4.0PLASTICS

IN CHINA

APC PLUS

PLASTICS 4.0 IN CHINA

DIGITALIZATION IN THE PLASTICS INDUSTRY

IPUL, FIBERFORM, HYBRID MATERIALS

NEW PERSPECTIVES IN LIGHTWEIGHT CON-STRUCTION

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue 01.2017

AHEAD

CONTENTS

COVER STORY

4 Digitalization in the plastics industry

is gathering pace

8 Nĭ haŏ PX

9 Interview: Customized for our

customers

BRAND & MARKETS

10 Three times more expensive –

but still much cheaper

12 Versatile and all-electric

14 Smart anniversary machine

PROCESSES & PRODUCTS

15 Small helpers with a significant impact

16 Cubed – not shaken

18 Proven gripping capability

PARTNERS & PROJECTS

20 More speed during pultrusion

22 Lightweight construction with

perspectives beyond vehicle

manufacturing

26 The hybrid is the future

of e-mobility

28 Premium-quality upholstery

KRAUSSMAFFEI GROUP

30 Interview: Growth from

our own efforts

31 Thai Beverage uses the

PET-LINE from Netstal

31 Trade show calendar

31 Imprint

EDITORIAL

Dear readers,

The global plastics industry is growing. Disruptive technologies such as Indus-

try 4.0, the Internet of Things and electromobility are acting as catalysts for the

development of our industry. New products and production concepts increase

efficiency and effectiveness. Providers are increasingly utilizing the advantages

of plastic components in vehicle manufacturing, the packaging industry, technical

applications and the medical industry. In China, this development extends to new,

highly automated production facilities. Plastics 4.0 from KraussMaffei is laying the

critical, technical groundwork for networked production systems.

In this issue, you will read firsthand information. We also have reports on ground-

breaking developments and new applications of our series and technologies.

For example, we present our new all-electric PX series as a PX SilcoSet for pro-

cessing liquid silicone and with inductive DMH technology for producing pre-

mium-quality surfaces in a one-shot process at Chinaplas. KTH Yildiz, located

near Hamburg, produces a wide range of technical components and packaging

elements on its new fleet of PX machines. DPI in France utilizes the options for

increasing efficiency offered by the GX swivel plate machine with cube mold.

And from Indonesia, we report on a packaging specialist that produces on

MX  machines with up to 32,000 kN of clamping force.

The 100th injection-molding machine for Grohe is a cause for celebration. The

CX  80-380 is part of a new, streamlined production line at the Porta Westfalica

location.

In the area of pultrusion, KraussMaffei is discovering new dimensions of efficiency

with iPul, especially in terms of lightweight construction in the construction indus-

try. The LEIKA project is researching hybrid processes and materials made from

fiber-reinforced plastics and metal for lightweight automotive construction. And

the new Vario nozzle is providing Spanish upholstery specialist Proseat with high

reproducibility in foam production. Even the applications for established technolo-

gies such as FiberForm and wet molding are expanding.

I hope youʼre excited to read this edition of AHEAD more closely.

With best regards,

Dr. Hans Ulrich Golz

Managing Director

President of the Injection Molding Machinery segment

Innovative product idea Innovative pull tabs are

produced on a KraussMaffei swivel plate machine.

New standards The all-electric PX celebrates its market debut in China.

New perspectives Development of lightweight plastic construction is

increasingly dynamic.

8

16 22

3KraussMaffei Contents

4.0PLASTICS

APC PLUS

DATAXPLORER

AHEAD Issue 01.20174 Cover Story

he efficiency-boosting Plastics

4.0 modules are a great fit with

respect to current development

within the industry in China.

Global competition is causing an

increase in the pressure for efficiency. “Ris-

ing wages, increasing energy costs and strong

demand for skilled workers make automation

solutions particularly attractive,” explains

Xiaojun Cui, CEO of the Chinese subsidiary of

the KraussMaffei Group. Integrated manufac-

turing processes used across many locations

and industries require effective data logistics.

An ever-increasing variety of models, particu-

larly with respect to automaking, can be cre-

ated using state-of-the-art data processing.

Favorable basic conditions“Plastics 4.0 from KraussMaffei is a modular

concept that fully utilizes new options for gen-

erating and analyzing large volumes of manu-

facturing data to create more efficiency in

plastics production and higher product qual-

ity,” explains Jörg Wittgrebe, Vice President

Sales at KraussMaffei in Shanghai. As a re-

sult, users can use the BlueBox to call up the

current status of individual machines on the

Internet and reconfigure them if necessary.

There is also an interactive teleservice to en-

sure that the machines are always running

optimally. These concepts are applicable for

the basic conditions in China, especially when

completely new factories are built. In these

situations, the full potential of Plastics 4.0 can

be utilized.

