DESMA – always in good shape » The experts in rubber ... · The experts in rubber and silicone moulding » DESMA – always in good shape »

The experts in rubber and silicone moulding »

DES

MA

– alw

ays in good shape »

2 Who we are

Competence, fairness, openness and entrepreneurial action are in the focus of our attention. We delight our customers with machines, moulds, systems and service performances which are marked by reduced total costs of ownership, thus the clearly increased profitability of the investment and by first-class quality.

We see ourselves as a team of experts that develops and realizes all processes around the article to be pro-duced.

All products and services provided by our company are geared to achieve a measurable added value for our customers.

In a partnership-based cooperation with customers and material suppliers we develop flexible and progressive production methods in the world of elastomers. We explore new outlooks for rubber and silicone processing enterprises in order to increase their competitiveness.

We are a globally active mechanical engineering enter-prise for innovative and resource-friendly turnkey system solutions for the production of rubber and silicone moulded articles.

Demanding products that seal up, dampen, connect, fix, insulate and protect are produced with our injection moulding machines, moulds and automation systems.

360-degree solutions for a sustainable production success

System solutions for the rubber and silicone industry

We rely on long-term success

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More than 500 employees work globally round the clock for the success of our customers.

With DESMA-owned production, sales and service loca-tions in Brazil, China, Germany, France, India, Japan, Mex-ico, Slovakia and the USA we have a powerful network in every important economic and growth region.

Worldwide present

3 DESMA worldwide

DESMA Germany in Fridingen

DESMA Slovakiain Považská Bystrica

DESMA USAin Hebron

DESMA India in Ahmedabad

DESMA China in Wuxi


New economic regions, an increasing demand and the more efficient development of resources are only three main topics when it comes to the future production of raw materials. In this field DESMA develops new and above all resource-friendly production solutions for the rubber and silicone industry.

White goods

An efficient assembly, a safe sealing function and a ro-bust handling are required in the market of white goods. With turnkey packages DESMA makes a productive contribution in this field as well.

The traffic and water infrastructure grow analogously to the world population. Higher speed, shorter construction periods and a longer service life are crucial in the future. DESMA offers state-of-the-art technology to its cus-tomers, e.g . for the production of pipe seals for water pipes or railpads for the construction of railroad tracks.

Medical technology

A steadily growing world population with an ever-increas-ing life expectancy calls for an efficient health care. By using DESMA manufacturing systems, the medical technology can rely on top quality and productivity.

Until 2013 the worldwide production of automobiles will expand by 30 %. The manufacturers focus on more ef-ficient motors, more driving comfort and new drive tech-nologies. DESMA provides system solutions for resource conservation and lays the foundation for more efficient internal combustion engines.

Energy industry New energy sources and new power grids require effi-cient production solutions. For this DESMA developed a variety of new production processes, e. g. for the reduc-tion of power losses.

Automotive

4 What is driving us

Companion of innovative industries

Infrastructure Mining industry



the FIFO injection units for pressures as high as 3,500 bar to process demanding elastomers more efficiently

the FlowControl+ system to reduce cure time

the FlowControl CRB to increase productivity and material efficiency

the 2-deck production to raise the output

For this we have implemented some successful innova-tive concepts over the past few years that have promoted the reduction of personnel and material expenses, the increase of productivity and the reduction in energy costs in a groundbreaking manner:

the 968 BENCHMARK machine series as a standard in the industry to reduce the working height

the 969 SEALMASTER machine series for a production in minimum space

The margins in today‘s business community are globally under extremely strong pressure.

The costs of acquisition of our solutions are often over-rated as against the benefit of reducing the total cost of ownership. We consider the order of our customers to be an active contribution towards lowering their produc-tion costs.

5 What we are doing

Trailblazer for a profitable production


The DESMA ZO series

With the ZO machine series DESMA offers a perfect universal machine up to 2,500 kN clamping force.

The especially successful small machine D 968.100 ZO (S1) has a clamping force of 1,000 kN and is fitted with all compo- nents of a big machine. With 1,600 kN the vertical machine D 968.160 ZO (S1) is ideally suited for medium quantities.

The DESMA vertical machine D 968.250 ZO (S1) with a clamping force of 2,500 kN has been the bestseller in the ZO standard machine series for many years.

Our space-saving COMPACT machine series is additionally available for clamping forces ranging from 2,500 to 4,000 kN.

