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News for our Customers and Friends

2012

Rising sales figures show that the BEKUM xBLOW has arrived and is be-coming established at a promising speed.

During the important K´2010 exhi-bition, BEKUM introduced the new xBLOW machine series. The “x” is syn-onymous for E = electric drive or HY = hydraulic drive. Formal media events and numerous customer discussions at the machine, provided the blow moulding industry with extensive in-formation – proving that interest in this flexible machine series is rapidly increasing. Since this introduction, the interest in this technology is validated by numerous machine sales.

HistoryBEKUM has demonstrated true fore-sight and composure during the de-velopment of this all electric blow moulding machine. We cautiously and methodically designed, manufactured and tested the technology with one goal in mind, offering the best techni-cal and most reliable solution for our valued customers.

To satisfy the current and future re-quirements of the plastics industry, this machine series was developed with several key advancements. First, the patented C frame clamp design provides numerous advantages for our customer. The new machine con-trol cabinets are designed for com-plete access for maintenance.

C frameThe patented BEKUM C closing unit combines the advantages of wear-free operation and fatigue strength, as well as precision distribution of force in the mould area and absolute-ly parallel plates. This is because the

A Successful ConceptThe xBLOW from BEKUM

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EBLOW 407D with removal robot – 8x coex bottles blown from top and bottom (Tandem Blow)

We have defined the following parameters as the basis of development: Characteristic Customer benefit Availability and productivity [ Large output Wide application fields [ Highly flexible Efficient use of resources [ Little waste Long service life and continuity [ Satisfied staff Very quiet and clean [Meets environmental regulations Item quality [Good price quality Precise and wear-free [ Long service life Easy to maintain [ Low servicing costs

FeaturesDrive: The series can be supplied both as fully electric or as an hydraulically driven BEKUM product. Series: xBLOW 307 /D 307L /DL 407 /D 507 /D 607 /D Platen width: 350 mm 500 mm 500 mm 500 mm 700 mm Closing force: 100 kN 100 kN 150 kN 200 kN 240 kN

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Dear reader,

“Our experience for your success.”

This is the concept that BEKUM is employing to continue last year‘s clear upward trend. This year orders have increased as well, proving that BEKUM, the global technology lea-der, can also handle setbacks during serious economic conditions and is a reliable partner – not just in good economic times. With its solid basis of technological knowledge and foresight, BEKUM Maschinenfabri-ken GmbH will confidently defend its deserved place at the top in the future as well.

In our last edition, we introduced our new machine series, the fully-electrical EBLOW. BEKUM is deligh-ted to inform you that after less than a year, the concept has been successful and is already proving itself – plentiful machine sales at home and abroad are the best evi-dence for this.

We are excited in this edition to pre-sent the latest developments from our company. We have a unique staff who participate with enga-gement in BEKUM‘s continuing success story, and the knowledge attained over decades is constant-ly being handed down to the next generation. We can thus stay true to the motto, “Profit from our ex-perience.” This will continue in the future.

The company is proud of this notab-le performance, and we would like to express our heartfelt thanks for the trust shown to us by all our cus-tomers and friends.

I wish you lots of enjoyment rea-ding BEKUMnews !

Yours, Michael Bamberger,Managing Director

Editorial plate guidance and force distribution functions are separated. There is full closing force over the entire stroke as the material is squeezed off, and this guarantees that the items are welded precisely. This is possible due to the electric closing unit with hydrostatic gear box exclusive to BEKUM.The hydraulic version, HYBLOW, has an hydraulic cylinder and behaves the same way. The closing force, stroke and build-up speed for both types can be freely selected on the screen.Because the C frame has more space, this allows calibration stations with electric or hydraulic drive technology to be installed from the bottom.

