KraussMaffei sets up a prize for efficiency!

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2 Dr. Dietmar Straub, KraussMaffei CEO. Dear Readers, EDITORIAL Technology advances mark the way forward. Forcing down costs, increasing efficiency and boosting productivity these are key concerns right now throughout the plastics industry. It takes newgeneration 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 AWARD 2010 KraussMaffei sets up a prize for efficiency! 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 resourceefficiency. 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, More information and details of how to enter are contained in a questionnaire that you can request by . p PUBLICATION DATA made by KraussMaffei Published by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, Munich, Germany Phone + 49/89/ , Fax + 49/89/ , Responsible: Matthias Andreesen Viegas Editorial office: mk publishing GmbH, Döllgaststraße 7 9, Augsburg, Phone +49/821/ , Fax +49/821/ , Photo credits: Becker Kunststofftechnik, Bikkoplast/ Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunststofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM Dr. Reinhard Schiffers Predevelopment/Energy Phone +49/89/ EDITORIAL NEWS MADE BY KRAUSSMAFFEI

3 COVER Perfectly paired off: pipe plus insulation TRADE SHOWS Events through to autumn 2010 KraussMaffei Berstorff is now offering complete systems for continuous production of PUinsulated 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 Chinaplas Shanghai, China Expoplast Algiers, Algeria RusChem Moscow, Russia Technics Belgrade, Serbia Plastex Cairo, Egypt Plastpol Kielce, Poland PU China Shenzhen, China Composites Essen, Europe Germany K 2010 Düsseldorf, Germany MULTI-MILLION INVESTMENT New Surface Treatment Center opened 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 Bavarian Economics Minister Martin Zeil (right) and Dr. Dietmar Straub, KraussMaffei CEO, at the opening of the new Surface Treatment Center. NEWS 03

4 KNOW-HOW SHARING DRIVES DEVELOPMENT Industry and research hand-in-hand 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. 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.). 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 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 04 FOCUS MADE BY KRAUSSMAFFEI

5 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 applicationrelated 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 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 Martin Würtele Manager Predevelopment New Technologies/Process Engineering Phone +49/89/ Josef Renkl Manager Research and Development RPM Phone +49/ 89/ Prof. Dr. Lothar Kroll, Prof. Dr. Bernd Poltersdorf Manager Foam, Film and Sheet Extrusion Phone +49/511/ Dr. Wolfgang Kempt and Dr. Wolfgang Nendel (from left) of the TU Chemnitz with the ZE 40 A x 50 D UTXi twinscrew extruder from KraussMaffei Berstorff, Hanover, which offers new scope for research. FOCUS 05

6 COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK Joint project in surface treatment technology 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. 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. 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 postmould paint process. A far shorter process chain A conventional process comprises multiple steps including quality controls, storage and transport 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 STEPS Inline scratch-resistant coating of PMMA Inject PMMA Compression/ cooling Open cavity & inject coating Compression & start heating Compression & heating 100% Compression & cooling 06 FEATURE MADE BY KRAUSSMAFFEI

7 KraussMaffei injection moulding machines are at the heart of CoverForm production cells. 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 Demoulding Final curing (UV curing) 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 Sven Schröbel, Evonik Industries, Martin Eichlseder, KraussMaffei, and Arne Schmidt, Evonik Industries (from left), showing off the Best of award at the Materialica. Marco Gruber Manager Application Engineering, Process Development IMM Phone +49/89/ Josef Renkl Manager Research and Development RPM Phone +49/ 89/ FEATURE 07

8 LIFE CYCLE SERVICE Always fit for purpose Consulting and advice Moving machinery Teleservice Technology upgrades LIFE CYCLE SERVICE FROM KRAUSSMAFFEI Plasticizing units Refurbishing Functionality upgrades 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. Robots, handling systems, automation KraussMaffei Service professionals have the expertise to make a complete success of any task, however big. 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 machines; 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. 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 multicomponent 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 commitment 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 operate a practical trade in used machines. In our skilled hands machines get a new lease on life. p Bolt-on units are a fast, sure route into multicomponent moulding. 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 processor might come to us with a request to adapt Josef Hammerschmid Service Sales Phone +49/89/ FEATURE MADE BY KRAUSSMAFFEI

