P KraussMaffei

Surface RTM Technology Fiber-reinforced, paintable surfaces such as roof elements, door inner panels, trunks or engine hoods

AHEAD

RTM Technology Structural and semi-structural components such as underbody structures, side frames or seat structures

Issue 02.2015

Wet molding RTM Technology Semi-structural components made of recycled carbon fibers, e. g. hybrid components

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI

www.kraussmaffei.com

AHEAD

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI

DRAFT

Issue 02.2015

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INCREASING COMPETITIVENESS

PRODUCTIVITY PLUS: THE FORMULA FOR SUCCESS

IMC Technology Fiber-reinforced, structural components such as front ends, mounting supports, instrument panel carriers

FiberForm Technology Continuous fiber-reinforced components such as crash elements, B-pillar reinforcements or seat structures

Fiber composite solutions for advanced lightweight components Engineering Passion

COVERFORM ®

INTUITIVE TOUCHPADS FOR MULTIMEDIA SYSTEMS

KraussMaffei

KraussMaffei

EDITORIAL

CONTENTS

Imprint

35

FOCUS ON CUSTOMER NEEDS

A WIN-WIN FOR ALL

IMPRINT

COVER STORY 6 Productivity PLUS: The formula for success

PROCESSES & PRODUCTS 12

Dear Customers, dear Readers, For the past several years, we have been completely committed to our one-ofa-kind performance promise: “Engineering Passion.” Our decades of expertise, our innovative ability and our passionate commitment to plastics engineering have been your competitive edge. KraussMaffei has a tradition of being at the forefront of groundbreaking topics of the industry. This issue features several projects that highlight our expertise in “Trendsetting,” some of which are in the areas of medical technology plastics, conservation of resources, lightweight construction, functional integration, energy efficiency as well as appearance. Not only are we taking a leading position here with our highperformance machines, but we also see ourselves as innovative leaders for new technologies. Prime examples include the SilcoSet, ColorForm, FiberForm and CellForm (MuCell) processes developed by KraussMaffei. With the new Adaptive Process Control System (APC), KraussMaffei has set a new benchmark in terms of cosistently achieving zero-defect production. Productivity PLUS is our 360 degree approach for your daily challenges in terms of efficient production. It provides you with increased flexibility in manufacturing, offers intelligent energy-saving solutions, extensive technology and upgrade options as well as ease of operation and perfect accessibility to the machines. Productivity PLUS combines the advantages offered by KraussMaffei through its skills, knowledge and experience in machine building, automation and technology.

Combination technology: Three processes in one production cell

14

Trendsetter silicone

16

Untapped potential

18

Easy and solid handle on all peripherals

19

Additional savings potential in mold changing

When t wo strong companies join for ce s , the r e sult is a win-win situation – and customers benefit from a performance capability that neither of the companies could have provided on its own. In South Korea, Netstal and DaeSang T&C are engaged in a reliable partnership on equal terms. As a result, the customers get the best of European technology and Korean relationship management.

Editorial team: Thomas Elfron, Michael Flurl, Dr. Sabine Kob, Anna-Maria Meyer, Petra Rehmet, Stephan Schierl, Dr. Reinhard Schiffers, Arne Schmidt, Sven Schröbel, Joachim Weber Photo credits: Colourbox, Daimler AG, Fotolia, Fuyao, iStockphoto, KraussMaffei, KraussMaffei Berstorff, Shutterstock

THERMAL INSULATION

20

ECOLOGY IN CONSTRUCTION – A GROWTH MARKET

Interview: “Fiber-reinforced lightweight construction as an innovation driver”

Publisher: KraussMaffei Technologies GmbH Krauss-Maffei-Strasse 2 80997 Munich Germany Phone +49 89 88 99-0 Fax +49 89 88 99-2206 www.kraussmaffei.com Responsible: Imre Szerdahelyi (responsible for content according to German media law) Chief Editor: Ashenafi Shawl

BRAND & MARKETS

PARTNERS & PROJECTS

Concept and design: Kirchhoff Consult AG, Hamburg www.kirchhoff.de Printing: omb2 Print GmbH, Munich

Extruded foams are the ace in thermal insulation. 22

Operating without looking

24

Pipe fittings in XXL format

26

Resourceful technological leader in Turkey

28

Continuous change provides stability

30

Always keep cool

32

Automotive glass: A brilliant outlook

34

Delivering successful solutions: The new sprue picker SPX 10

Productivity PLUS is also our motto at this year's Fakuma. Our dedicated team is already looking forward to greeting you there and speaking with you about trends, production and energy-efficient systems as well as the high quality and variety of our products. It's just too bad that we will only be able to show you a small part of our wide range of technologies at this large plastics trade show. These exchanges with you, as well as the up-to-date information on new technologies that we receive from universities and institutions, are an important part for our success and daily work.

KRAUSSMAFFEI GROUP

I hope you enjoy reading this edition of AHEAD and would like to take this opportunity to turn your attention to the brief introduction of the new CEO of the KraussMaffei Group on page 5. I look forward to working closely with Dr. Stieler!

35 Netstal: A win-win for all

4 Strong together and unique all over the world

The customer magazine is published twice a year in German and English. The magazine may only be reprinted with the written permission of the publisher.

Nearly 40 percent of German energy consumption can be attributed to the building sector. About half of that is used for heating private homes. That means this area offers enormous savings potential. KraussMaffei Berstorff contributes to realizing them. Partially spurred by lawmakers and partially by cost-conscious home builders or buyers, the construction industry has made energy savings one of its top priorities. Thermal insulation is the name of the game. Buildings everywhere, new ones as well as existing ones, are being covered with a second envelope for thermal insulation. Less visible: The insulation of heating or hot water pipes in order to avoid heat loss.

5 New CEO of the KraussMaffei Group

35 KraussMaffei Berstorff: Ecology in construction – a growth market 35 Trade show calendar

Dr. Hans Ulrich Golz Managing Director President of the Injection Molding Machinery segment

Netstal and DaeSang are successfully collaborating in South Korea.

35

Imprint

TRADE SHOW CALENDAR FROM OCTOBER 2015–MARCH 2016 Fakuma, Friedrichshafen, Germany

13.10.2015 – 17.10.2015

KraussMaffei Group

Composite Engineering Show NEC, Birmingham, England

04.11.2015 – 05.11.2015

KraussMaffei

Expo Plásticos, Guadalajara, Mexico

04.11.2015 – 06.11.2015

KraussMaffei, Netstal

RubberTech, Shanghai, China

11.11.2015 – 13.11.2015

KraussMaffei Berstorff

Putech Eurasia, Istanbul, Turkey

12.11.2015 – 14.11.2015

KraussMaffei

Plast Eurasia, Istanbul, Turkey

03.12.2015 – 06.12.2015

KraussMaffei

Interplastica, Moscow, Russia

26.01.2016 – 29.01.2016

KraussMaffei Group

JEC World, Paris, France

08.03.2016 – 10.03.2016

KraussMaffei

KraussMaffei

Contents

3

6 CUSTOMIZED SYSTEM SOLUTION KraussMaffei provides individualized product packages, offering its customers clear added value.

Prize awarded by the Automotive Award Society of Plastic Engineers 2015

14 Trendsetter silicone The best way to enter the silicone growth market is with an experienced partner.

22 CoverForm® Technology enables the production of harder and scratch-resistant three-dimensional surfaces.

4

KraussMaffei Group

AHEAD Issue 02.2015

KraussMaffei Group

STRONG TOGETHER AND UNIQUE ALL OVER THE WORLD The KraussMaffei Group is among the worldʼs leading suppliers of machinery and systems for producing and processing plastics and rubber.

1919 Purchase of the present-day production center of KraussMaffei Berstorff in Hanover (an der Breiten Wiese).

2,000 machines of the MX series have been installed worldwide to date.

550 t -year anniversary celebration for the Viersen plant in 2015. Together with the location in Georgsmarienhütte, Viersen forms the business area of Automotive Component Systems – trimming and mold technology for PUR components in cars.

1.593

billion closures

10

was the clamping force of the first, self-constructed injection molding machine by KraussMaffei in 1959.

– thatʼs how many the ELION 4200 from Netstal can manufacture per year.

KraussMaffei

KraussMaffei Group

PERSONNEL NEWS

NEW CEO OF THE KRAUSSMAFFEI GROUP With Dr. Frank Stieler, the KraussMaffei Group has gained a highly accomplished executive with more than 20 years of international experience in renowned German industrial companies with a global presence, especially in mechanical and plant engineering.

Dear Customers, the KraussMaffei Group is a remarkable company. It has three strong brands at its disposal with a portfolio of a wide range of premium-quality, high-performance products and services, of which technological expertise and the capacity to innovate form the basis. I have formed a deep respect for the wealth of knowledge, motivation and passion of our workforce all over the world, who are solely focused on you – our customers. These strengths are an excellent foundation for the continued development of the company and its portfolio of products and services. As our valued customers, you are at the heart of all our activities. It is for this reason that I dedicated the first weeks to numerous personal meetings with our longstanding customers in Europe, China and the USA, and I will continue to do so in the future. This enables me to gain valuable insight into your expectations and how we can assist you in gaining and maintaining a competitive edge in your markets.

DR. FRANK STIELER, Since July 27, 2015 Chairman of the Executive Board (CEO) of the KraussMaffei Group.

DR. FRANK STIELER – PROFESSIONAL CAREER It is a great honor for me to take on this challenge. I look forward to continue working with our experienced and excellent management team and our proud and committed workforce.

Since July 2015

Until 2001

KraussMaffei Group GmbH:

Lurgi Bamag: CEO, also Senior Vice Presi-

Chairman of the Executive Board (CEO)

dent of Azurix Corp.