ApplicationsIn addition to the familiar standard applications that can, of course, be

performed with this series, there are three special applications that should be highlighted that give our custom-ers a competitive advantage – result-ing from high productivity and effec-tive resource use:

High performance - Tandem Blow for double the output:The xBLOW series has been designed so that a bottom blowing station can be fitted optionally. “Tandem Blow” – blowing from top and bottom – in-creases output by 100%, enabling 20,000 bottles/hour to be produced.Using this concept, several Tandem Blow high-performance machines, of the EBLOW 607 D type, could recent-ly be sold. With 240 kN closing force,

they produce small drinks packaging in 40 mould cavities.

Precision - Tandem Blow for medical items: Another application for the EBLOW 307 DL is the manufacture of high-quality items for medicine. Manufac-tured from an extremely soft PVC, the items are calibrated in the Tandem Blow procedure from both top and bottom.There is only one BEKUM HiPEx ex-truder and one barrier screw for mul-tiple production. This is a world first because no manufacturer or operator has until now succeeded in bringing the machine configuration described to the production stage with this or similar materials.This production was focused on the

item weight, perfect wall-thickness distribution and reproducibility of the high-precision medical item, in order to keep to the quality criteria required by the customer or to make improve-ments in this application. The combination of machine and BEKUM application technology achieves a very large production win-dow for the one-way and long-term production planned by the customer. This gives the customer reliability of production and supply, even when wear occurs.

Coextrusion - Tandem Blow for Coex items:Coex versions of containers for the chemical industry are also calibrated

+ Newsticker + BEKUM has delivered an EBLOW 307 DL & 407 D for manufacturing medical products. +

High performance – 40-cavity Tandem Blow

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from top and bottom. The machine used, a fully electric EBLOW 407 D, produces these prod-ucts in extremely short cycle times, at double the output compared to con-ventional Coex productions.The requirements made of layer dis-tribution and item quality in this area are as similarly high as in medical tech- nology. BEKUM planned for this, as well as many other applications, an entire system consisting of a blow moulding machine, Tandem Blow moulds, a removal robot and belts for conveying the items for finishing.

Results:The special applications of the EBLOW series show that, when great demands are made in terms of quality, output and energy savings, BEKUM is still the partner that can deliver complete sys-tems – “everything from one source”.

Fully electric blow moulding machines in the EBLOW series require only 50% of the energy compared to traditional blow moulding machines – the extrud-

Precision medical items manufactured with the Tandem Blow procedure

er energy requirement is considered neutral. Using BEKUM high-perfor-mance extruder technology (HiPEx), the extruder size could be reduced a step for the high-output special ap-plication. This also reduces the energy requirement by around 20% and does not damage the material. At the same rotational speed, i.e. a circumferential screw speed reduced by 16%, there is

the same throughput at higher quality.The precision of BEKUM Tandem Blow technology allows the cost of manu-facturing items to be reduced. This concept and the new xBLOW machine series means that BEKUM is well pre-pared for the years to come. The tasks set by our customers are positive challenges that BEKUM fulfills together with the customer.

EBLOW 407 D

+ Newsticker + BEKUM has delivered two EBLOW 307 DL and one EBLOW 407 D coex tandem blow with top and bottom calibration. +

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Project Expertise for Engine Oil Canisters from Gazprom NeftGazprom Neft, one of the largest and fastest growing oil and gas producers in Russia, internationally tendered a project for the manufacture of extrusion blow moulded engine oil containers for its G-Energy brand-name products. BEKUM presented the most convincing price and performance concept, and successfully asserted itself against renowned international tenderers from Germany, Italy, and the Far East, among others.

The entire project encompasses the manufacture of engine oil containers for 4 and 5 liter canisters with handles and view stripes produced on a BEKUM type BM 806 D double-station blow moulding machine (270 kN clamping force), and the manufacture of 1 liter canisters with view stripes, produced on a type BM 406 one-station blow moulding machine (140 kN clamping force). Furthermore, the delivery includes all blow moulds, material conveyor equipment, complete with dryer, waste and item transport bands, regranulation and item inspection, as well as the injection moulding machine with tools and connected peripherals.