9 NANOSKIN PROCESS Finely structured 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. The nanoskin process generates transparent parts with finely structured surfaces. 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 antireflective 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 nanostructure 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 success 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 NANOSKIN PARTNERS Plasmatreat GmbH and Fraunhofer IWM: Regenerative hybrid layer systems and processintegrated 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 Martin Eichlseder Process Development Systems & Solutions Phone +49/89/ FEATURE 09

10 Frank Peters, General Manager, Reaction Process Machinery. Dear Readers, KEYNOTE Working together to add value! Two important strategic responses to difficult economic times are to optimize production processes and to open up new business areas. KraussMaffei can support you here. As a worldwide premium partner for the plastics and rubber processing industries, we offer highly productive solutions that deliver maximum efficiency and return on investment. Our engineers deliver complete custom solutions by combining modules from the wide KraussMaffei product portfolio and pooling their special expertise in the different process technologies and automation. Our solutions combine the advantages of series production machines with the benefits of application-specific technology. Typical examples are our special machine for producing drug delivery systems, or our mobile RimStar system for SPS sandwich plate systems. We developed custom production solutions for both these applications, supporting our customers drive to optimize their production processes and reinforce their market success. As with all our products and services, these customers can rely on our competence as a system supplier capable of delivering the quality and know-how they need. We ve also optimized our service and product portfolio, for example, by adding to our WinCap series of mould carriers, by improving our foam moulds, and with a revised price structure for our EcoStar series. Together with our innovative engineering and ultra-efficient production solutions, these improvements are part of our drive to offer you real added value the best basis for our common success. With best regards, MANUFACTURING METERING PUMPS IN-HOUSE Benefits for customers KraussMaffei s Reaction Process Machinery division has long pursued a policy of offering complete production solutions as a single vendor. Key to the success of this policy is our ability to apply our experience and know-how to continuously improve individual system components. Now we ve taken a further step in this direction by moving the manufacture of metering pumps in-house. This change will give us the opportunity to align our products even more closely with the needs of our customers, emphasizes Wolfgang Frehsdorf, Business Area Manager in the Reaction Process Machinery division. In particular, we ll be able to better adapt our pumps to the specific processing requirements of current and future plastic monomers. In addition, KraussMaffei made pumps will have longer service lives and deliver a better return on investment. In future, the EcoStar, RimStar Compact, RimStar Modular, MiniDos and our hybrid machines will all be fitted with KraussMaffei metering pumps. From April 2010, we ll be producing pumps rated for 16 to 40 litres a minute. During the year, we plan to add more pump sizes to our portfolio. p KraussMaffei is now manufacturing metering pumps in-house. Frank Peters, General Manager, Reaction Process Machinery Siegfried Eidenmüller Manager Precision Parts Assembly and Service RPM Phone +49/89/ KEYNOTE NEWS REACTION MADE BY KRAUSSMAFFEI