It is my hope that I have been able to bring across my enthusiasm. I look forward to doing so in a personal conversation as well.

until July 2015

Until 1997

Independent consultant;

Metallgesellschaft AG:

Senior Advisor of Sun Capital Partners

Head of Executive Board Office and Senior

With best regards,

Until 2012

Vice President HOCHTIEF AG:

Until 1995

Member of the Executive Board, lastly CEO

Lurgi AG (since April 2014 Air Liquide Global E&C Solutions Germany GmbH): Head of

Dr. Frank Stieler

Until 2009

Legal Affairs, lastly Chief Financial Officer of

Siemens AG, various management positions

Lurgi Energie und Umwelt GmbH

in the Power Generation Group, then CEO of the Oil & Gas Division

Education: Doctor of Law

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6

Cover story

AHEAD Issue 02.2015

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KraussMaffei

KraussMaffei

Cover story

7

INCREASING COMPETITIVENESS

PRODUCTIVITY PLUS: THE FORMULA FOR SUCCESS Maximum flexibility and efficiency are the key topics in state-of-the-art plastics processing for companies looking to assert themselves among international competition. Manufacturers have different tasks depending on whether they are producing technical parts, medical products, packaging or automotive components. The key to success is called Productivity PLUS – KraussMaffei supplies a tailor-made system solution for every application purpose consisting of an injection molding machine, automation and additional peripherals, thus increasing productivity in your production. For example, injection molding machines with small and medium clamping forces of up to 400 tonnes. TEXT: DR. SABINE KOB, PETRA REHMET

EDITORIAL SUPPORT: ANNA-MARIA MEYER

ost pressure challenges The plastics industry is an international business and production is increasingly moving directly into countries that represent the markets for the products. This means providers from high-price regions must be able to keep up with competitors, that inherently have lower costs for energy, production facilities and personnel. Therefore, the key to success is increased productivity, either by decreasing the cost or increasing the output quantity. In both cases, KraussMaffei opens up a wide range of opportunities for its customers with its Productivity PLUS approach.

C

There are numerous factors influencing the injection molding process and thus the product quality, such as temperatures and movements on machines and molds or different material quality, either through batch and moisture variations or changing proportions of recycled material. This results in a different melt viscosity and the once-stable process configuration suddenly finds itself outside the specified quality tolerances. Interruptions caused by mold changes and maintenance have a similar effect. This is where Adaptive Process Control (APC), the only machine function of its kind on the market, effectively steps in. The function measures the melt viscosity online and adjusts – without delay – the point of changeover and the pressure level in the holding pressure for every shot. Operation of the machine becomes easier and the processor immediately obtains extremely uniform part

PHOTOS: KRAUSSMAFFEI

quality. The result: is fewer scraps and a higher return on investment. Dr. Reinhard Schiffers, Head of Machine Technology, has this to say on the topic: “Zero-defect production is possible with the Adaptive Process Control System, and even difficult raw materials can be continuously and efficiently processed into premium-quality components.” Money can also be saved when investing in a new production plant by using the cost-effective ClassiX product line from the CX series. There are just under 450 basic clamp and screw diameter combinations and plasticizing units available that can be supplemented by over 500 options. The customer benefits from such a large selection at an optimal price point. The basic design of the small and medium-sized machines, such as the CX series, already embodies the concept of high efficiency. Due to the space-saving twin-platen design, the small and medium-sized machines require less installation area and their cantilevered clamping units provide enough space underneath for mold temperature controllers or removal equipment. This is ideal if capacities need to be expanded in tight spaces or if a cleanroom is to surround the production cell. The CX is ready for anything. In the 35 to 160 tonne clamping force range, the new CX is an impressive 15 percent faster, 30  percent

8

Cover story

AHEAD Issue 02.2015

The exhibits at the Fakuma trade show showcase a variety of options for increasing productivity with KraussMaffei in both small and medium-sized machine segments: > Exciting surface effects with laser or hologram appearance emerge from a CX 160 using inductive DMH (Dynamic Mold Heating) _ an efficient alternative to film technology. The industrial robot is completely integrated into the protective housing. > 40 percent weight reduction for airbag housing: the FiberForm application on a CX 300 makes it possible _ with a cycle time of 42 seconds. The APC function also stabilizes the process here. The new LRX-TwinZ multiple kinematics is integrated into the standard protective enclosure. This saves installation space and also costs. > Incredibly versatile silicone: An all-electric AX 50 SilcoSet produces nasal respirator units made from silicone in a 4-cavity mold. Premiere of the APC function for silicone applications, as well as for the expanded functions of the sprue picker.

KraussMaffei

Cover story

9

KraussMaffei offers its customers a significant increase in productivity through its skills, knowledge and experience in machine building, automation and technology. Users across all business areas can increase their competitiveness with customized packages.

quieter and 25 percent more efficient. A CX Hybrid solution is also available now: Manufacturing is even more efficient and precise with its electric injection unit. The challenge of specialization Using the new technologies presents a possibility for many processors to better position themselves in a very competitive environment. A prime example is multicomponent technology, which enables a high degree of functional integration. KraussMaffei also offers individualized, flexible solutions here. Each KraussMaffei injection molding machine can be conveniently expanded with a bolt-on unit. Surface processes, such as film technology, offer similar potential for more specialization. Thermoplastic lightweight construction solutions such as the FiberForm process developed by KraussMaffei, which is a combination of injection molding machinery and thermoforming of composite sheets, also offer this potential. KraussMaffei supports its customers on their path to discovering new technologies from the beginning – from the project configuration, test runs in the TechCenter up to the commissioning of the finished individualized production solutions and the after-sales service. The investment pays off. Dr. Hans Ulrich Golz, Managing Director of KraussMaffei and President of the Injection Molding Machinery segment of the KraussMaffei Group, adds: “The path to specialization is a worthwhile endeavor. Those willing to take a chance will be successful in the long run.”

The challenge of fl exibility While traditional manufacturers have a certain amount of planning certainty due to defined release order quantities and throughput times, providers involved in contract manufacturing have to deliver flexibility first and foremost. As a result, their machinery needs to be designed to meet a wide variety of different requirements. KraussMaffei has them covered with optionally available clamping platen sizes and distances, among other products. This is also true of the new CX series, which allows the platens to be up to 13 percent wider. The resulting benefit is that applications requiring a 160 tonne machine from the competition, run at 130 tonnes on a KraussMaffei machine – an efficiency advantage of up to 15 percent, from requiring fewer work hours to reducing operating costs to make the same piece. Even molds up to 40 percent larger fit on the machine with XXL platens! The adaptation for the plasticizing unit also enables enormous flexibility. This facilitates the production of shot weights, which were too small for the available machine and previously had to make due with a large sprue (and thus wasted resources). The new, intuitively operable MC6 Multitouch, which is being used in all series, is a revolutionary highlight for the machine control system. It is the only one on the market to use a capacitive 24 inch multitouch screen and is as easy to operate as a smartphone. Even complex processes can be run using gestures such as swiping or pinching your fingers. To allow operators to control machine movements without even looking at the screen, the SlideX guideway engraved on the glass provides the necessary tactile orientation. The control of linear

10

Cover story

AHEAD Issue 02.2015

“The path to specialization is a worthwhile endeavor. Those willing to take a chance will be successful in the long run.” DR. HANS ULRICH GOLZ, MANAGING DIRECTOR OF KRAUSSMAFFEI

APC The new APC (Adaptive Process Control) machine function enables quick restarting of the injection molding machine. APC even lets you use difficult material batches and high quantities of recyclate to produce high-quality components.

robots can easily and conveniently be integrated into the MC6 using the WizardX programming wizard. Intuitive operator guidance supports the user and allows even beginners to create basic automation processes in the shortest possible time. The challenge of resource conservation Resources are limited and raw materials are becoming ever more expensive. This makes reducing the amount of energy, oil and material we use worthwhile in the long run. Therefore, the drive concept for the new CX series has been energy-optimized so that the machine already requires ten percent less electricity than before due to intelligent storage management. The optionally available BluePower Vario Drive improves the efficiency even more, it saves up to 30 percent compared to the typical hydraulic variant. The oil volume has also been reduced by 20 percent and in the plasticizing area, KraussMaffei stands alone as the leader for this type of design. Because injection can take place in one line of action, even fully hydraulic machines achieve a precision that other providers can only achieve with hybrid or all-electric models. Moreover, the good homogenization performance of the HPS-M screw really saves money. The color masterbatch, for example, can often be reduced by up to 30 percent, which, at prices as high as 20 euros per kilogram, easily adds up to a few thousand euros per year. Intelligent KraussMaffei BluePower energy management systems also support sustainable production. Such as the new weekly timer, which prepares the injection molding machine with pinpoint accuracy at the time of production start. This saves time and energy. Additional energy-saving potential – up to 15 percent – is the result of active storage management, with which the optimum operating pressure is determined and the charge pressure is adjusted in the memory. The “Eco-Button” function also compares the energy consumption before and after optimization and thus determines the energetic optimum setting values. The operator now decides whether the new values are accepted or rejected.

HPS-M The screw and non-return valve ensure uniform color distribution in the component. This allows the use of complex materials. Achieve batch savings of up to 30% and change colors up to 20% faster!

TECHNICAL PARTS

Those who manufacture technical parts need precision. Metal inserts are extrusion-coated, a high percentage of recycled materials and fiber-reinforced plastics are used and there are frequently multiple color variants and multicomponent applications, especially in the consumer area. Klaus Bange, Head of Business Unit TEC: “Nearly every screwdriver from the DIY store today already has a grip with hard-softconnections. Flexible bolt-on units allow our customers to quickly and perfectly enter the world of multicomponent technology.”

KraussMaffei

Cover story

CX STANDS FOR HIGH EFFICIENCY Thanks to its smart battery management, the machine uses ten percent less electricity than before.

AUTOMOTIVE

MEDICAL

LOGISTICS/ PACKAGING

Automotive industry suppliers know the story: Extremely narrow tolerances and high specifications for the product quality. Highly visible parts require absolutely immaculate surface quality, because even the smallest defect often only becomes apparent after a subsequent refining step, resulting in the loss of even more added value.

Long throughput times and the cleanest production situations: Many products in the medical industry are only subject to a few changes. High quantities and long service lives are sought after in disposable items. In addition, silicone applications are becoming more and more interesting (for more information, refer to: article on pages 14–15).

When quantities are approaching the millions, two things in particular are key: speed and raw material efficiency. In addition to rapid cycle times, every last tenth of a gram of saved plastic counts here because material costs account for more than 60 percent in the packaging industry.

Bengt Schmidt, Head of Business Unit Automotive, explains: “The APC function has received a very warm reception from our customers in the automotive sector, for instance during cost-intensive procedures such as the in-mold labeling (IML).” (For more information, refer to: Foliotec user report on pages 28–29).

Thomas Hörl, Key Account Management MED: “KraussMaffei machines perform very well with cleanroom capability by virtue of their clean, compact design. In addition, applications can be run on smaller machines than competing brands by using our wide platens. This saves valuable cleanroom installation space and reduces operating costs.”

Klaus Zeiler, Deputy Head of Business Unit Logistics/Packaging: “The plasticizing unit from KraussMaffei is the best on the market. Alone with our unit and combined with the HPS-M screw, our customers can save thousands of euros a year.”