6 Vertical machines ZO series

Facts about the ZO machine series:

ergonomic machine overall design working height generally 1,100 mm only largely dimensioned clamping unit fully hydraulic clamping system extensive automation possibilities one-piece design for maximum flexibility available in the sizes: 1,000 kN, 1,600 kN, 2,500 kN

D 968.250 ZO (S1)

D 968.160 ZO (S1)D 968.100 ZO (S1) D 968.250 ZO COMPACT

D 968.400 ZO COMPACT



The most ergonomic vertical machines of the BENCHMARK series have achieved the highest marks in all areas. Thus DESMA has set new standards in the processing of elastomers. Even large machines sized up to 10,000 kN of clamping force are easy to operate, be- cause the vertical BENCHMARK machines are accessible without pits, ladders or platforms.

Ergonomic vertical machines of DESMA set new standards

7 Vertical machines BENCHMARK

The DESMA BENCHMARK series

Facts about the BENCHMARK machine series:

user-friendly working heights from 750 mm to 900 mm (floor - upper surface of the heating platen)

very good access to the material intake

minimum overall height of the machine

fully hydraulic clamping system with automated mould height adjustment

long opening strokes

an extremely deflection-resistant and large clamping unit

D 968.560 ZO BenChMArk (S2)

D 968.400 ZO BenChMArk (S2)

D 968.250 ZO-BenChMArk (S1)

D 968.1000 ZOBenChMArk (S1)

D 968.700 ZOBenChMArk (S1)


The clamping force of the T machine series is ranging from 2,500 kN to 40,000 kN with injection volumes from 85 cm3 to 25,000 cm3. The cold runner conversion manifold allows for injection to be alternatively performed from top or from bottom. A 2-deck production can be easily realized through central injection.

The vertical injection moulding machines of the T series can also be used for paste silicone applications, since even large silicone stuffing systems can be filled at a comfortable height. The laterally arranged injection unit is adjustable in height.

Lateral injection makes maximum flexibility possible

8 Vertical machines T series

The DESMA T series

lateral injection with height adjustable injection unit

alternatively with downward or upward acting clamp stroke

very big shot volumes are possible

very big stuffing volumes for HTV silicone are realizable

2-deck production

Facts about the T machine series:

D 968.400 T (S1)


The stable machine design with a tremendously deflection-resistant clamping unit ensures high- quality rubber and silicone moulded parts. In conjunction with a DESMA FlowControl cold runner block and/or a DESFlex system competitive edges in elastomer processing are secured.

Perfect conditions for the large-scale production of high-quality elastomer articles

The DESMA horizontal machines

9 Horizontal machines Z series

Facts about the horizontal machine series D 969 (S1):

optionally with retractable injection unit FIFO B or C

electrically driven automation systems, automatic demoulding control

DESFlex system to minimize flash

very deflection-resistant assembly of the clamping unit in 4-column design

stable design of the machine base for heavy moulds

perfect manual accessibility of the complete clamping unit area ergonomic overall design

the SEALMASTER models particularly suited for the production of seals

D 969.560 Z (S1)


D 969.160 Z (S1)D 969.100 Z (S1) D 969.400 Z (S1)SeALMASTer

D 969.300 Z (S1)SeALMASTer

Particular industry requirements call for individual technical answers. The DESMA machines series for special applications provide viable approaches to various applications in different industries. The expert team of DESMA is oriented to specific customer needs and gives advice on any questions around new production solutions.

Injection moulding machines for special applications

The DESMA special machine series

10 Special machine series

Stator machines Round-table machines Big machines Presses ZU machine series


11 Special machine series C-frame series

With the machine series D 956 and D 957 DESMA presents very stable C-frame machines for elastomer processing in its delivery program. The machines are available with clamping forces ranging from 250 kN to 1,600 kN. Extensive special equipment provides the right solution for every type of application. DESMA delivers also additionally injection units for TPE usage.

The DESMA C-frame series

Facts about the C-frame machine series:

DESMA 956 (clamping from bottom)

DESMA 957 (clamping from top)

very stable C-frame

clamping forces between 250 kN and 1,600 kN

extensive special equipment

injection units for TPE usage

D 956.100 ZO

D 957.100 ZOD 956.050 ZO


Advice - Construction - Project Management

The DESMA mould shop

A team of committed and knowledgeable DESMA employees in construction and production shape the technical lead for the rubber and silicone industry. DESMA supplies fully operative moulds ready for pro-duction. Thus optimization times can be reduced and machine capacities increased.

A skilled team with broad field knowledge and new ideas is always available at DESMA to implement an optimal production solution. Wide experiences in most different article groups and a variety of turnkey packages realized so far emphasize the competence of DESMA in elasto-mer technology. The team of experts already supports the manufacturers of elastomer articles in the planning phase and attends them until the finished product stage.

DESMA produces moulds for all sizes of clamping force and machine makes. The team of experts further offers complete production systems from one source for a new or already existing injection moulding machine.