11 PRODUCTION PLANT IN GEORGSMARIENHÜTTE Doubling production space Automotive Component Systems (ACS), a business area of KraussMaffei, is expanding its production plant in Harderberg-Georgsmarienhütte/Lower Saxony from 1,350 to 2,700 square meters. A symbolic groundbreaking ceremony took place on February 4, Construction is due to be completed by late summer ACS makes moulds for polyurethane processing at its Harderberg plant. Frank Peters, member of the board of management, said the expansion was indicative of two of KraussMaffei s great strengths, On the one hand, as a technology company with an in-house mouldmaking operation, we re big enough to serve every market segment and specialized niches which are still growing. And secondly, we are creating future capacity ready for the time when the economy begins a strong recovery, rather than the current hesitant growth. p Frank Peters (center), KraussMaffei RPM General Manager, Heinz Lunte (3rd from right), mayor of Georgsmarienhütte, and Plant Manager Rainer Janotta (2nd from left) at the groundbreaking ceremony. EXPANDING THE SALES ORGANIZATION IN BENELUX AND AUSTRIA More service, more performance KraussMaffei has expanded Reaction Process Machinery activities in Belgium, the Netherlands, Luxembourg and Austria. In these countries, the company now offers not only injection moulding machinery, but also our classic portfolio of Reaction Machinery products mixing heads, metering NEW ADDRESS KraussMaffei Benelux Minervum 7408 NL ZG Breda Phone +31/ Fax +31/ machines, moulds and tooling for polyurethane processing, including cutting and routing technology. Sales Manager Johan Van Der Schueren is now reponsible for RPM customers in Belgium and Luxembourg, while Mark Verveer, Managing Director of the KraussMaffei branch in Breda, looks after customers in the Netherlands. Austrian customers can rely on Area Sales Manager Wolfgang Rößler. By expanding the Reaction Process Machinery division s presence in these countries, KraussMaffei has reinforced its status as system supplier providing local service and support, and complete system solutions. p Mark Verveer Managing Director Netherlands Phone +31/ Johan Van Der Schueren Sales Manager Belgium & Luxembourg Phone +32/ Wolfgang Rößler Area Sales Manager Phone +49/89/ OVAL CONVEYOR SYSTEM FOR ROYAL TECHNOLOGIES CORPORATION Special order from the USA Our US subsidiary, KraussMaffei Corporation, recently booked a large order from Royal Technologies Corporation. This company develops and manufactures products mainly for the automotive industry, but also for consumer goods and office furniture. We supplied Royal Technologies Corporation with a turnkey oval conveyor system, with 26 stations and a four-component duplex mixing head, to produce seat cushions from PU foam. The conveyor system was modified to guarantee extremely fast mould changing a roller system that was integrated that allows just the mould itself to be changed via a special screw mechanism. This system ensures that mould changing is extremely fast and completely unproblematic; the customer is spared the necessity of exchanging the complete cassette with the mould carrier as in a conventional system. p Steffen Bauer Area Sales Manager Phone +49/89/ NEWS REACTION 11

12 FOAM SYSTEMS FOR REFRIGERATORS AND INSULATION TECHNOLOGY Competence in white goods KraussMaffei Italiana is a competence center for PU systems for white goods and insulation technology. The innovative insulation solutions and high-performance systems for foam filling refrigerator doors and cabinets developed in our competence center in Abbiategrasso are already in operation around the world. The RotoStar drum unit is a reliable solution for foam filling and finishing doors. Within the worldwide KraussMaffei group, KraussMaffei Italiana in Abbiategrasso is the competence center for white goods and insulation technology. The company s core business is production systems for foam filling refrigerator doors and cabinets for both household and commercial refrigerators. Foam moulds and thermoforming tools for these applications are part of the product spectrum. The materials used in all applications are heavy-duty PU rigid foam systems capable of guaranteeing excellent thermal insulation even in relatively thin layers. KraussMaffei combines the know-how and the technology for high-performance solutions for the white goods sector whether customers want complete refrigerator foaming systems, individual foam moulds or extending and upgrading existing lines, explains Gianmario Bossi, sales manager for white goods. We can supply customized concepts, for every manufacturer and product specification including high-end foam moulds, optimally engineered for the manufacturing process. In addition to production systems for white goods, the KraussMaffei Italiana product portfolio also includes production systems for panels and sandwich panels for the construction industry. When we supply a system, our highest priorities, from the planning phase onwards, are efficient processes, a compact design and a very high level of automation. Once the concept has been accepted, we build, ship and commission the system. Our comprehensive service and support is available to our customers at every stage and our after-sales service is unsurpassed. RotoStar: designed for success As a rule, KraussMaffei Italiana supplies the dry side components of a system, with the other components being engineered in Munich. One example is the RotoStar drum unit for foam filling and processing doors. This is a provenly successful system, it consists of a base frame in which the drum with the water-heated mould carriers revolves. A hydraulic control system makes it possible to adjust the acceleration and braking phases and to ensure the drum revolves at a uniform speed. RotoStar systems can be fitted with varying numbers of mould carriers, depending on production and process requirements, explains Andrew Garnett, Area Sales Manager at KraussMaffei. Short cycle times, highest 12 FOCUS REACTION MADE BY KRAUSSMAFFEI