Market Success

Competition livens up the (3D) MarketBEKUM is supplying a further 3D blow mould system for the production of 7-layer filling tubes to TI Automotive. This double-station system, a BAR 10D 7-Layer Coex is manufactured for a German fuel filling tube OEM.

BEKUM‘s innovative concept is to ena-ble the completely new, space-reduced and user-friendly options for manufac-turing with BAR 10D.The design of the BAR 10D provides essential advantages for both half and fully automatic operation modes. With the central item entry, the fully auto-

matic post-processing and after-cooling of the tubes becomes especially easy to implement. Only one unit is necessary for each step in the process. The cont-rolling technology differentiates how-ever, which part is taken out of which clamping unit. Equal processing times are always guaranteed with this pro-duct flow system. An elaborate com-bination of items from clamping units 1 and 2 is not required. This is equally true for the half-automatic production, meaning the removal of the item by the user at the central item output.

+ Newsticker + BEKUM has installed worldwide 12 high-performance blow moulding machines for engine oil canisters in the last 2 years. +

The experts know that different times in the production chain also mean dif-ferences in the item geometry.The heart of the extrusion unit is the spiral mandrel die head. On top of its advantages in terms of extrusion, it also has a decisive advantage over the heart-shaped die head used by com-petitors – the minimum throughput of EVOH is under 500 g/h.This enables our customers to have a large variation in layer thickness, even in one-station operations, in other words, in production with low throughputs.

The canisters for the G-Energy brand oils must fulfill high quality criteria in terms of item surface because of the metallic master batch used, and must also undergo leak testing and drop tests. Nonetheless, it was possible for BEKUM to achieve a reduction in weight while satisfying the quality demands.

After successfully completed projects in the Middle East, this order, which was recently delivered, represents the fruitful continuation of the project tradition begun in the nineties in Russia.

www.gazprom-neft.com

G-Energy engine oil canisters with view strip

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BEKUM High-Performance Blow Moulding Machines in the Middle KingdomConfucius once said, “The journey is the reward.” With its new represen-tative office Morglory International Co. Ltd., BEKUM has begun its journey into the Middle Kingdom. Three high-performance blow moulding machi-nes, blow moulds and a variety of ac-cessory units were already sold to Chi-nese customers, who put their trust in machine quality “Made in Germany”.

These machines were twin-station blow moulding machines of type BM 206 DL with 80 kN of closing force and BM 806 D with 270 kN of closing force. The blow moulding machines, which are manufactured in Berlin, are equipped with internally produced 5x and 10x BKZ extrusion heads in order to be able to fulfill the very meticu-lous specifications for wall thicknes-ses, internal thread diameters, article weight and volume tolerances, as well as ensure a high efficiency value. For the very fast running extrusion pa-risons and the tilting function of the

extrusion head and extruder, special attention was paid to the reproducibi-lity of the articles in order to be able

to guarantee and produce a machine output of 179,400 articles/day.

Customer and representation at pre-inspection in Berlin

+ Newsticker + BEKUM is extending its co-operation with Magneti Marelli/Fiat. Two BA 220 M coex tank systems for various plastic fuel containers were delivered in 2011. +

New: BA 100S BEKUM expands the BA-Series by a further machine size

Because of the high customer demand, BEKUM is expanding the machine se-ries BA with another variation. As well as the BA 62 with 600 kN clamping force and the 800 kN BA 62S, the pro-duct range will now be expanded by a BA 100S with 1000 kN clamping force.

BEKUM relies here also on the 3-pla-ten clamping system, controlled with 4 symmetrically positioned tie bars. On top of the high precision, the closing system also stands out with its excel-lent clamping force distribution. The parallelism of the closing plates is an excellent +/- 0.2 mm. The advantages of the system are clearly evident:

Principle of 3-platen closing unit

• Trouble-free welding seams by par- allel closing of the blow moulds.• Maintenance-free system.• Plenty of space for equipment in the machine base.