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12

Processes & Products

Processes & Products

PROVEN ONCE AGAIN: THE VALUE OF COOPERATION WITH COLLEGES AND UNIVERSITIES

COMBINATION TECHNOLOGY: THREE PROCESSES IN ONE PRODUCTION CELL Natural fibers have established their place in the automotive industry as a more lightweight and cost-effective raw material for interior components. The mass production of components like these is a part of everyday industrial life, up to this point; although, applying surface lamination has been time-consuming in downstream working steps. The combination of processes is, however, a promising approach for shortening the process chain. TEXT: JOACHIM WEBER

EDITORIAL SUPPORT: STEFAN SCHIERL

PHOTO: KRAUSSMAFFEI

T

his is likely a dream come true for many automotive suppliers: a new process for manufacturing natural fiber-reinforced components has been developed by the Institute for Lightweight Structures and Plastic Processing at the Chemnitz University of Technology in close collaboration with KraussMaffei and Hugo Stiehl GmbH Plastics Processing. It brings three process steps under one roof: thermoforming, injection molding and surface application using reaction process machinery. Up until now, the state of the art has been pressing natural fiber mats interspersed with plastic fibers into the desired shape by first applying heat (thermoforming). High percentages of long fibers can be processed in the press method, which acts as the basis for components that can withstand high mechanical stress with relatively low wall thickness and low structural weight. The materials are then processed further in downstream working steps. They are first provided with fasteners and then laminated with decorative materials. Until now, all of the process integration efforts had to be finalized before surface decoration.

3

AHEAD Issue 02.2015

CURRENT TRENDS Automakers are increasingly relying on the use of natural fibers in cars.

Now, the developer community has broken down this barrier. Through the communityʼs efforts, all three production steps have been combined into a single production cell. A standard injection molding machine was all that was needed. The process is amazingly well suited to mass production, as cycle times of 60 seconds on a manufacturing cell

can produce more than half a million components in a year. Combinations of methods shorten the process chain As in the previous standard process, a textile semifinished fiber fleece product made of polypropylene fiber (PP) and natural fiber

31 KraussMaffei

Processes & Products

13

1

THERMOFORMING + 2

(NF-PP mat) with a defined weight per unit area is the starting point of the procedure. NF-PP mats with a weight per unit area between 1,400 g/m² and 2,000 g/m² are usually used depending on the mechanical requirements. In the first process step, this semifinished product is first heated to approximately 200 °C and fixed in the mold of a standard injection molding machine. The mold closes and the semifinished product is reshaped into a thin-walled NFRP lightweight carrier (NFRP: natural fiber-reinforced plastic).

The second process step occurs in injection molding and takes place in the same mold as the first process step. The lightweight carrier is back-injected with function elements or structural reinforcements made of PP. In the previous pressing process, the back injection areas were omitted. This way, the PP melt can be screwed into the heated NF-PP mat during the injection process. This creates a reliable connection between the semifinished product and the molded-on structures. Both components cool together – internal stresses are minimized in the component. As soon as the applied melt is cooled, the reaction process machinery comes into play. Numerous material systems are available for coating. Surfaces with a soft-touch effect

in

“We are convinced that partnerships with universities can substantially accelerate innovation.” MARTIN WÜRTELE, HEAD OF TECHNOLOGY DEVELOPMENT FOR KRAUSSMAFFEI

and scratch-resistant paint surfaces can be applied depending on requirements. Both coatings are two-component materials. They are introduced into the closed mold with a mixing and metering system and react from there. Effectively decreasing cycle times Carrying out this process directly on the injection molding machine requires expanding the mold by the corresponding coating thickness. This is handled by mold systems from well-established multicomponent variants, such as sliders, turntables, indexing and spin platens. The component can be removed from the mold after the reaction time has elapsed. A swivel-platen machine makes it possible to significantly reduce cycle times even further.

INJECTION MOLDING + 3

SURFACE APPLICATION

This requires reforming and back-injecting the next semifinished product into the other cavity at the same time as the coating process is happening in the second cavity. Initial close-to-production tests demonstrated the bond strength of the three components as well as the processʼ potential in industrial applications.

Martin Würtele, Head of Technology Development for KraussMaffei, believes this has definitively proven the value of the development strategy, “Weʼve always been convinced that partnerships with universities can provide a significant boost to innovation. This project has reinforced our decision to continue down this successful path in the future as well.”

YOUR CONTACT: Martin Würtele Head of Technology Development [email protected]

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Processes & Products

AHEAD Issue 02.2015

CONFIDENTLY TAKING YOUR FIRST STEPS INTO SILICONE PROCESSING WITH KRAUSSMAFFEI

TRENDSETTER SILICONE

Components made of silicone – whether as stand-alone products or in conjunction with common thermoplastics – are gaining ground. Medical technology and the automotive industry in particular are increasingly interested in the outstanding physical and chemical properties of the material. The best way to enter the silicone growth market is with an experienced partner such as KraussMaffei. TEXT: DR. SABINE KOB

EDITORIAL SUPPORT: ANNA-MARIA MEYER

PHOTOS: KRAUSSMAFFEI

KraussMaffei

t is very resistant to aging and chemicals, highly flexible, flame resistant and free of plasticizers. And itʼs a trendsetter: New areas of application are bringing double-digit growth to silicone processing around the world. This growth stems from technical developments such as more and more powerful motors, as well as the increasing population in Asia and the increasing importance of lighting technology in everyday applications. These are all good reasons to delve into the topic of silicone in greater detail.

I

New paths to precision If you compare processing silicone to processing thermoplastics, two things become immediately apparent: The material is created from two individual components in a reaction process and temperature control in the plasticizing unit and injection mold is precisely the opposite of conventional applications, i.e., cold in the screw (approximately 20 °C and hot in the mold (approximately 160 °C). As part of its SilcoSet product line, KraussMaffei makes hydraulic, electric and hybrid machines with clamping forces from 35 to 650 tonnes designed to process silicone – even post-manufacturing processing. Turnkey solutions even provide a complete system – including the injection mold and peripherals. Doing this for the mold is quite a challenge. Because liquid silicone (LSR: liquid silicone rubber) has a consistency ranging from honey to water, the mold must clamp extremely tight and the creation of a vacuum is often necessary. KraussMaffei has proven partners for silicone molds with up to 256 cavities and excels on the machineside with its plasticizing unit. On proven inline injection units, the force is transferred to the screw via the piston along a direct line of action. This allows even fully hydraulic machines to achieve the precision necessary for processing silicone. Exceptional physical and chemical properties The enthusiasm for materials that can be used in extreme temperatures continues to rise in the automotive industry. As engines become increasingly more powerful, TPEs just cannot handle the heat under the hood. Silicone, by contrast, is stable from –110 to +250 °C and even up to 300 °C in special formulations. In addition, self-adhesive types cling tightly to coverings made of polyamide (also with glass fiber content) or other thermoplastics as a seal in two-component applications. A production and transfer process is recommended for two-component parts, which can involve handling within the machine, can occur between two separate

Processes & Products

machines or, if space is at a premium, can be achieved using a rotary table. In any case, the silicone is sprayed onto the still-active thermoplastic surface to produce the finished product.

15

trends. First, the population in Chine is aging at a rate similar to Europe. Second, the number of very young users of silicone products is increasing due to the easing of Chinaʼs one child policy.

New areas of application are bringing double-digit growth to silicone processing around the world. The new highly transparent silicone is of interest for applications throughout vehicle production and in other areas where the demands on lighting technology continue to increase in complexity. They enable the production of extremely thin and precise lenses, such as for LEDs. The low viscosity of LSR makes it possible to create light-scattering textures that are hardly even feasible with thermoplastics. The material has additional advantages: It does not yellow and is resistant to aging. Leading know-how in the growth market Silicone is most frequently associated with the health sector. These products include cannulae, baby pacifiers and breast pumps – all ideally made on all-electric machines with cleanroom equipment. This use focuses on the biocompatible, hypoallergenic properties of the material and the fact that bacteria-resistant types are also available. Access to medical care is increasing in many countries around the world – and demand along with it. In the booming market in China, growth is also influenced by two other

In addition to liquid silicones (LSR), there are also solid silicones (HTV: high-temperature vulcanizing), which comes in rectangular blocks before it is processed into its final shape. Due to their insulating properties and even higher dimensional stability, they are particularly well suited to applications in the electronics industry or with high mechanical stress. KraussMaffei also offers the equipment needed for processing HTVs, including patents for the automatic feed unit AZ. Plastics processors considering the idea of entering the silicone area are in good hands with KraussMaffei.

YOUR CONTACT: Cordula Regensburger Product and Technology Management [email protected]

FAKUMA: SILICONE PROCESSING LIVE

Ensuring the flow of oxygen: KraussMaffei is demonstrating the production of nasal respirator units made of silicone at Fakuma. The product runs on an all-electric AX with 50 tonnes of clamping force in a four-cavity mold. The SPX 10 sprue picker with extended function takes the parts, separates them and deposits them. The AX SilcoSet is cleanroom-compliant and qualified for the manufacturing of medical products.

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Processes & Products

AHEAD Issue 02.2015

THE INTELLIGENT MC6 CONTROL SYSTEM FOR SAVING ENERGY

UNTAPPED POTENTIAL Sophisticated programming, large quantities of sensory data: These provide the basis for a wealth of setting options that state-of-the-art injection molding machines offer. Their operators, as well as the manufacturer, can access a vast amount of parameters and information to optimize the process. However, many of these areas available for optimization remained underutilized until now. TEXT: JOACHIM WEBER

EDITORIAL SUPPORT: DR. REINHARD SCHIFFERS

PHOTO: KRAUSSMAFFEI

dmittedly, not every employee is permitted to make adjustments. Access works on various levels. The operator can directly input one part of the optimization processes. But this requires in-depth familiarity with the machine. Another area of machine parameters cannot be reached from the outside. It depends directly on the process involved and is set to safe, general values defined by the manufacturer. And finally, there are interactions that can only be made while the machine is running.

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The control system in the injection molding machine holds this built-in intelligence. It has process “knowledge” in two forms. Information about the machine itself – you could say its configuration and options are fixed by the software blueprint. On the other hand, the measured values from the ongoing process vary, are dynamically processed and regulated as needed. At the same time, they help the control system acquire additional process knowledge, essentially allowing it to learn.

the task of finding the optimum parameters here. The Eco Assistant is a standard function for all hydraulic machines with an MC6 control system. Intelligent pausing The option of minimizing the energy use during planned downtime, such as during pauses in production, is also interesting. The drives can usually be switched off during these standby times while the barrel and mold heating are dropped down to a certain level. This level changes depending on which plastic material is being used. Polyethylene can cool down completely; polyacrylic or PMMA, on the other hand, would likely damage the machine if they solidified completely. The operator can also leave this function to this control system; the operator just needs to specify the times for the idle mode.