13 RimStar mixing and metering machines (below) are ideal for applications in the white goods and insulation sector (left). product quality and absolutely reliable control of the process make the RotoStar the system most frequently chosen worldwide for foam-filling refrigerator doors. RimStar: the perfect match A polyurethane mixing and metering machine from our RimStar range is the ideal match for a RotoStar mould carrier system. The small and compact RimStar machine can be flexibly configured making it the optimal choice, for example, for refrigerator production. Hallmarks of the RimStar are minimal pressure losses, precision temperature control and improved control systems thanks to shorter, rheologically-optimized supply lines between machine components. The machines are easy to operate and maintain and engineered for easy access. Add-ons for the RimStar system from tanks with integrated agitators to complex configurations with heat exchangers and circulation pumps help to ensure that the PU components are perfectly conditioned, mixed and metered. This is important for white goods production as well as in other sectors. Worldwide success Today, KraussMaffei production solutions for white goods and insulation technology are in operation around the world. In a joint project, KraussMaffei Munich, KraussMaffei Italiana and KraussMaffei Machinery in Shanghai recently supplied a complete multicomponent system with 20 stations to manufacture refrigerators in China. Qingdao Haier Refrigerator China, the biggest white goods manufacturer in China, is using the system to produce refrigerators for the Sanyo Electric, Japan. Production uses the Side-by-Side system, where two mixing heads foam-fill the refrigerator elements simultaneously. Engineering and building this system was a real first for KraussMaffei, it was the result of outstanding teamwork involving KraussMaffei people in Germany, Italy and China, says Gianmario Bossi. Innovative process knowhow and our grasp of the complex technology enabled us to supply a complete, highly-customized solution and the customer naturally profits from our comprehensive, local service offering. We also shipped systems for white goods and insulation technology to China and Brazil. Six RimStar systems with six Pentamix units and 20 mixing heads went to Maersk Container Industry Qingdao China. In Brazil, Electrolux do Brasil is operating two RimStar machines and three RotoStar systems in the production of refrigerator cabinets while two more RotoStar systems are foam filling refrigerator doors. p Gianmario Bossi, Sales Manager for white goods at KraussMaffei Italiana. Gianmario Bossi Sales Manager KMI Phone +39/02/ FOCUS REACTION 13

14 RIMSTAR SYSTEMS AT ELELE, BURSA, TURKEY Milestone machine with proportional technology KraussMaffei s RimStar range of polyurethane mixing and metering machines includes models capable of meeting every production requirement. Elele, a KraussMaffei customer in Turkey, has recently taken delivery of its third RimStar system. Its delivery marked a special milestone for KraussMaffei, because it brought to 100 the number of mixing and metering machines the company has supplied to processors in Turkey. Emre Yilmaz, Commercial Manager at Elele (right) and Steffen Bauer, Area Sales Manager at KraussMaffei. KraussMaffei s RimStar machines are engineered as modular systems. This means they can be flexibly configured to match application specifications and customer requirements. One of the customers who welcomes this approach and who has installed a total of three RimStar machines is Elele Döseme Sanayi ve Ticaret, in Turkey. The machine supplied to Elele at the end of 2009 was a RimStar Compact 40/16. Together with the machine, Elele also installed a foam robot and an MK 12/18 ULP-2KVV- G mixing head with proportional technology. As Steffen Bauer, KraussMaffei Area Sales Manager, points out, It s only our proportional technology that allows the very fast shot cycles that are essential if users plan to manufacture different products on one and the same production system. Elele is using this RimStar machine to produce seat squabs for automotive seating in its production plant in Bursa. One of Turkey s major cities, Bursa is a center of the country s automotive industry where carmakers and international components suppliers operate production plants. Market leader in reaction process machinery The machine was shipped directly from KraussMaffei s Munich plant to Bursa. The sale was processed by Alp Chemicals, KraussMaffei s sales partner in Turkey, headquartered in Istanbul. Taner Erbil, responsible for sales at Alp Chemicals, says, This machine was the third RimStar to go into operation at Elele, as part of a capacity expansion. Elele s decision to invest in this new machine not only shows the company s satisfaction with KraussMaffei s machinery and customer care, it is also a sign that the market for plastics processing machinery in Turkey is picking up again. With its three technology divisions, Injection Moulding Machinery, Extrusion Technology and Reaction Process Machinery, KraussMaffei supplies not only the Turkish automotive industry, but also other industries, such as construction, home appliances, medical technology and packaging. By shipping the 100th mixing and metering machine to Turkey, Reaction Process Machinery has underscored its claim to be market leader in the region. p Steffen Bauer Area Sales Manager Phone +49/89/ APPLICATION MADE BY KRAUSSMAFFEI