Optimally, the BA 100S is used in the produc-tion of long items. Moulds up to a length of 1500 mm can be driven in the accumu-lator head operation without opening the upper tie bar. This in-creases the stability of the clamping unit.

The plant is designed in such a way that 220 litre L-ring drums can also be produced.

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BEKUM AmericaDevelopment trials at BAC hit record levels!

BEKUM America’s Applications Labo-ratory serves as the initial proving grounds for many new and unique blow moulding concepts. BAC’s Lab is an area of constant activity with resin trials, mould evaluations, and

process optimizations. Equipped with “state of the art” BEKUM machines, a 6-layer coextrusion line and a double-station mono-layer machine, rarely is there a blow moulding development that we cannot support!

Recent mono-layer projects have ranged from complex medical parts to packaging applications in engi-neering thermoplastics to new extru-sion blow mouldable grades of PET.

On the coextrusion side, we are chal-lenged to meet an ever increasing customer demand for coextrusion development work in numerous & varying market sectors. The flex-ible nature of our 6-layer, 6-extruder BA 14 Coex machine has enabled us to run 2, 3, 4, 5, and 6-layer trials with articles up to 20 liters in capacity. There are only a few open weeks in the Applications Lab for the first half of 2012 and a number of projects are already scheduled for the second half of 2012.

We remain committed to supporting your future blow moulding develop-ment needs!

www.bekumamerica.comDevelopment lab, BEKUM America

BEKUM AmericaBEKUM America builds its first BA 34.2-Machines

The very successful BA 34.2 machine is now being built by BEKUM America. Two US-based customers have placed orders for a BAC-built version of this popular machine line from BEKUM Austria. The first machine is for the two-pari-son, continuous extrusion production of up to 8 liter PP medical containers with angled neck calibration and full in-machine automation with special neck finishing. The second machine is for the single-parison, continuous extrusion of 14 - 20 liter agricultural sprayer containers in HDPE with full in-machine automation and special secondary finishing of the tank ope-nings.BEKUM America has been manufac-turing the larger BA series machines in Williamston, Michigan for over 15 years, so the decision to offer the

BA 34.2 for these two projects was quickly approved and the two orders were placed. The first machine was delivered in 2011 and the second in early 2012.

+ Newsticker + BEKUM America Corporation in Williamston / USA has delivered 2 fully automatic production lines for medical containers. +

This success again proves that the BA 34.2/D series machines continue to lead the global blow moulding in-dustry for the high quality, completely automatic production of up to 30 liter containers.

BA 34.2 - made in USA

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+ Newsticker + BEKUM do Brasil is still the most successful supplier of BA 25 blow moulding machines for 5 gallon water contai-ners. 10 of this machine type, with components from the BEKUM plant in Berlin, were delivered in the last two business years alone. +

BEKUM do BrasilRelocation of manufacturing

At the end of March 2011 BEKUM do Brasil relocated its headquarters to a new manufacturing facility at Rua Miguel Yunes, 823 in the Interlagos district of São Paulo. The new facility is located in the easily accessed southern suburbs. Production procedures and manufacturing processes have been optimised at the new location. With an entire surface area of approx. 5000 m², the new facility offers the ideal

The Brazilian market for Coex applica-tions in the packaging and automo-tive industry is continuing to develop. BEKUM is a full service supplier and provides its customers with integrated systems and experienced local cus-tomer service for a great number of multi-layered products. Because of BEKUM‘s long experience with over

conditions for flexible and reasonably priced local production of all the pre-vious models from the BA, BM and H series.