“The Eco Assistant is stan-

dard for all hydraulic machines with the MC6 control system.”

The weekly timer offers another opportunity for savings. This function DR. REINHARD SCHIFFERS, HEAD OF MACHINE TECH– long a part of KraussMaffei control systems – makes it possible to NOLOGY FOR KRAUSSMAFFEI switch on the heating and the pump motor on a timer. How much time beComplete control fore the beginning of production do Entirely new options for achieving the perfect machine optimization warm-up processes need to be started so that the machine can be result from this setup, particularly the option of operating it in an enready on time but doesnʼt use an unnecessary amount of energy? ergy-efficient manner. The measured values include information such This is where the learning effect comes into play. The control system as the hydraulic accumulator charge pressure and the injection presalready has empirical values after powering up a system for the first sure limit. KraussMaffei has integrated an electronic specialist in the time and can calculate how long such a process will take based on MC6 machine control system to adjust them automatically: The Eco the current (temperature) conditions. Button. At that point, the operator just has to enter the desired times for the Activating it sets it to work determining the optimum energy values daily start of production. The processes of warming-up the hydraufor various setting parameters. The operator then has the choice of lic fluid and heating up the barrel start automatically. The machine is either accepting or refusing the suggested parameter settings. This warmed-up at the desired time and can immediately start production gives the operator full control over component quality and makes it at the lowest energy expenditure. The weekly timer for start of propossible to achieve maximum energy savings – the machine handles duction is available on every MC6 control system.

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MC6 MULTITOUCH The intuitive control system of the future.

Load peaks under control Every machine can also be integrated into external energy management systems (EMS) through the MC6 control system. The reason stems from energy provider rates, which make load peaks expensive. Coordination when powering up the machinery is necessary to avoid these kinds of peaks. An integrative EMS can prevent machines from all operating in peak-load phases at the same time.

“The extensive bundle of intelligent functions built into the MC6 control system creates many ways for processing companies to save energy to the tune of several kilowatt hours. In total, when calculated over the year, this can add up to considerable amounts,” concludes Dr. Reinhard Schiffers, Head of Machine Technology for KraussMaffei. “This is why we want to help all of our customers discover and utilize additional functions in the control system.”

Using stored priorities and performance data as a basis, this system individually signals all of the MC6 control systems in operation when they should show a low profile. The control system continues preventing additional loads such as pump drives, heaters or connected peripheral units from being switched on until the machine is cleared to operate again. As a result, individual machines can be ramped up via time-delay and load peaks can be prevented. YOUR CONTACT:

Considerable savings Limiting peak loads can also be enabled during ongoing production to temporarily throttle the energy draw of the machinery. In this case, the EMS also gives the control systems a start/stop signal. The control systems continue inserting a cycle pause if this is permitted by the mold and product quality.

Dr. Reinhard Schiffers Head of Machine Technology [email protected]

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Processes & Products

AHEAD Issue 02.2015

MULTISUBMIT CENTRALIZES THE OPERATION OF THE ENTIRE LINE

EASY AND SOLID HANDLE ON ALL PERIPHERALS COMPLETELY UNDER CONTROL The MC6 look and feel using the VisuX program interface.

The dream of every operator is to have the ability to simultaneously operate and program up to seven peripheral processes with a handheld robot – from moving to sorting to packaging. This is possible with the Multisubmit control function from Kuka integrated into the KraussMaffei MC6 control system. This keeps KraussMaffei one step ahead of the competition. TEXT: JOACHIM WEBER

PROGRAMMER HELP Generating a command line free of errors. Drop-down selection list for more functionality.

A LIBRARY FOR EVERYTHING Multisubmit implemented in the ProgTechX command library.

EDITORIAL SUPPORT: MICHAEL FLURL

“The new Multisubmit programming function provides the perfect complement to our proven MC6 operating concept. Centralized system operation, control and programming can be carried out via the handheld terminal of the robot. In addition, the complex integration of an additional programmable logic controller (PLC) is made obsolete in a wide range of applications. Basically, system operation is being centralized and, in turn, simplified,” states Thomas Marufke, Managing Director of KraussMaffei Automation GmbH. The new function has been available in combination with the KUKA KR C4 control system version 8.3 since the beginning of 2015. Above all, the system operator notices the additional convenience. The operator can monitor, control and, where necessary, program both the injection molding machine and all of the functions and parameters of the peripheral devices from the familiar control unit. Almost nothing indicates that third-party software is responsible for this. No new expertise necessary KraussMaffei is expanding the standard of the available MC6 ProgTechX command library with the new Multisubmit program function. The diagnostic and pneumatic functions, as well as variable monitoring, are displayed via the MC6 VisuX visualization. Additional programmable logic controllers and PLC operating expertise are no longer required. This lowers the time and expense

PHOTOS: KRAUSSMAFFEI

required for training machine operators as well as the amount of investment required. The option of retrofitting an existing system with additional peripherals is also a major key feature. For those interested in IT: An interpreter is a computer program that – instead of converting program source code into an executable file directly on the system like an assembler or compiler – reads in, analyzes and runs the source code. Kukaʼs Submit Interpreter is a logic program that runs in parallel with the robot program. While the previous robot control system from the company only had one Submit interpreter each, the new KUKA KR C4 has eight interpreters running independently (Multisubmit). The most important application of Multisubmit is the activation of external peripheral components operated at the same time, such as conveyor belts with separators, assembly stations or drawer systems and magazines.

YOUR CONTACT: Rudi Brand Technology – Control Technology [email protected]

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Processes & Products

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“INSERT, MAGNETIZE – DONE”

ADDITIONAL SAVINGS POTENTIAL IN MOLD CHANGING Large leaps are not the only path to more productivity for injection molding. It is oftentimes the small steps that lead to success and have an overall large effect. KraussMaffei showcases two essential work steps that can further optimize the complex process of mold changes. TEXT: JOACHIM WEBER

EDITORIAL SUPPORT: ANNA-MARIA MEYER

PHOTOS: KRAUSSMAFFEI

hanging a mold more often means more time devoted to setup: the interlocking connection between the machine ejector and the mold. In order to accelerate this work step without impacting safety or service life, KraussMaffei has developed a new mechanical ejector coupling.

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The result is a new ejector coupling that gives the user noticeable time savings. It is characterized by the fact that it is flexible when coupling. This ensures the minimum possible axis offset between machine and mold. After locking, a positive connection is created on both sides. This not only guarantees a precise ejection but also a long service life. The coupling releases easily, opens quickly, easily couples back together and clamps quickly. Owing to its streamlined design, it is very readily accessible, which makes these steps easier. As a whole, convenient operation leads to a significant decrease in setup time for mold changing. Magnet instead of screws The magnetic clamping plates from technological leader Stäubli add a bit more weight to the scales – both in terms of the productivity boost and physical weight. Instead of unscrewing and reattaching at least eight mounting clamps for changing the mold as on a conventional clamping plate, all the mold setter needs is two commands for extending and retracting the molds: demagnetize and magnetize. The operator does not require any additional equipment. As a result, the magnetic plate offers the fastest and most flexible solution for clamping molds. KraussMaffei adds even more to the equation. The Stäubli magnetic clamping plate (for 35 to 5,500 tonnes) is fully integrated into the KraussMaffei MC6 control system, including its highly intuitive programming and user interface with touchscreen.

SIMPLE AND QUICK Mold changeover with flexible ejector coupling.

All the data at a glance This means that the clamping plate does not require its own control unit; all of its functions can be controlled directly using the MC6 control system. The operator does not need to become familiar with another system (and the corresponding training expenses), does not have to swap control panels during ongoing operation and has all the data relevant to the process – such as holding force and the temperature of the clamping plate – available at a glance automatically on the same interface as usual. All specific commands, such as “magnetize” or “demagnetize” are input using the control system directly. The operator can find the previous working steps stored in the memory as usual when checking the process or looking for errors. The combination of MC6 plus magnetic clamping plate ensure noticeably smoother processes. This is not the only reason that investing in a clamping plate such as this is worthwhile. There are other, tangible reasons: For one, the service life is very long; more than 20  years is not uncommon. The efficiency gains are also measurable. On average, a machine setter requires 20 minutes for setup (insertion, centering and clamping) on a 300 tonne machine with a conventional mechanical clamping device. This time

is reduced to five minutes with the magnetic clamping plate. The same process on a 1,600 tonne system previously required two persons to spend 30 minutes working on it. Magnetic clamping lets one worker finish this task in ten minutes. This results in a potential increase in machine operating time of 15 minutes in the first scenario, or even 20 minutes in the second. “Insert, magnetize – done. This is clearly the fastest, universal type of mold changing,” states Jochen Mitzler, Head of Strategic Product and Technology Management at KraussMaffei. “The user gains a high level of flexibility and productivity with the combination of the control system and magnetic plate. In the highly competitive markets for plastic injection molded parts, this always entails an increase in competitiveness as well.”

YOUR CONTACT: Götz Scheibe Product and Technology Manager [email protected]

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Brand & Markets

AHEAD Issue 02.2015

Brand & Markets INTERVIEW WITH NICOLAS BEYL ON THE TRENDS AND POTENTIAL FOR REACTION PROCESS MACHINERY

“FIBER-REINFORCED LIGHTWEIGHT CONSTRUCTION AS AN INNOVATION DRIVER” The trend towards lightweight construction suitable for series production is noticeably spurring development in reaction process machinery. Development does not stagnate in an industry with new machines and procedures that allow for the production of high-performance composite components from epoxy resins alongside polyurethane raw materials and other materials, such as cast polyamide. AHEAD spoke with Nicolas Beyl, President of the Reaction Process Machinery Segment of the KraussMaffei Group, about the current trends and developments. INTERVIEW: PETRA REHMET

PHOTOS: KRAUSSMAFFEI

NICOLAS BEYL: The HP-RTM (high pressure RTM) process developed by KraussMaffei significantly shortens cycle times.