12 DESMA mould shop

Production - Assembly – Optimization


DESMA ranks among the leading suppliers of cold runner systems. Executed in closed design, these systems have been performing brilliantly in the rubber and silicone indus-try. Due to polished manifold channels, deflections and a special structure, almost every cold runner system can be vulcanized and purged when changing the compound.

DESMA STAndARd cold runner

The DESMA cold runner systems

13 Cold runner systems

DESMA FlowControl DESMA FlowControl+

The patented FlowControl+ cold runner is equipped with dynamically adjustable nozzles which make a controlled shear hear input into the compound possible. The FlowControl+ is thus the first cold runner by which considerable cure time reductions – in the seal sector as much as 25 % – are feasible.

DESMA VARIO cold runner

The innovative DESMA VARIO cold runner technology allows for nozzle distances to be variably adjusted for the first time in order to cover different moulds. Since so a multiple use is possible, the VARIO cold runner provides a significant cost-saving potential for smaller series as well.

With the patented cold runner system FlowControl the company defines again its technology leadership in the elastomer processing sector.

The FlowControl technology that has already been broad-ly launched into the market brings new possibilities and flexibility in the production of rubber and silicone moul-ded parts. DESMA won the Product Award 2006 given by the German Rubber Society (DKG) for it.Together with an innovative individual nozzle control via the injection moulding machine, the cold runner technol-ogy FlowControl permits a largely free arrangement of nozzles. When the compound needs to be changed, this innovative cold runner system is easier to be cleaned.


The injection moulding systems of DESMA are supposed to be working optimally and to furnish customers from various industries with sustainable success in production. There is hence a high-level team of process engineers in the process engineering center who takes care of the op-timization of systems, machines, moulds and production methods. The technicians and engineers are engaged in the perfect implementation of innovations such as Flow-Control and complex customer projects with the latest ma-nufacturing systems. In addition to trials and pilot series, training programs for employees and clients are offered. On request, direct production support for customers can be also carried through in the process engineering center. Further engineering centers are available at the locations USA, India and China.

Process engineering center for optimal production processes

The DESMA Process Engineering Center

14 DESMA Process Engineering Center

The DESMA Training Center

courses can be conducted at very short notice

all quarterly seminars also in English language

new quarterly seminar „DESMA FlowControl cold runner technology“

certified as per AZWV (decree of the German government regarding admission and certification of advanced training programs) – up to 80 % re- imbursement of expenses of the attendance fee for recipients of short-time benefit (through the Germany‘s Labor Agency/ESF)

A particular strength of DESMA is the Customer Care Center which features the wealth of experience of the service staff. 500 man years of after-sales service prove the efficiency of the Customer Care Center.

Maintenances, rebuilds and minor reconditioning projects are carried out directly on the ground by the DESMA service technicians. In case of overhauls and major rebuilds the machines are transported to our headquarters. Moreover, DESMA provides a large number of options and accessories enabling to adapt a machine to altered production processes and products.


New methods for elastomer processing are developed and made ready for the production stage by versed application technicians and process engineers in the DESMA process engineering center – a state-of-the-art test center at the Fridingen location. It goes without saying that the cooperation between DESMA and their customers is particularly close in the development phases.

Especially for extensive turnkey packages DESMA offers project-oriented training programs to guarantee an effective introduction into your production. The versed DESMA service team is globally at your disposal and keeps your production running.

Reliable project management The experienced DESMA project engineers support and advise you from project engineering to run-off tests. In the realization phase the engineer in charge of your project is your contact. Thus DESMA guarantees a seamless communication.

State-of-the-art and flexible machine concepts are the basis for successful turnkey production systems. The open control architecture of the DESMA injection moulding machines enables the integration of complex automation systems as well.

Innovative mould shop With the in-house DESMA mould shop new ideas are realized in a hands-on and process-oriented way. Short ways in the production process ensure steady success of the enterprise in the rubber and silicone industry in the long run.

Modular machine concepts

System solutions for elastomer processing

15 System solutions

Worldwide service and hands-on transfer of knowledge

Development of new production methods in elastomer technology


Kloeckner DESMA Elastomertechnik GmbHAn der Baera78567 Fridingen/GermanyPhone +49 (0) 74 63-8 34-0Fax +49 (0) 74 63-8 34-1 86eMail [email protected]

www.desma.biz

BENCHMARK S3

For eyes and ears

Sharp lines, excellent accessibility, carefully thought-out and designed conduit arrangement in conjunction with an innovative design and robust overall construction offer the best platform for a long machine life in tough production environments.

For us, delivering reliability for the future by way of efficient state-of-the-art drive technologies in conjunc-tion with perfect ease of operation is a commitment: in line with the spirit of the successful BENCHMARK series.

New standards

The BENCHMARK S3 by DESMA is a vertical machine featuring a totally new design. An impressive package of technical features – such as ServoGear, ActiveFeed, PlastControl, QuickLock and the FIFO-Advanced injec-tion moulding unit – definitely sets new standards.