In this context, the company recently employed several highly-trained engi-neers with many years of experience, thus more than doubling the capacity in the development department. The new structure of BEKUM‘s Brazilian fa-

100 installed Coex systems, its cus-tomers receive from the very begin-ning, application-specific advice, with the best manufacturing results and guaranteed economical production. Even after installing the complicated systems, BEKUM takes care of its cus-tomers in all questions of process op-timisation, maintenance and the quick

cility is well positioned to nationalise modern machinery concepts and blow moulding technology and to manu-facture locally. Among other things, the manufacture of new head, extrud-er and machine varieties with higher productivity is planned, using the most modern technology in coopera-tion with the parent plant in Berlin.

www.bekum.com.br

supply of spare parts. All systems pre-viously installed by BdB require ex-tremely little maintenance and have functioned for years on a 24-hour ba-sis with very few breakdowns and un-changing efficiency. In the last 3 years, a total of 10 multi-layer systems have been installed by BdB.

New plant, BEKUM do Brasil

BEKUM do BrasilBdB, more Coex projects with up to 6 layers

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Service Department of BEKUM Maschinenfabriken GmbH

Card Replacement

Innovation and economy are the two essential driving forces of the plastic industry. It is important that customers form a long-term bond with the brand, and they must be constantly satisfied. Essential for sustainable growth is the-refore an even stronger professionali-sation of the service business and the bonding with existing customers. This is true regardless of whether we are looking at new, used or spare parts, OEM, or trade and the service busi-ness.Companies in machine and system construction find themselves under in-creasingly strong competitive pressure. The recent past shows that innovati-on alone is no longer a protection. It is much more important to enrich the business with services that are less vul-nerable to economic changes, and, in this way, to strengthen the customer bond with convincing service. The ever improving interlocking of products and services provides for new business models in service and support. Therefore, it is important to reproduce this economically and globally to a high quality.

The development of new componen-ts is subject to a high level of innova-tion by all manufacturers of control systems. Although in the past compo-nent and software programs lasted 15 years, nowadays strong changes can be registered only after a few years, resulting in shorter product cycles.

For existing components this means smaller production batches or even the production of single parts. The consequent price, which is sometimes considerably higher, is very hard for customers to accept.

BEKUM has created a solution with “replacement cards” for BMC control systems. The up to 70 % lower price is an unbeatable argument. Further-more, the components are available a

Publisher

BEKUM Maschinenfabriken GmbHLankwitzer Straße 14/15 12107 Berlin, GermanyPhone: +49 (0) 30 74 90 - 0 Fax: +49 (0) 30 74 90 - 2441E-mail: sales@bekum.de www.bekum.de

BEKUM Maschinenfabrik Traismauer GesmbHVenusberger Straße 40 3133 Traismauer, AustriaPhone: +43 (0) 27 83 4111 - 100 · Fax +43 (0) 27 83 4111 - 109E-mail: office@bekum.com

BEKUM America Corporation1140 West Grand River - Williamston, Michigan 48895 – 0567 USAPhone: +1 (517) 655 - 4331 Fax: +1 (517) 655 - 4121E-mail: sales@bekumamerica.comwww.bekumamerica.com

BEKUM do Brasil Indústria e Comércio Ltda.Rua Miguel Yunes, 823-A-InterlagosCEP 04444–000 São Paulo, BrasilPhone: +55 (11) 5686 - 9100 Fax: +55 (11) 5524 - 3734E-mail: bekum@bekum.com.brwww.bekum.com.br

good deal longer and shorter response and delivery times are possible.

The procedure for exchanging cards is as follows:The original price and replacement price are included in the offer. When the replacement card is ordered after-wards and shipped, the invoice value and original price are stated. When the defective card is returned at short notice to the BEKUM service depart-ment, a credit for the difference is issued after repair. If the card cannot be repaired, the original price is cal-culated. With this reduction in main-tenance costs and machine down-times, the service life and reliability of BEKUM machines has again been gre-atly improved.

+ Newsticker + In 2011 3 apprentices were hired in the Berlin plant. + 2011: 6 employees celebra-ted 25 years of being with the company – 1 staff member celebrated 40 years of service. +

BEKUM service department, Berlin

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