15 PRODUCTION SOLUTION FOR DRUG DELIVERY SYSTEM Efficient teamwork on an innovative project KraussMaffei recently developed a production solution for a drug delivery system. The solution consists of a mixing and metering machine together with a sheet mould and a punch with tooling. The innovative, application-specific, integrated solution was developed as a joint project by teams from the KraussMaffei plants in Munich and Viersen, in Germany. The mixing and metering machine is at the heart of the three-part production solution. To develop a highly automated process for the production of drug delivery systems was exactly the right challenge for KraussMaffei development and application engineers. They planned a threepart production system, consisting of a mixing and metering machine, a sheet mould and punch tooling. The mixing and metering machine was built in Munich, the other two elements were supplied by Tooling Technologies, KraussMaffei s subsidiary in Viersen. Every part of the machinery in contact with the end product at any stage of the production process had to be manufactured from a stainless steel grade approved by the US Food and Drug Administration (FDA). The hydraulic oil used in the system had to be certified for conformity with FDA specifications. stamps out the shape of the pessary, the drug delivery system. Complete application-specific solution The three system elements are being integrated into the final system at the KraussMaffei plant in Munich. The ultimate challenge in this project was to select the correct components and materials to ensure full compliance with the standards, says Andrew Garnett. The project shows that KraussMaffei experts from our different locations and specializations are more than capable of teaming up efficiently to produce highly customized, integrated solutions for totally new application areas. p The polymer sheet 0.8 to 1.0 millimeter thick is formed in the sheet mould. Precision drug delivery In the mixing and metering machine, the raw material is melted and dehydrated under vacuum conditions. It is then mixed with the isocyanate and a catalyst in the mixing head. The focus was on high-precision metering, explains Andrew Garnett, Area Sales Manager at KraussMaffei. The mixing ratio for the components which are both processed at approximately 70 C must be precisely adhered to. The KraussMaffei MK 5/8 CCM tandem piston mixing head is ideal for this task, the catalyst is added using a micro-volume metering piston. The polymer sheet 0.8 to 1.0 millimeters thick is then formed in the sheet mould and a punch tool Andrew Garnett Area Sales Manager Phone +49/89/ A punch stamps out the final drug delivery system. APPLICATION 15

16 PU METERING FOR SANDWICH PLATE SYSTEMS (SPS) One of the many applications for sandwich plate systems (SPS) is repairing and strengthening ships. Mobile RimStar is ready for action worldwide KraussMaffei recently shipped a RimStar system installed on a tracked vehicle to Intelligent Engineering Ltd.. The PU mixing and metering machine will be used in the production of the company s sandwich plate systems (SPS) made of sheet steel with a PU core. The mobile RimStar system fits into a shipping container and has a universal power connection at the touch of a button, it s ready to operate anywhere in the world. The mobile RimStar machine can be connected up and operated anywhere in the world. Compared with steel and reinforced concrete, the sandwich plate system (SPS) delivers notable engineering and cost advantages. The RimStar system that KraussMaffei recently supplied to Intelligent Engineering Ltd. was an unusual one. Intelligent Engineering specializes in making and installing sandwich plate systems (SPS) made of two metal sheets with a PU core. SPS has several advantages compared with steel alone or concrete. These include high stiffness combined with light weight, soundproofing and vibration damping properties, and the fact that the plates can be installed quickly and easily. SPS elements are used in new construction, but also in repairs, of ships, oil platforms, conveyor systems, bridges, stadiums and high-rise buildings. The sandwich elements are generally fabricated at the site where they are to be installed. Demanding product specifications The RimStar system will be used to mix and meter polyurethane in various grades to form the plate cores. Fitted with two 80-litre pumps, it stands for extremely reliable and stable processes and premium product quality. Hallmarks of the RimStar are minimal pressure losses, precision temperature control and improved control technology thanks to short rheologically-optimized supply lines between machine components. The RimStar s modular engineering makes for flexible configuration of customer- and application-specific machines. Intelligent Engineering specified a number of unusual features. The whole system had to fit into a 20-foot container, have its own drive system and be fitted with a universal power connection so as to be able to operate anywhere in the world, explained Andrew Garnett, Area Sales Manager at KraussMaffei. This RimStar machine was engineered as an autonomous system, capable of being simply plugged in to the local power supply and starting production immediately. The machine was mounted on a tracked vehicle sourced from an Italian manufacturer. It can move under its own power to wherever the sandwich panels are required, for example, in a dry dock, or on a bridge. Strong market potential This latest RimStar system is the fourth that KraussMaffei has supplied to Intelligent Engineering; each machine is engineered and modified to match specific customer needs. The outcome is always a highly effective production solution that is absolutely right for the job, sums up Andrew Garnett. As a preferred partner of Intelligent Engineering, we look forward to continuing cooperation and to more projects in this interesting market. p Andrew Garnett Area Sales Managert Phone +49/89/ APPLICATION MADE BY KRAUSSMAFFEI