AHEAD: BMW led the way with the i-series: Lightweight construction ready for series production with carbon-fiber reinforced plastic. The other automakers, on the other hand, are still holding back. What can we expect in this area in the future? Beyl: The development and acceptance of carbon-fiber reinforced plastic in the automotive industry is almost exactly like that of aluminum 20 years ago. In 1994, Audi produced the first sedan series with a self-supporting car body made of aluminum. The experts were skeptical at first, but the material caught on at other manufacturers due to its good properties. Today, BMW is the

pioneer of carbon-fiber reinforced plastic. Composite construction will catch on in large-scale series production, with CFRP making up bigger and bigger portions of the mix. AHEAD: The high costs of carbon fibers and the long cycle times used to be the largest obstacles to the use of CFRP. What potential do you see here? Beyl: It is important to look at the big picture when looking at costs. For CFRP components in the automotive industry, fibers, processes and rework costs are all cost drivers, each accounting

KraussMaffei

for about one-third of the cost. The costs for fibers and cycle times will drop. In the HP-RTM process (high-pressure resin transfer molding), times as low as two minutes are already possible. And automation is expanding further in the process as a whole. AHEAD: You talk about the HP-RTM process as an important trendsetter for series production. What sort of advantages does the process offer compared to extrusion-coating and back-injection of inserted composite sheets with similar, very short cycle times? Beyl: Unlike the conventional RTM process, the HP-RTM variant – that is to say, high-pressure injection – allows processing of fastreacting resin systems. This significantly shortens cycle times. Extremely lightweight structural components can be made with the HP-RTM process. Today, a fiber content of up to 70 percent can be achieved and the fibers can be aligned with load paths. This allows us to achieve strength and stiffness that exceeds the performance of steel components. The HP-RTM process clearly outpaces the injection molding process. AHEAD: But there is still the argument that it has comparatively long cycle times... Beyl: We set the highest priority on having manufacturing processes that are suitable for automation. That is the decisive factor

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for cutting costs. HP-RTM can be fully automated and is suited for series production from the manufacturing of preforms up to post-mold processing. Of course, we still need to look at the cycle times in the mold, but these continue to get shorter and shorter with faster curing matrix materials and new mixing and metering technology. AHEAD: How is KraussMaffei advancing the technological development of HP-RTM? Beyl: The T-RTM process is especially interesting. T-RTM stands for thermoplastic resin transfer molding. Polymerizing thermoplastic systems, such as cast polyamide, are used in place as matrix material here. These reactive caprolactam systems have three important advantages. First, they have very low viscosity, almost like water, and therefore offer fast impregnation of the semifinished fiber components and short process times in processing. Second, they can be welded; additional functional parts can be injected onto the component. And third, they can be recycled as epoxy resin or polyurethane more easily. The first references for KraussMaffei are B-pillar reinforcement prototypes manufactured in the Volkswagen F VK TechCenter. The spectrum of all five different HP-RTM processes from KraussMaffei is diverse and offers a lot of potential – we are planning to pursue every avenue of development for them in the future.

“The spectrum of all five different HP-RTM processes from KraussMaffei is diverse and offers a lot of potential – we are planning to pursue every avenue of development for them in the future.” NICOLAS BEYL, PRESIDENT OF THE KRAUSSMAFFEI GROUP REACTION PROCESS MACHINERY SEGMENT

FRONT-END CARRIER Maximum structure load capacity and approximately 50 percent lighter than a metal structure.

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Partners & Projects

AHEAD Issue 02.2015

Partners & Projects EXTREMELY SCRATCH-RESISTANT TOUCHPAD SURFACES THANKS TO COVERFORM ®

OPERATING WITHOUT LOOKING Intuitive touchpads for multimedia systems ensure more operating convenience and safety on the road for current Mercedes models. Continental manufactures the advanced plastic upper shells using the CoverForm® process from KraussMaffei and Evonik. This lets the automotive supplier benefit from extremely scratch-resistant and chemical-resistant surfaces in series production. TEXT: PETRA REHMET (KRAUSSMAFFEI), ARNE SCHMIDT, SVEN SCHRÖBEL (EVONIK)

TOUCHPAD

Extremely scratch-resistant, providing a long service life: The manufactured top cover of the three-dimensional molded Touchpads from Continental in the CoverForm® process.

PHOTOS: DAIMLER AG

KraussMaffei

wiping, zooming, scrolling – the touchpad integrated into the center console in the current Mercedes models enables intuitive operation of the multimedia system just like a smartphone. In addition, the touchpad confirms the action of the driver with haptic feedback just like a button. This lets the driver operate the system without looking down, keeping the driverʼs focus on the road. This is an important aspect for more comfort, convenience and safety while driving.

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Naturally, the more contact there is with a personʼs hand, the higher the stress of the touchpad surface. Therefore, the top cover of the touchpad has to be even more resistant than a conventional plastic surface, that is to say extremely scratch-resistant and chemical-resistant. But those were not the only strict design and quality requirements that

The touchpad can withstand a load of

80 kg 2m No. 1 and

operations.

1st Place and the Grand Award, Electronic/Optical Parts Category, Automotive Award Society of Plastic Engineers (SPE) 2015

Partners & Projects

Daimler placed on the automotive supplier Continental. “The touchpad had to work in a temperature range of minus 40 °C to above 80 °C, and withstand loads of 80 kilograms as well as two million operations,” says Jürgen Diefenbach, Head of Haptic Devices Project Management at Continental, while naming some of the test criteria from Daimler.

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many downstream steps such as cleaning the component surface or applying and airing out the primer and hardcoat. In short, this makes it possible to have significantly more compact systems than in typical manufacturing processes.

Hand-in-hand development Daimler and Continental took an early interest in the new technology. KraussMafWith the CoverForm® technology, it was possible to meet these criteria perfectly. “We fei and Evonik had already subjected Coverdeveloped a premium product for premiForm® to numerous standardized tests and um customers,” says Diefenbach of the new demonstrated its superior material proptouch panel. “The technology allows the proerties. However, KraussMaffei and Evonik duction of harder, more chemical-resistant, had to bring this young technology to the more scratch-resistant and more transparcommercial stage. In the automotive indusent three-dimensional surfaces than with try, for example, it is typical for a compoother processes.” The nent to cycle through production site locatthree to four samed in Babenhausen is ple phases in which expected to achieve the design requiremaximum producments can change tion volume of over significantly. For all one million top covof these intermediate ers with two injection steps, KraussMaffei molding machines by and Evonik needed to 2016. This makes the demonstrate time and automotive supplier again that the altered and Daimler the first design requirements JÜRGEN DIEFENBACH, to bring CoverForm® could be met with HEAD OF HAPTIC DEVICES PROJECT into automotive series CoverForm®. MANAGEMENT AT CONTINENTAL production together with KraussMaffei In close collaboration, and Evonik. ever yone involved succeeded in putting Injection molding and scratch-resistant the process into action on time and in accorcoating in one system dance with the specifications from ContinenCoverForm® is both a material and a protal and Daimler. This makes Daimler the first cess technology. It is for this reason that automaker that can offer a touchpad with a KraussMaffei and Evonik worked so closecurved surface for the operation of infotainly together on development right from the ment system in its vehicles. All other autostart. The key to success on the material makers are still using flat surfaces. For Udo side is a specially developed material sysGayer, Team Manager Interior-Materials tem from Evonik for this process: A very Technology at Daimler, the new touchpad is hard PMMA (polymethyl methacrylate) bondnot only a technical marvel, but also an eyeed with an additional coating for particularcatching addition to the new interior design. ly high requirements. But the material alone “Overall, I am impressed by both the high reis not everything. The conventional manusistance to scratches and chemicals as well facturing process for a three-dimensional as the amazing collaboration with the comcomponent with these exceptional qualities panies involved: Continental, KraussMaffei would require injection molding followed by a and Evonik,” says Gayer. separate lacquer coating – a procedure with a total of 14 steps. A costly and time-consuming method. The CoverForm® process, on the other hand, substantially speeds up manufacturing while making it more cost-effective. It enables injection molding and application of a scratch-resistant coating in a single, fully integrated process. This soluYOUR CONTACT: tion is the only one of its kind in the world: Martin Würtele PMMA directly flow-coated in the injection Head of Technology Development mold with a reactive system. This [email protected] ing in the mold extends the cycle time by roughly ten to 15 seconds compared to the standard injection process, but it eliminates

“ We developed a premium product for premium customers.”

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Partners & Projects

AHEAD Issue 02.2015

THE LARGEST INJECTION MOLDING MACHINE IN SWITZERLAND OFFERS MAXIMUM FLEXIBILITY

PIPE FITTINGS IN XXL FORMAT The pipe fittings of GF Piping Systems in Schaffhausen are true heavyweights with a diameter of up to 500 mm and a weight of up to 120 kg. The connecting pieces for the water supply are being manufactured on an MXH 3200 from KraussMaffei. With the option of freely selectable shot weight, the largest injection molding machine ever installed in Switzerland offers maximum flexibility on a large machine. TEXT: PETRA REHMET

PHOTOS: KRAUSSMAFFEI

ven the technical data of the MXH 3200 – 101.000/101.000 is impressive: A clamping force of 3,200 t, maximum shot weight of 120 kg, screw diameter of 2 x 265 mm. “A large machine with these values in this combination is unique on the market. This lets us underscore our leading position in the development and implementation of large injection molding machines of the MX series,” says Bruno Schleiss, Managing Director of the Swiss subsidiary. The products made on the machine are just as large and complex – pipe fittings with a diameter of up to 500 mm and a weight of up to 120 kg. These are used as connecting pieces for the public water supply. “The investment and implementation of a new injection molding system of this size was certainly a special challenge for us. In addition to the technical parameters such as a high shot weight and high quality at every point, the system also had to meet other criteria with regard to flexibility in materials and geometry selection. KraussMaffei is the professional, reliable partner at our side with whom we succeeded in making this challenging project a reality,” explains Claude A. Fischer, Head of Business Unit Utility at GF Piping Systems.

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LARGE MACHINE WITH LARGE CAPACITY Solemn commissioning of the MXH 3200 – 101.000/101.000 from KraussMaffei, the largest injection molding machine in Switzerland, at GF Piping Systems.

