulding.

PORTRAIT

The latest KraussMaffei

machine to be supplied

to Arnold was delivered

in summer 2008.

MADE BY KRAUSSMAFFEI 1 ¦ 201016 APPLICATION

KUNSTSTOFFTECHNIK WIESMAYER GMBH, NEUSTADT AN DER DONAU

Kunststofftechnik Wiesmayer GmbH does much more than make plastic components for the automotive industry – it supports its customers every step of the way, from planning through to delivery of the finished article. For its large parts, Wiesmayer relies on KraussMaffei MX and CX injection moulding machines.

Increased productivity

This specialist producer of plastic parts makes

small, medium and large production runs. For

example, the two 1,600-tonne MX machines are

currently producing nothing but inner carriers

for the doors of the Mercedes E Class. The

technologies employed – MuCell and the tandem

system – are both innovative and forward-

looking. “Because the MuCell process operates

without holding pressure, the parts we make are

less subject to warpage,” says Robert Gassner,

process engineer at Wiesmayer. “And the tandem

system has boosted productivity by a factor of

1.6, because while one part is cooling, the other is

already being moulded.” The two CX machines,

which were only commissioned this year, have

enabled Wiesmayer to move into the world of gas-

assisted injection moulding. This method achieves

substantial material and weight savings without

sacrificing stiffness, especially in the production of

thick-wall parts, such as map pockets. p

More than 30 automotive and electronics

customers use the services of Kunststofftechnik

Wiesmayer GmbH, which boasts 35 injection

moulding machines with clamping forces

ranging from 40 to 1,600 tonnes. Founded

in 1992, it is a direct supplier for some car

manufacturers such as Audi, while its other

products take a detour via subcontractors such

as Johnson Controls and Faurecia. “Some of

the parts we make in our shops are extremely

complex, others must have pristine surfaces,”

says Stephan Weber, Commercial Director at

Wiesmayer. “Our experts work closely with

customers, right from the development stage.

Not only that, but we also make majority of the

moulds used.” The company started using large

production machines in 1994 and has worked

closely with KraussMaffei ever since. Today,

Wiesmayer runs six KraussMaffei machines

– two 800-ton MX’s, two 1,600-ton MX’s and

two 650-ton CXs.

Always ready for new technologies

Wiesmayer relies

on heavy-tonnage

injection moulding

machines from

KraussMaffei to

produce large parts.

CONTACT

Christian RösslerSales Injection Moulding MachinesPhone +49/8031/[email protected]

A special tandem

mould has boosted

productivity of door

inner carriers by a

factor of 1.6.

17APPLICATION

Ready for the future

For many years, two trends in the automotive

industry have been accelerating rapidly. One is the

increasing use of plastics in automotive

components, the other is the increasing size of

individual plastic components. Where these large

parts are injection moulded, this trend is pushing

demand for higher clamp forces and shot weights.

Aware of these trends, Ford invested in a high-

performance injection moulding machine for its in-

house plastics processing operation in Saarlouis.

Since September 2009, a 4,000-tonne KraussMaffei

MX 4000-24500 injection moulding machine has

been installed in Ford’s plant in Saarlouis. The

machine is currently producing bumpers for the

passenger car models Focus, Focus ST and Kuga,

which by no means stretches its capacity reserves.

“In the foreseeable future, automotive components

are likely to become bigger and more complex

with every model generation,” explains Serjoscha

Skrabs, the manager responsible for the plastics

plant and bumper painting at Ford in Saarlouis.

“The big MX machine is an investment that will

continue to pay off in terms of future production

tasks,” he continues. Rainer Hoefner, zone

manager for the paint shop and plastics

production, adds, “Regular benchmarking shows

that running our own injection moulding

operation at the Saarlouis plant brings clear

efficiency gains. This was the basis for our decision

to expand our machine park with a big tonnage

machine.”

Perfect machine/robot pairing

There aren’t many manufacturers offering

injection moulding machines in the MX 4000

performance segment. Ford’s investment decision

was influenced by the machine’s convincing

performance in preseries acceptance trials, by

KraussMaffei’s many years of experience with big

machines and by the attractive price/performance

ratio. As often before, KraussMaffei supplied a

complete production cell. The system, painted to

customer specifications rather than in the

standard KraussMaffei colours, is paired with an

IR 2100-1000 S/K industrial robot (Kuka KR 210

L100 K). To match the large size of the machine,

the robot has a payload of 100 kg and a working

range of 3,900 mm. The robot places the plastic

parts on a 2-belt conveyor belt where they are

buffered for the 30-minute cooling period. The

complete package from KraussMaffei includes the

safety housing, and the platforms and ladders for

maintenance access to the injection unit and the

clamp. p

MX MACHINE IN FORD‘S SAARLOUIS PLANT

It’s no secret that not all the traffic lights in the automotive industry are set on green – especially in the USA and in Germany. Against this background, it’s remarkable that, in 2009, the Ford-Werke GmbH, based in Cologne, invested in a large, new KraussMaffei machine for in-house plastics processing at its production plant in Saarlouis, Germany.

CONTACT

Thomas HörlProduct Manager MX SeriesPhone +49/89/[email protected]

Impressive size: the MX

4000 installed with Ford

in Saarlouis, Germany.

KOMPAKTE ZWEIPLATTENTECHNIK FÜR GROSSE AUFGABEN

Spritzgießmaschinen der MX-Baureihe

Machines from

KraussMaffei’s MX series

are engineered for sizable

tasks, for example, making

automotive bumpers.