17 THE WINCAP ELECTRIC MOULD CARRIER SERIES Success story with a future Productivity that s hard to beat, outstanding ergonomics and practical options all these have made our WinCap mould carrier series a real success story. At the same time, KraussMaffei is committed to continuous further development of all our mould carriers. KraussMaffei developed the first electric mould carriers for automotive applications around three years ago. Now there are many of them in operation with customers around the world. They re used in encapsulation of car windows and glass roofs and for backfoaming interior trim elements and other automotive components. Our policy of continuous optimization applies especially to our best-selling models. The knowhow and experience of our whole division flows into the ongoing development of our electric mould carriers, says Erich Fries, Area Sales Manager at KraussMaffei. Then add our strength in innovative engineering and the outcome is application-specific mould carrier solutions which will drive our future success in this area. Application-specific performance profile The standardized, modular engineering of our WinCap range cuts the time required for assembly and commissioning. Very easy operation and excellent ergonomics were high on the list of development priorities. For example, programming mould functions in situ using the OP177B touch panel is a simple task. All mould carrier movements and mould functions are freely programmable at the operator console; this adds a high degree of flexibility to production processes. High-speed and parallel mould carrier movements yield shorter cycle times and higher productivity in almost any application. Even heavy moulds are moved fast and reliably, thanks to the use of poly- V-belt with transfer rolls for the lift function. Customized flexibility Low maintenance effort is another important plus-point of the WinCap series together with the quieter operation and lower power consumption associated with electric motors. There is a wide choice of practical options, including additional mould functions, extra safety features and a customer-specific mould-fixing system. Moreover, WinCap mould carriers can be flexibly adapted to many different types of plant. The acid test The ability of KraussMaffei s electric mould carriers to deliver the performance required in the challenging automotive environment is underlined by recent orders from international automotive components suppliers. They include 10 mould carriers shipped to ArvinMeritor in Slovakia and Germany and 3 systems for Webasto in Korea. p Erich Fries Area Sales Manager Phone +49/89/ Glass roof for an Audi A5, foam encapsulated on a WinCap mould carrier in a mould made by KraussMaffei. Best sellers with multiple benefits: our WinCap series of electric mould carriers. FEATURE 17

18 MORE EFFICIENT, LESS WASTE Optimized foam moulds The instrument KraussMaffei has optimized the foam moulds it supplies for automotive instrument panels. New seal technology now minimizes material consumption and almost completely eliminates trimming and waste. This saves time and money, resulting in more efficient processes and lower manufacturing costs. Instrument panels for the new Peugeot 3008 and 5008 are being made using these innovative moulds. panels of the new Peugeot 3008 and 5008 models are made using KraussMaffei foam moulds. The newest foam moulds practically eliminate trimming and waste. Automotive Component Systems (ACS) in Georgsmarienhütte, Germany, a KraussMaffei subsidiary since 2005, specializes in tooling technology, mainly for the automotive industry. Of more than 500 foam moulds sold to date, over 100 of them have been for instrument panel production. Each KraussMaffei production system is engineered as an exact match for customer requirements. Customers profit from applicationspecific solutions supplied by a single expert vendor. Our foam moulds deliver what customers want, says Rainer Janotta, plant manager at Automotive Component Systems, That s premium product quality and vanishingly low reject rates. But we never stand still our engineers work continuously to make foam processes, and the whole process of making a component, more efficient and economical. a joint development by KraussMaffei and Visteon Systémes Intérieurs, one of the leading international automotive components suppliers. One development priority was lower material consumption. The new foam moulds with their innovative seal technology minimize material consumption. At the same time, the process becomes more efficient because trimming and waste are practically eliminated, explains Rainer Janotta. This brings substantial savings in material costs and in processing time. One of the detail changes is in the windscreen area where the décor film is inserted into the reinforcing section directly in the mould. Around the tachometer, the center console and the air vents, tear-off edges in the décor film eliminate trimming and disposal of the PUR foam and reinforcing material. 48 of these optimized foam moulds are already in operation, 23 more are currently under construction. Apart from the new Peugeot models, they re being used to produce components for carmakers like BMW, Citroen, Ford, Renault, Volvo and VW, where they ensure highest precision and quality, plus lower material consumption and unit manufacturing costs. p Less trimming, shorter cycle times Currently, one of the best examples of this continuous-improvement approach are the new foam moulds for the instrument panels for the new Peugeot 3008 and The moulds were Rainer Janotta Plant Manager, Automotive Component Systems, Georgsmarienhütte Phone +49/5401/ FEATURE MADE BY KRAUSSMAFFEI