The result of the collaboration is an MXH 3200 – 101.000/101.000. A clamping force of 3,200 t and a shot weight from 5 kg to a maximum of 120 kg makes it the largest injection molding machine in Switzerland. An IR KR500 L340 industrial robot ensures reliable handling of the pipe fittings, which can weigh up to 120 kg. This is another record, because – with a maximum payload of up to 340 kg – this is the largest industrial robot that has ever been installed on an injection molding machine. Best quality and high shot weights The size and weight of the pipe fittings, as well as high quality at every point, were the customerʼs central requirements for designing a suitable MX machine. Large machines of the MX series from KraussMaffei are ideally suited for these applications. They feature a high melt quality and shot weight consistency, thereby ensuring continuously high product quality. One special challenge was the high-viscosity polyethylene 100 material to be processed on the large machine. The solution involves optimized screw geometries and drives for the plasticizing unit, which are specially designed for processing demanding

340 kg maximum payload

3,200 t clamping force

120 kg maximum shot weight

WHEN THE CHEMISTRY IS RIGHT The teams from GF Piping Systems and KraussMaffei worked hand in hand from the start.

material. “The controlled melt temperature during plasticizing prevents the melt from overheating during the plasticizing, preventing thermal decomposition of the material as a result. At the same time, high plasticizing output with outstanding melt qualities are possible,” Schleiss adds. Maximum flexibility on a large machine Yet this large machine must do more than just produce large components with high quality. The customer also wants high flexibility with regard to material, size and geometry when producing the pipe fittings. For this reason, the large machine is equipped with two injection units that can be interconnected as needed. “We offer our customer, GF Piping Systems, use of a shot weight they can freely choose from 5 to 120 kg, thereby providing maximum flexibility on a large machine,” Schleiss says. Furthermore, each injection unit can be operated independently. This results in high application-specific flexibility in the process control. The adapter modules of the plasticizing unit provide additional flexibility in the production of pipe fittings. For example, GF Piping Systems can install a smaller SP 33000 injection unit; this makes it possible to quickly change to production with other materials. What makes this so special is that the material and melt geometry are perfectly matched to one another. The IR KR500 L340 industrial robot used has an additional axis for linear motion (7th axis), provides additional freedom of movement and more flexibility as a result, especially when handling heavy components. The special gripper technology permits precise interaction of

removing and gripping. The multifunctional gripper is designed for the various nominal diameters of the fittings. A special padding on the jaws protects the fittings from getting damaged. “The skilled and close coordination with the persons responsible at KraussMaffei, both leading up to the project and during the project phase, made a strong impression on us. The result is an automation solution that is perfectly matched to our requirements,” states Claude A. Fischer. Save electricity with the BluePower drive concept BluePower Servo Drive Technology from KraussMaffei supports an energy-efficient manufacturing process. For the energy-related optimization of hydraulic drives, it uses the high dynamics of servomotors to adapt the rotational speed of the hydraulic system pump to constantly adapt to the actual requirements. The same dynamics are used to reduce idling losses to almost zero by reducing the speed, such as during cooling times and during demolding. As a result, the energy consumption of the machine can be significantly reduced.

YOUR CONTACT: Daniel Notter Project Planning [email protected]

FARPLAS WORKS TOGETHER WITH KRAUSSMAFFEI TO DEVELOP NEW TECHNOLOGIES AND MARKET SHARES

RESOURCEFUL TECHNOLOGICAL LEADER IN TURKEY You can find plastic parts made by Farplas, a customer of KraussMaffei based in Gebze, Turkey, everywhere inside, outside and under the hood of cars. Technical innovations and high-speed machines have made the company the technological leader in the automotive sector in Turkey, and the company also delivers parts to the US, UK, Mexico and all over Europe. TEXT: DR. SABINE KOB, PETRA REHMET

EDITORIAL SUPPORT: ANNA-MARIA MEYER

arge-scale parts like inner door panels, dashboards, front grills, cable ducts and finishers for the engine and water tank form the core focus of business. Farplas recently made a concerted effort in developing its portfolio further with continuous increases in the production of what are known as Class A products – visible parts with premium-quality surfaces. In the past, these were painted parts, but the future also holds promise for decoration using film. Accordingly, the range of processes that have been employed and implemented together with KraussMaffei is very broad. While weight-saving technologies like MuCell and FiberForm show their prowess

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under the hood, a greater emphasis is placed on the quality appearance provided by inmold decoration (IMD) in the carʼs interior. KraussMaffei will soon provide a turnkey system for this technology. Farplas continues to specialize even further, and KraussMaffei is supporting the company along the way. GX high-speed machine shows its strengths Holding your own among international competition and opening up new sales markets require exceptionally efficient production. Farplas was able to start taking advantage of potential savings in this area by investing in a new GX 600-4300 from KraussMaffei with 600 tonnes of clamping force. The innovative GearX and GuideX systems enable

the implementation of exceptionally highspeed clamping movements. This reduces the standard cycle time for a center console with a shot weight of 535 g by almost five percent. In addition, energy consumption could be reduced considerably – which also brings tangible benefits when it comes to sustainability. However, for Sinan Yamuç, Process Development Team Leader Farplas, one the most striking aspects of the cooperation between Farplas and KraussMaffei is the technological advances that have resulted in greater visual quality for complex visible parts. He associates this with the GX plasticizing unit and its HPS AT screw, “Itʼs one of the greatest strengths of KraussMaffei machines. Weʼre very impressed with the

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A STRONG PARTNERSHIP FOR MAXIMUM RESULTS (From left to right) Aykut Basol, Production Manager, Sinan Yamuç, Process Development Team Leader, and Ali Rıza Aktay, General Manager, all from Farplas together with KraussMaffei representative Volkan. Yildirim.

consistent shot weight and uniform melt. Itʼs easy to see the quality consistently delivered by the KraussMaffei machine.” Because Farplas provides around 2,000 injection-molded parts – 600 of which are rotating through series production – the flexibility offered by the GX also pays for itself through easy accessibility and resourceful mold change systems, as well as the resulting quick setup. Overall, it is a rugged, dependable partner for high process reliability and reproducible product quality. The premiere of MuCell in Turkey It is no wonder that the amount of KraussMaffei machines is on the rise in Farplas manufacturing facilities. The company was founded in 1968 and has been actively engaged in the introduction of new production technologies. It is the sole provider of many of these technologies in Turkey, such as MuCell. For physical foaming processes, a blowing agent like nitrogen or CO 2 is added to the plastic melt to create a foam structure inside of the finished component. This can reduce the weight by up to 20 percent, depending on the part geometry. The cycle time is also shorter. Injection is 15 to 30 percent faster than for parts made entirely of plastic and the holding pressure time is no longer required because it is replaced by foaming in the cavity. Machines with smaller clamping forces can often be used and less strain is placed on the mold. During the introduction of MuCell technology, Farplas took advantage of KraussMaffeiʼs expertise as a complete system provider. Yamuç emphasizes the outstanding collaborative effort, “Our development surged forward and we appreciate having direct communication with KraussMaffei, which afforded us an advancement in knowledge. The provision of this kind of in-depth exchange is the foundation of a successful cooperation.” Another important step for Farplas is the introduction of FiberForm technology, a process developed by KraussMaffei that offers automakers substantial potential savings in

terms of component weight. FiberForm is Ford, Fiat, Hyundai, Mercedes). As a result, a fully automated process in which organic Farplas is continuously investing in updating sheet inserts are thermoformed in the mold and expanding its machinery and is focusing and then encapsulated with a glass fiberprimarily on large parts. In this production, reinforced polyamide. The finished parts the company utilizes machines with a clamp(such as those for impact protection) feature ing force > 600 tonnes and continues to outa high level of stiffness, despite potential source smaller applications. Farplas made a weight reductions of up to 20 percent and conscious decision to move towards greater competitive costs. This does not necessarily entail a new investment either. Existing injection molding machines from KraussMaffei can also be upgraded using this technology, such as at SINAN YAMUÇ, PROCESS DEVELOPMENT TEAM LEADER FARPL AS Farplas. “We were very impressed by the speedy, straightforward installation of FiberForm components on our existing specialization through its investment in new, CX  650 machine. The technical support and groundbreaking technologies like MuCell, assistance in carrying out on-site tests was FiberForm and IMD. Success has proven they also outstanding,” says Yamuç. made the right choice. Production capacity is already being fully utilized, and additional inSince Farplas is part of an entire corporate vestments are planned for the future. Yamuç group, the technical insights from the autohas plenty of praise for the outstanding colmotive sector easily transfer over to other laboration with KraussMaffei in making this divisions, such as commercial vehicles or a reality, “We appreciate the skilled support household appliances. This is the case for that KraussMaffei provided as a complete MuCell, where the first system has since provider from the beginning to help us imreached its peak installed capacity. This will plement the new technologies. This is also certainly also apply to the IMD film technolotrue of current and future projects. This type gies on deck for implementation in the comof partnership is very important to us and is, pany. A turnkey system from KraussMaffei in a sense, vital for our long-term success.” has already been ordered and is expected to go into operation at the end of the year.

“The technical support and assistance in carrying out onsite tests was outstanding”

On the path to success through specialization The competitive situation in the automotive sector is quite fierce, and is sure to become even more so. Versatile, innovative companies like Farplas are taking the opportunity to expand their market share at the expense of large, well-known suppliers and open up new market areas alongside existing customer brands (Renault, Toyota, Honda,

YOUR CONTACT: Andreas Handschke Product and Technology Manager Multinject/SpinForm/TwinForm/ MuCell andreas.handschke@ kraussmaffei.com

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Partners & Projects

AHEAD Issue 02.2015

PROCESS STABILITY WITH APC

CONTINUOUS CHANGE PROVIDES STABILITY Process stability is a concept that embodies the idea of uniform quality with minimal scrap. The new adaptive process control (APC) machine function from KraussMaffei also provides this stability even during continuous change. The customer KH Foliotec utilizes APC in the production of premium-quality interior components with in-mold labeling (IML). TEXT: DR. SABINE KOB, PETRA REHMET

PHOTO: FOTOLIA, KRAUSSMAFFEI

t first glance, it seems like an injection molding process should simply function with exceptional reliability and stability once optimal machine parameters have been found and no changes should be required from that point on. But a multitude of factors affect the quality of the parts produced. Temperatures and movement affect molds and machines. Material can be affected by anything from fluctuations in viscosity between individual batches from different recycled material admixtures to the moisture content of the pellets.