The new 19“ DRC 2020 HT visualisation unit features the Haptic-Touch innovation, opening the door to many new possibilities. The service-friendly covering offers integrated vapour extraction and much reduced noise generation – thanks to the new ServoGear hydraulics – together with the improved overall ergonomics: all adding up to significantly lower stresses on the operator.

The new injection unit FIFO-Advanced

Exploiting cost-cutting potentials

The ActiveFeed option is the first system to offer a fully integrated active-drive feeding roller. This allows strips of much larger dimensions to be fed-in. It can also reliably draw in strips with fluctuating dimensions and also those made with difficult compounds. This can save considerable costs in strip production and help avoid production stand-stills due to strip tear.

The PlastControl system (patent applied for) incorpo-rates a hydraulically operated non-return valve offering for the first time the option of actively shutting the non-return valve. This raises dosing precision by a factor of approx. 50 %. When using low-viscosity materials it guarantees definite closure of the non-return valve. In connection with the standard swivel unit for the screw cylinder unit, it makes changing materials all the more easier.

The new FIFO-Advanced injection unit offers a range of new options. In addition to a raised injection accuracy, the new extremely stable overall construction allows the integration of a significantly larger silicone stuffing system. This in turn allows substantial reductions in refill cycle times.

It almost goes without saying that the FIFO-Advanced injection unit is also available with the patented FlowControl+ injection technology for cure time reduction.

FIFO-Advanced with silicone stuffing system ActiveFeed PlastControl Swivel unit

ServoGear – the new hydraulics

Saving energy, quietly and precisely Fast mould change

BENCHMARK S3 introduces ServoGear, a servo-driven hydraulic system. With two independent servo drives, power can be either combined or split for parallel move-ments. The generation of noise has been significantly reduced. In addition positioning accuracy is greatly im-proved. All of which goes hand-in-hand with significantly lower energy consumption. For a machine of average equipment level and average cycle time, the savings potential ranges between 10 – 13 % of total energy con-sumption. This in turn represents an approx. 45 % energy saving for the drive.

The new hydro-mechanical QuickLock is an optional quick-clamp system which also enables “hot” mould changes. The integrated quick-clamp system on the machine guarantees reliable attachment to the heating platens and the hydraulic lifting devices.In conjunction with the pre-heat units available on DESMA machines, this also means shorter set-up times.

ServoGear hydraulics QuickLock hydraulic lifting device QuickLock mould plate clamping QuickLock mould package change

The new operating panel DRC 2020 HT

By way of graphically animated machine subassemblies, logical interconnections of the entry masks are estab-lished. The system is very user intuitive.

The new DRC 2020 HT operating panel is suitable for retrofitting to machine generations with DRC 1210 and DRC 2010 visualisation systems. This means the state-of-the-art in control technologies is also available for existing units.

Feel what is happening with the new DRC 2020 HT visualisation

It effectively makes the man-machine interface much smaller.

When redesigning the screen pages, the programmers concentrated on creating a logical user prompting and on the simple display of even complex subjects. Thus, for example, the entry of function sequences (Fx-series) has been greatly simplified and much improved, espe-cially for concurrent movements of several pumps.

Featuring a massive 19” high format screen, this system opens up a new chapter in simplified and logical con-trol of rubber injection moulding machines. A new user prompting and the perfect display of processes set new standards.

The operating panel is the first to integrate a Haptic-Touch screen which provides users not only with visual information, but also “touch” feedback.

Summary of advantages

Kloeckner DESMA Elastomertechnik GmbHAn der Baera

78567 Fridingen / GermanyPhone +49 (0) 7463-834-0Fax +49 (0) 7463-834-186

[email protected]

Persuasive arguments

FlexInterlock allows freely programmable core puller lockings

Further improved stroke ratios

FIFO-Advanced injection unit for even better injection precision

Combination options with large silicone stuffing systems

ActiveFeed for more reliable feed of material strips of larger dimensions

Footprint reduced by 10 %

– Subject to technical modifications –

Energy saving drive thanks to ServoGear hydraulics Significant reductions in noise emission

Much improved positioning accuracy of all hydraulic movements Simple machine operation thanks to 19” Haptic- Touch screen with new intuitive user interface

Up to 50 % further improved injection accuracy thanks to PlastControl

Swivelling screw cylinder unit for simplified material change

High-speed mould change thanks to QuickLock system

New covering for improved accessibility for servicing

Hydraulic lines almost totally ducted to reduce maintenance costs

Integrated extraction option for vapours and satisfying overall design

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DESMA – always in good shape » The experts in rubber ... · The experts in rubber and silicone moulding » DESMA – always in good shape »