19 PREMIUM QUALITY, WIDELY AFFORDABLE New pricing structure for the EcoStar series Our EcoStar series of mixing and metering machines has a sure-fire formula for success modularity, reliability and ease of operation. Following a systematic improvement programme, KraussMaffei has revised the pricing structure for EcoStar machines and is offering them at budget prices. This will attract especially small and medium-sized PU processors in many parts of the world, who are already using EcoStar machines in a wide range of manufacturing processes. High-performance PU mixing and metering: our EcoStar series delivers premium quality at budget prices. KraussMaffei s EcoStar mixing and metering machines meet the highest standards in polyurethane processing. These are small, highperformance systems, based on high-quality components, for high-pressure processing with transfer and linear mixing heads. A very compact configuration keeps the supply lines between the separate machine components very short. This, in turn, enables temperatures to be precisely controlled, minimizes pressure losses and makes for optimal process control. In this way, KraussMaffei customers can count on a stable process and highest product quality. The machines are easy to operate and maintain and they re specifically engineered for easy access. Improved price/performance ratio Through systematic standardization and reducing the number of variants, KraussMaffei has been able to improve the price structure for the series, so that customers can now benefit from an improved price/performance ratio for the EcoStar. This makes powerful, premium-quality PU metering machines available at budget prices, which should appeal especially to small and medium-sized PU processors. The basic EcoStar version includes volume flow meters, double-walled component tanks, MKE3B mixing heads, axial piston pumps and the Siemens control system. This basic version can be upgraded with function packs to suit product specifications and production requirements, for example, closedloop control, transfer mixing heads, plate heat exchangers and different-sized outriggers. Worldwide sales success Customers around the world have been buying EcoStar systems. Typical are some of the latest orders, mainly from small and medium-sized enterprises, which are using the KraussMaffei machines to produce a huge range of projects. Three EcoStar systems recently shipped to processors in Brazil: two to Piatex Indústrie e Comércio de Fiberlass Ltda. and one to Frisokar Equipamentos Plásticos Ltda.. Both companies are using them to produce components from flexible, semirigid and integral foam that are widely used in the automotive sector. The latest system supplied to India went to Supreme Treves PVT. Ltd., which will be using the EcoStar for backfoaming carpets. In Iran, by contrast, the Pishgam company is using an EcoStar to make seat squabs for office chairs. p Klaus Bange Sales Manager Reaction Process Machinery Phone +49/89/ Small, compact and a power pack: the EcoStar series is ideal for small and mediumsized PU processors. FEATURE 19

20 Ultimate performance with machines from KraussMaffei. What s your choice for ultralight components that are also ultrastrong? Fibre composites are the answer. Today s production technology delivers cost-competitive, fibre-composite products with outstanding mechanical properties and paintable surfaces. To source this technology you need to look no further than KraussMaffei. We offer far more than high-performance production systems. We partner with you all the way to drive the success of your production project. However specialized your product and however demanding the specifications, we ll supply the process for the job LFI, FCS, RRIM, SRIM, SCS or RTM. INJECTION TECHNOLOGY REACTION PROCESS MACHINERY EXTRUSION TECHNOLOGY In-depth information and contact details are at KraussMaffei Technologies GmbH Phone