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Interruptions to the production cycle have a particularly serious effect. In the event of an interruption, the melt stays in the machine longer than usual, normally decreasing in viscosity as a result. The configured machine parameters are no longer correct because it is easier to fill – and ultimately overfill – the cavity. This results in excessive part weight and deviations in dimensional stability. The APC machine function from KraussMaffei evens out these fluctuations in the injection molding process by adapting and continuously modifying the changeover point between pressing and holding pressure for each individual shot by utilizing online measurement of the melt viscosity. Optimum product quality after restarting KH Foliotec GmbH is headquartered in Sparneck, in the German region of Upper Franconia, and manufacturers high-quality surface parts for the automotive industry using the in-mold labeling process and has retrofitted all the necessary KraussMaffei machines with APC. APC can be installed quickly and easily without impairing production in any way. A KraussMaffei CXZ 500-2000/750 is now used to create a two-component radio dial panel in

KraussMaffei

a 1+1 injection mold. First, the transparent gray PC component for the display is injected. Then, the mold rotates and black PC-ABS for the case body follows in the same cavity in the second step while the other cavity is already being filled for the next display. This all takes place on the back of a PC film with scratch-resistant coating and decorated in black that is inserted into the mold. Its glasslike surface makes it necessary to clean the mold several times per shift in order to remove particulates. These interruptions in the production process, and the accompanying need to compensate for fluctuations, provide an ideal application space for APC for achieving perfect product quality again immediately after restarting the process. Compared to operation using a fixed changeover point, standard deviations in molded part masses (over a 24 hour run time) have been reduced from 0.16 g to 0.03 g with APC enabled. According to Daniel Müller, Divisional Manager for the Molding Department at KH Foliotec, it also significantly reduces the rejection rate in series production. He also points out another noteworthy aspect of IML production that the process temperature control system has brought to light. If the company ran the mold at an operating temperature of 60 degrees and inserted a piece of film, the film would act as an insulator, meaning the back of the film would be colder. If the hot plastic hit that location, it would harden faster than desired, which could increase the tendency of the finished plastic part to warp. One option for addressing this problem would be to increase the mold temperature. But this is best avoided in IML applications, because the more the film is heated in the mold, the easier it is for the screen-printed color coating applied on the back to run. In the injection area, this can cause the incoming plastic to wash off a portion of color, leading to circular spots. APC makes it possible to control the partʼs tendency to warp without having to increase the mold temperature. Significant reduction in scrap rates Due to the complex value-adding chain, investing in APC truly pays for itself in IML production. Screen printing as well as forming and punching combined together each constitute approximately 25 percent of the value-adding portion of IML parts. The typical scrap rates for both production steps is in the low single-digit range. The subsequent injection molding process provides the

Partners & Projects

The APC technology from KraussMaffei allows you to reduce your manufacturing costs drastically. And the principle behind it is simple and works like this: – Input of the “shot weight,” “cycle time” and “price for new material” parameters – Choice of “reducing the scrap material portion” as well as “increasing the portion of recycled material” – Automatic calculation of savings in euros per year You can find the APC calculator at the following address: URL: www.kraussmaffei.com/en/apc-calculator.html

other 50 percent of added value, but also entails the highest risks for the complete part. The scrap rate for black, high-gloss visual parts can reach up to 30 percent. For every defective IML component – some of which can be worth more than ten euros a piece – this means the value added from imprinting and forming in earlier steps is also ruined. As a result, manufacturers of premium-quality IML components have a keen interest in maintaining the stability of their injection molding process. APC does not replace the mold setter on a machine; instead, it provides the setter with valuable support. Sebastian Huss, Process Optimization Officer at KH Foliotec explains: “APC helps to reduce the sources of errors and to achieve better part quality as a result.”

YOUR CONTACT: Hans Malinowski Product & Technology Management [email protected]

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Partners & Projects

AHEAD Issue 02.2015

POLYURETHANE WET-SIDE EQUIPMENT IN REFRIGERATORS

ALWAYS KEEP COOL Refrigerators have to be well insulated so that cooling capacity and energy efficiency can come together. This is particularly true for tropical climatic conditions. In India, Whirpool India places its trust on KraussMaffeiʼs RimStar mixing and metering technology for producing the critical insulating layer made of foamed polyurethane (PUR) in the housings and doors. TEXT: PETRA REHMET

PHOTOS: ISTOCKPHOTO, KRAUSSMAFFEI

e Profil 0: Brief r 80/8 a t S Rim

ntrol ure co t a r e emp ntrol cise t > Pre ess co c o r p le ity t qual > Stab c u d o ads h pr ing he > Hig x i m o 10 > Up t

KraussMaffei

Partners & Projects

n India, Whirlpool India – a subsidiary of US-based global conglomerate Whirlpool – is the market leader in manufacturing refrigerators and cooling systems. The plant produces approximately 6,800 refrigerators daily in the northern Indian city of Faridabad. From there, they are sold throughout India and in neighboring countries. Five RimStar mixing and metering systems from KraussMaffei ensure the perfect insulation of housing and doors. The equipment also includes Pentamix systems from KraussMaffei.

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Whirlpool is not a new customer for KraussMaffei. The collaboration started back in 2012. The first wet-side equipment, a RimStar 80/80, was sent to Brazil and has been successfully producing refrigerators in South America ever since. “The RimStar system in Brazil has impressed us with its reliability and production efficiency in recent years,” says Rohit Dhiman, Projects Director at Whirlpool Faridabad, “It was only logical for us to choose KraussMaffei again when making the new investment.” Stable process control and high product quality The primary strengths of the RimStar systems include stable process control and high product quality. The definitive reason for this is the KraussMaffei mixing head technology. Depending on the application, the five new RimStar systems at Whirlpool are equipped with up to ten mixing heads. For the polyurethane foaming of the refrigerator housings and doors, linear and transfer mixing heads from KraussMaffei are used. The main characteristic of these transfer mixing heads is laminar and splash-free pouring of

the mixture into open and closed molds. They are particularly designed for processing hard-to-mix systems. In short, the customer benefits from high service lives as well as low maintenance expenses. Another outstanding feature of the KraussMaffei RimStar machines is the particularly precise temperature control of the components, which guarantees a constant temperature at all times. In this application, pentane is employed as the blowing agent to avoid using chlorofluorocarbons. The entire equipment configuration was manufactured in accordance with German TÜV specifications, successfully receiving acceptance from TÜV Süd on-site. Optimum premixing of the pentane component in the production line for refrigerator housings and doors is provided by the fully enclosed Pentamix 40 premix stations from KraussMaffei. The pentane is safely introduced into the polyol component. For this purpose, a 40 l high-pressure pump developed in-house is used on the polyol side in addition to a 5 l plunger metering pump. High metering accuracy is achieved even at very low feed rates. Dhiman, the project manager, was particularly appreciative of the technical expertise of, and the close collaboration with, KraussMaffei, Goodies International and the KraussMaffei representative in India: “All of our contact partners provided professional support throughout the project engineering process and commissioning phase and handled our requests quickly and individually. Overall, collaboration with Whirlpool employees on-site was perfect.”

YOUR CONTACT: John-Paul Mead Head of Business Unit White Appliances [email protected]

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Partners & Projects

AHEAD Issue 02.2015

A WIDE VARIETY OF SUCCESSFUL POLYURETHANE INSTALLATIONS AT THE FUYAO GROUP

AUTOMOTIVE GLASS: A BRILLIANT OUTLOOK Seals made of polyurethane are not only resistant to UV light, very lightweight and reliable, they also have practically no compression set and reduce vibration and sound. One of the areas their advantages are showcased best is in the encapsulation of car windows. And this is also where the Fuyao Group, the market leader in China, has been using the RimStar mixing systems and WinCap mold carriers developed by KraussMaffei right from the start. TEXT: PETRA REHMET

EDITORIAL SUPPORT: THOMAS ELFROTH

n its home market of China, the Fuyao Group is the largest Chinese manufacturer of glass for the automotive industry and already the market leader. Founded in 1987, the company is also one of the worldʼs largest suppliers in this segment. Its customers include the largest internationally operating manufacturers of automobiles and buses, including VW, General Motors and Ford. In order to encapsulate car windows, Fuyao has exclusively used the sophisticated polyurethane mixing and metering technology from KraussMaffei from the start. The Fuayo Group and KraussMaffei started their

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PHOTOS: FUYAO, COLOURBOX

cooperation in 2002. Since then, 19 RimStar mixing and metering machines with a total of around 50 mixing heads for polyurethane processing have been used successfully at six Fuyao plants. In 2014, KraussMaffei made another delivery of five RimStar systems with another nine mixing heads to China and another system with two mixing heads as the first of several machines to the Fuyao plant in Lake Orion, MI, in the United States. Polyurethane performs extremely well during encapsulation compared to other materials with numerous advantages. The material is UV light-resistant, very lightweight but still

GEARED FOR GROWTH In its home market of China, Fuyao is already number one in the market for automotive glass. Founded in 1987, the company is also one of the worldʼs largest suppliers in this segment.

resilient; it also has basically no compression set and reduces vibrations and sound. Polyurethane systems facilitate large-scale automation and have very short curing times. This makes them ideally suited for applications in the automotive industry. “Although the RIM windows encapsulation process is the most expensive process compared with other processes, RIM windows encapsulation is now the industry standard on account of the durability of the polyurethane seals, the process reliability and the installation advantages of a polyurethane seal compared with bonded rubber seals or thermoplasticinjected seals,” explains Thomas Elfroth, Technology Manager for Window Encapsulation at KraussMaffei, and who is responsible for the markets in Asia. Versatile metering and mixing technology makes the difference Engineered as modular systems, the machines in the RimStar Series can be flexibly configured to match application specifications and customer requirements. Polyurethane materials can be perfectly conditioned, metered and mixed using RimStar machines. The wear-optimized high-pressure pumps in the RimStar series, which were developed and produced in-house by KraussMaffei, also permit exact and reliable metering of different matrix components. Magnetic couplings, volume

BEST PROSPECTS Polyurethane is resistant to UV light, very lightweight, extremely reliable and reduces vibrations and sound.

or mass flow measurement, temperaturecontrol systems and sophisticated MSR technology also form part of the metering system standard. KraussMaffei offers its

components in KraussMaffei technology provide short, rheologically optimized line paths between the individual machine components with the result that only low pressure losses occur and heat-balancing can be controlled precisely. This means that we can always guarantee the high process reliability and excellent product quality that our automotive customers demand,” added Junlong Shen, Director Product Validation at Fuyao.

Polyurethane systems facilitate large-scale automation and have very short curing times. customers a large number of variants for optimum availability and heat-balancing of material components. “It does not matter what size of component and what production volume customers want to produce, KraussMaffei has a customized solution for them,” said Elfroth. Mixing heads are the second main component of the RimStar machines. The two normally liquid components of the polyurethane system are mixed in the mixing head. In polyurethane processing one component consists of polyols, catalysts and additives, while the second component contains isocyanate. “The ideally matched system

WinCap mold carriers - Ergonomic and functional The electric mold carriers in the WinCap Series, which were completely revamped in 2013, have been successfully used for many years to encapsulate vehicle glass panes with polyurethane. The improved mold carriers offer machine operators better ergonomics and greater user-friendliness because the swiveling mold fixing platens make it easier to remove mold parts and insert substrates. Parallel mold carrier movements and high traveling speeds enable short cycle times and high productivity. The other main advantages are a reduced noise level and low energy consumption due to the electric drive

units. Optionally available magnetic clamping plates also make it easier to perform necessary mold changes. This ensures fast flexible production. Long-standing employees in China guarantee customer proximity and success The highly skilled KraussMaffei staff in China, who remain in close contact with colleagues in Munich at all times, are the main contact for Fuyao. They ensure smooth installation and commissioning at the customerʼs facility and offer the reliable service our customers have come to expect.