No less than 16 KraussMaffei injection moulding

machines populate the production floor of Becker

Kunststofftechnik GmbH in Hohentengen,

Germany. With clamp forces from 30 to 1,600

tonnes, these machines mirror the full performance

range of the hydraulic CX series, and include the

jumbo machines – the MXs. The star of the fleet,

the 1,600-tonner, is used for producing visible

automotive interior trim. This type of product

imposes two tough requirements: high shot weight

and perfect looks. Aside from the automotive

sector, Becker has customers across many other

industries, including sanitation, medicine,

horticulture and water engineering. It has a

particularly strong foothold in components for

white goods. This is one area where Becker not

only operates as an injection moulder, but also

covers a good part of the supply chain: 2K injection

moulding, pad printing and assembly are key steps

in production of operating panels for fully

automatic washing machines prior to shipment to

the manufacturer.

18 PORTRAIT

BECKER KUNSTSTOFFTECHNIK GMBH, HOHENTENGEN

Partners creating customer loyalty

Managing Director Alfred Becker founded the

company in 1997. Today, there are roughly 75

employees working at the Hohentengen site.

Becker prides itself on the production of high-end,

moulded technical components. A focus on

quality, rather than the production of cheap

plastic parts, has always been the company’s

recipe for success. And, as everyone knows,

quality has many aspects. At Becker, it extends to

regular staff training, comprehensive service

packages for customers – including design and

mould making – and, of course, the right

machines for the job. “We have the injection

moulding capability, for example, to implement

complex 2K solutions. Not everybody can do

that. We view our machine supplier as a partner

who helps us generate customer loyalty,”

summarizes Alfred Becker, who sources the

company’s machines exclusively from

KraussMaffei. p

Service packages all along the supply chainQuality in the end product and in all upstream steps – that’s been the motto of Becker Kunststofftechnik GmbH for 13 years. KraussMaffei was one of its machine suppliers back in its start-up days, and has since taken on this role exclusively. It’s a solid partnership, which over the years has helped Becker to build a customer base across a large number of industries.

CONTACT

Helmut StörkSales Engineer Injection Moulding MachineryPhone +49/741/94 24 [email protected]

In Hohentengen, Becker

Kunststofftechnik

injection moulds high-

end plastics parts on

machinery made by

KraussMaffei.

19FEATURE

KraussMaffei injection moulding machines

are rock-solid technology and, when regularly

professionally serviced and modularly upgraded

as needed, nothing stops them from operating for

decades – in fact such a lifespan is not uncommon,

especially for large machines. It’s often relatively

simple to boost the performance of existing

injection moulding machines. “Our retrofit

programme helps plastics processors achieve just

that,” says Manuela Schmidbauer from product

management at KraussMaffei Automation. This

company has been equipping injection moulding

machines with industrial robots (IR) for almost

on two decades. As part of the current retrofit

programme, KraussMaffei experts will devise

automation solutions on extremely attractive

terms. KraussMaffei is also offering application

engineering and service packages – including

optimized plasticizing units – supplied on demand

and as needed.

The aim is to optimize production processes and

to ultimately reduce the cost per output. “This

is where our standardized IR series comes in. We

launched it in autumn 2009 as an automation

solution for all new and existing machines,”

explains Thomas Marufke, Sales Manager

at KraussMaffei Automation. “The lower

maintenance and operating costs are of enormous

benefit to the user. And, if it’s a new investment, he

gets a production cell where the robot is controlled

directly via the operator panel of the injection

machine.” In the current retrofit program,

KraussMaffei customers are benefiting from

the exclusive partner

programme which the

KraussMaffei set up with

Kuka.”

Every size catered for

The industrial robots

come in 11 sizes, and

their payloads cover

the entire spectrum

– from 6 to 210 kg – of

KraussMaffei injection

moulding machines,

whether hydraulic or

all-electric. The series

includes floor- and console-mounted robots as

well as models that integrate into the safety guard.

As always, for new investments, KraussMaffei

supplies complete, CE-compliant production cells.

And we’ll replace existing handling systems and

retrofit injection moulding machines made by

KraussMaffei or other manufacturers. p

STANDARDIZED INDUSTRIAL ROBOTS

Automated solutions keep machines on their toesThere’s no time like the present for plastics processors to secure crucial production advantages by making a modest investment in upgrading existing machinery. KraussMaffei offers a highly standardized range of industrial robots for automating new and existing machines.

The current

KraussMaffei retrofit

programme provides

robots on very

favourable terms.

CONTACT

Manuela SchmidbauerProduct Management AutomationPhone +49/89/[email protected]

Switch and save – with the new, low-energy, all-electric AX from KraussMaffei

SAVINGSCOST

Clever, clean, precise and economical – meet the AX series! It’s our new all-electric injection molding machine that saves energy in a big way. With energy prices spiralling, the AX is a prudent investment. Flexible design and an automation solution contained inside the safety housing add space savings to energy savings – a production cell for an extra effi ciency bonus. Profi t from KraussMaffei experience, expertise and quality at a bargain value. Opt for the new, compact AX.

KraussMaffei Technologies GmbH ··· Phone +49 89 [email protected] ··· www.kraussmaffei.com

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide.


SAVINGS

Clever, clean, precise and economical – meet the AX series! It’s our new all-electric injection molding machine that saves energy in a big way. With energy prices spiralling, the AX is a prudent investment. Flexible design and an automation solution contained inside the safety

KraussMaffei is a premium partner for the plastics and rubber



Anz_intern_AX_GB.indd 1 23.03.09 09:30

km made by 1 2010 eng

Documents

Transcript of km made by 1 2010 eng