YOUR CONTACT: Thomas Elfroth Technology Manager for Window Encapsulation [email protected]

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Partners & Projects

SEAMLESSLY INTEGRATED

DELIVERING SUCCESSFUL SOLUTIONS: THE NEW SPRUE PICKER SPX 10 It was about a year ago that KraussMaffei introduced the newly designed SPX 10 sprue picker for the CX series of injection molding machines. Since then, it has been very well received on the market. AHEAD spoke with Tobias S. Müller, Fabrication Plastics Parts Manager for Rockwell Automation AG, at the companyʼs Aarau location in Switzerland, about his experiences with the fully integrated sprue picker. TEXT: JOACHIM WEBER

EDITORIAL SUPPORT: MICHAEL FLURL

PHOTOS: KRAUSSMAFFEI

In February of this year, an SPX sprue picker accompanied a pair of new injection molding machines coming into the Rockwell Automation production hall in Aarau, Switzerland. The two newcomers increased the number of KraussMaffei machines to nine and the hightech picker was the first of its kind at the companyʼs facility. In total, Rockwellʼs plastics processing machinery includes 40 injection molding units from various manufacturers working in combination with rather simple handling equipment and sprue pickers. 400 molds in use There is a reason for this extensive machinery. The primary product focus for Switzerland-based Rockwell Automation is manufacturing circuit breakers. And this includes a very extensive vertical range of manufacture. For quality reasons, a large portion of the individual parts of the breakers are even produced in their own plant. The company is a subsidiary of the US company with the same name (sales volume 2014: 6.6 billion dollars), one of the worldʼs leading providers of automation products. One number impressively illustrates the wide spectrum of the Aarau manufacturing plant: “Due to the high in-house production, we have approximately 400 molds of various sizes in use here in our injection molding production,” explains Tobias S. Müller, Fabrication Plastics Parts Manager. Because the molds are replaced twice weekly per machine, a high level of process automation is imperative. In the meantime, three generations of MC control systems are in use on the nine machines from KraussMaffei: The MC4, MC5 and the MC6 with its incredibly simple and intuitive operation. Seamless integration into the control system “The change to KraussMaffei machines was very well received by our operators at the time. Itʼs an easy-to-learn control concept that has become even more intuitive over the years,” says Müller. The fact that the MC6 made it possible to integrate the SPX sprue picker seamlessly into process automation also met with plenty of appreciation. “Since users were already familiar with the MC6 control system, they were able to familiarize themselves with the SPX operating concept in no time. Integration gives us the advantage of being able to program and operate the sprue remover with a control system here. Programs

are created in minutes via the additional use of the WizardX programming wizard – and thatʼs incredibly important for the large variety of molds and programs we have as a result!” Quick and intuitive High flexibility is required not just from the hardware and software, but from the operating personnel as well. “Our molds are organized by clamping force size. Because we use quick release platens, one mold can often be used on multiple machines. A simple and speedy program switchover is very important to this process. One of the most important things is that the user can intuitively and quickly learn how to operate and program the control system,” says Müller about the requirements. These requirements also apply to the servomotor-controlled SPX 10 sprue picker. Complete integration into the control system leads to a noticeable reduction in changeover times and costs. Going above and beyond with safety The production manager also has his eye on another aspect: work safety. “A safe machine is our top priority,” he concludes. This is where the SPX 10 really shines – the safety it provides comes at essentially no cost. It combines with the machine to form one unit. The detached sprue is stored within the machineʼs housing. This means that there is no need for a side extension in the form of a protective fence or subsequent adjustment to the machine housing. This also saves production floor space and valuable commissioning time. “KraussMaffei quickly got us on board with the concept of a fully integrated sprue picker complete with sprue chute,” says Müller in praise of the design.

YOUR CONTACT: Michael Flurl Product Management [email protected]

KraussMaffei

EDITORIAL

CONTENTS

Imprint

35

FOCUS ON CUSTOMER NEEDS

A WIN-WIN FOR ALL

IMPRINT

COVER STORY 6 Productivity PLUS: The formula for success

PROCESSES & PRODUCTS 12

Dear Customers, dear Readers, For the past several years, we have been completely committed to our one-ofa-kind performance promise: “Engineering Passion.” Our decades of expertise, our innovative ability and our passionate commitment to plastics engineering have been your competitive edge. KraussMaffei has a tradition of being at the forefront of groundbreaking topics of the industry. This issue features several projects that highlight our expertise in “Trendsetting,” some of which are in the areas of medical technology plastics, conservation of resources, lightweight construction, functional integration, energy efficiency as well as appearance. Not only are we taking a leading position here with our highperformance machines, but we also see ourselves as innovative leaders for new technologies. Prime examples include the SilcoSet, ColorForm, FiberForm and CellForm (MuCell) processes developed by KraussMaffei. With the new Adaptive Process Control System (APC), KraussMaffei has set a new benchmark in terms of cosistently achieving zero-defect production. Productivity PLUS is our 360 degree approach for your daily challenges in terms of efficient production. It provides you with increased flexibility in manufacturing, offers intelligent energy-saving solutions, extensive technology and upgrade options as well as ease of operation and perfect accessibility to the machines. Productivity PLUS combines the advantages offered by KraussMaffei through its skills, knowledge and experience in machine building, automation and technology.

Combination technology: Three processes in one production cell

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Trendsetter silicone

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Untapped potential

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Easy and solid handle on all peripherals

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Additional savings potential in mold changing

When t wo strong companies join for ce s , the r e sult is a win-win situation – and customers benefit from a performance capability that neither of the companies could have provided on its own. In South Korea, Netstal and DaeSang T&C are engaged in a reliable partnership on equal terms. As a result, the customers get the best of European technology and Korean relationship management.

Editorial team: Thomas Elfron, Michael Flurl, Dr. Sabine Kob, Anna-Maria Meyer, Petra Rehmet, Stephan Schierl, Dr. Reinhard Schiffers, Arne Schmidt, Sven Schröbel, Joachim Weber Photo credits: Colourbox, Daimler AG, Fotolia, Fuyao, iStockphoto, KraussMaffei, KraussMaffei Berstorff, Shutterstock

THERMAL INSULATION

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ECOLOGY IN CONSTRUCTION – A GROWTH MARKET

Interview: “Fiber-reinforced lightweight construction as an innovation driver”

Publisher: KraussMaffei Technologies GmbH Krauss-Maffei-Strasse 2 80997 Munich Germany Phone +49 89 88 99-0 Fax +49 89 88 99-2206 www.kraussmaffei.com Responsible: Imre Szerdahelyi (responsible for content according to German media law) Chief Editor: Ashenafi Shawl

BRAND & MARKETS

PARTNERS & PROJECTS

Concept and design: Kirchhoff Consult AG, Hamburg www.kirchhoff.de Printing: omb2 Print GmbH, Munich

Extruded foams are the ace in thermal insulation. 22

Operating without looking

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Pipe fittings in XXL format

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Resourceful technological leader in Turkey

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Continuous change provides stability

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Always keep cool

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Automotive glass: A brilliant outlook

34

Delivering successful solutions: The new sprue picker SPX 10

Productivity PLUS is also our motto at this year's Fakuma. Our dedicated team is already looking forward to greeting you there and speaking with you about trends, production and energy-efficient systems as well as the high quality and variety of our products. It's just too bad that we will only be able to show you a small part of our wide range of technologies at this large plastics trade show. These exchanges with you, as well as the up-to-date information on new technologies that we receive from universities and institutions, are an important part for our success and daily work.

KRAUSSMAFFEI GROUP

I hope you enjoy reading this edition of AHEAD and would like to take this opportunity to turn your attention to the brief introduction of the new CEO of the KraussMaffei Group on page 5. I look forward to working closely with Dr. Stieler!

35 Netstal: A win-win for all

4 Strong together and unique all over the world

The customer magazine is published twice a year in German and English. The magazine may only be reprinted with the written permission of the publisher.

Nearly 40 percent of German energy consumption can be attributed to the building sector. About half of that is used for heating private homes. That means this area offers enormous savings potential. KraussMaffei Berstorff contributes to realizing them. Partially spurred by lawmakers and partially by cost-conscious home builders or buyers, the construction industry has made energy savings one of its top priorities. Thermal insulation is the name of the game. Buildings everywhere, new ones as well as existing ones, are being covered with a second envelope for thermal insulation. Less visible: The insulation of heating or hot water pipes in order to avoid heat loss.

5 New CEO of the KraussMaffei Group

35 KraussMaffei Berstorff: Ecology in construction – a growth market 35 Trade show calendar

Dr. Hans Ulrich Golz Managing Director President of the Injection Molding Machinery segment

Netstal and DaeSang are successfully collaborating in South Korea.

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Imprint

TRADE SHOW CALENDAR FROM OCTOBER 2015–MARCH 2016 Fakuma, Friedrichshafen, Germany

13.10.2015 – 17.10.2015

KraussMaffei Group

Composite Engineering Show NEC, Birmingham, England

04.11.2015 – 05.11.2015

KraussMaffei

Expo Plásticos, Guadalajara, Mexico

04.11.2015 – 06.11.2015

KraussMaffei, Netstal

RubberTech, Shanghai, China

11.11.2015 – 13.11.2015

KraussMaffei Berstorff

Putech Eurasia, Istanbul, Turkey

12.11.2015 – 14.11.2015

KraussMaffei

Plast Eurasia, Istanbul, Turkey

03.12.2015 – 06.12.2015

KraussMaffei

Interplastica, Moscow, Russia

26.01.2016 – 29.01.2016

KraussMaffei Group

JEC World, Paris, France

08.03.2016 – 10.03.2016

KraussMaffei

Surface RTM Technology Fiber-reinforced, paintable surfaces such as roof elements, door inner panels, trunks or engine hoods

AHEAD

RTM Technology Structural and semi-structural components such as underbody structures, side frames or seat structures

Issue 02.2015

Wet molding RTM Technology Semi-structural components made of recycled carbon fibers, e. g. hybrid components

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI

www.kraussmaffei.com

AHEAD

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI

DRAFT

Issue 02.2015

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INCREASING COMPETITIVENESS

PRODUCTIVITY PLUS: THE FORMULA FOR SUCCESS

IMC Technology Fiber-reinforced, structural components such as front ends, mounting supports, instrument panel carriers

FiberForm Technology Continuous fiber-reinforced components such as crash elements, B-pillar reinforcements or seat structures

Fiber composite solutions for advanced lightweight components Engineering Passion

COVERFORM ®

INTUITIVE TOUCHPADS FOR MULTIMEDIA SYSTEMS

KraussMaffei