Some reservations“In Europe, there are still some reserva-

tions regarding the exchange of production

data with machine manufacturers,” explains

Dr. Schiffers. “Customers in the USA are much

more open to this option. However, Chinese

customers encourage and demand that ma-

chine data be analyzed. Chinese engineers

place a high value on increasing efficiency

through process optimization and, in the pro-

cess, they want to utilize the full experience

and expertise of machine manufacturers,”

T

“Internet of Things” and big data are some current buzzwords. When these concepts

are combined, they often result in Industry 4.0. This means that large volumes of

data are collected via an Internet connection and evaluated in real time using state-

of-the-art calculation algorithms. Production and retail are becoming increasingly

networked and integrated, which increases efficiency. Exchanges between suppliers

and customers regarding their options and needs are becoming quicker and more

precise. KraussMaffei utilized Plastics 4.0 to develop these opportunities for the

plastics processing industry. The concept offers great areas of potential to Chinese

companies.

TEXT: GERHARD KONRAD PHOTOS: KRAUSSMAFFEI

PLASTICS 4.0 IN CHINA

DIGITALIZATION IN THE PLASTICS INDUSTRY IS GATHERING PACE

5KraussMaffei Cover Story

“ Rising wages, increasing energy costs and strong demand for skilled workers make automation solutions particularly attractive.”XIAOJUN CUI, CEO OF THE CHINESE SUBSIDIARY

OF THE KRAUSSMAFFEI GROUP

explains Dr. Reinhard Schiffers. He is in

charge of the Machine Technology business

area at KraussMaffei.

Trust and openness“We develop analysis tools that utilize data

from the machine control system for contin-

uous process optimization,” states Product

Manager Stefan Fenske. “As an experienced

manufacturer, we can do more than just col-

lect and display the data. We also know what

fluctuating values or changing measured val-

ue trends mean.” This enables KraussMaffei

to recommend to the customer specific

measures for keeping the machines at the

optimum productivity level.

Integrated intelligence State-of-the-art control systems depict the

expertise of mechanical engineering compa-

nies and users in algorithms. A good example

of this is the KraussMaffei APC system. This

system provides stable ratios for each shot,

ensuring that almost every produced part is

a good part. Fluctuations in the shot weight

can be decreased. This conserves material

and saves money as a result.

Integrated productionEfficiency is created when the interaction be-

tween all modules within a production pro-

cess is optimal. Plastics 4.0 is backed by the

vision of fully integrated plastics processing.

The Euromap 77 standardized control station

computer interface based on the UPC-OA

data transmission protocol marks an im-

portant milestone for integrated production.

This interface enables transmission of pro-

duction-relevant data to the central control

station computer in real time. This yields ad-

vantages in production efficiency at the end of

the production batch, right at the scheduled

start of production and for production alarms

for the peripherals and the machine.

Process data reduces maintenance costsPreventive maintenance is the future of

plastics processing. It ensures continuous

production at a uniform level of quality. In

turn, this creates a high level of availability

and enables long-term planning of main-

tenance work. In addition, service tasks can

be scheduled for the most convenient times.

These services determine the actual state of

the system parts.

STABLE PROCESSES

APC plus boasts numerous

new intelligent features

which make injection mold-

ing even more stable and

precise.

APC PLUS

AHEAD Issue 01.20176 Cover Story

Energy savings at the push of a buttonEnergy costs constitute an increasingly

larger portion of manufacturing costs for

plastic components. For this reason, energy

conservation is extremely important. The

KraussMaffei ECO Button, which keeps energy

consumption of the injection molding machine

at the lowest possible level, is an instrument

that has been yielding the best results in this

area. One advantage of the ECO button is that

it optimizes the plasticizing speed during pro-

duction. This is a good example of the direct

benefits of Plastics 4.0. In addition, the clamp-

ing force is adjusted to the best energy value

and hydraulic power management ensures

efficient operation of machine movements.

DataXplorer for even more efficiency and securityOnly evaluation of data gathered over an ex-

tended period can offer continuous improve-

ment of production efficiency. For this reason,

KraussMaffei developed DataXplorer. This

module is available with new machines and

can be retrofitted for older machines. “We

can use DataXplorer to provide our users

with information on the plasticizing speed,

mold speed or melt pressure in the form of

curves on a graph,” explains Fenske. An in-

jection molding machine can deliver up to 520

different signals. They are typically stored for

approximately seven days in the machine con-

trol system.

Storage and analysisDataXplorer continuously stores the data

stream and forwards the data to a manufac-

turing execution system (MES) or another “big

data” application. As such, machine data is

integrated directly into process optimization.

Monitoring and documentation enable quicker

corrective action, diagnosis and identification

of potential for optimization.

Traceable qualityDataXplorer can be used for direct quality

optimization. Important quality parameters

related to production are compared with the

process data. One application is quality moni-

toring. A QR code printer assigns an individu-

alized code to each produced part. This code

links to the specific set of production data that

is stored in DataXplorer. The desired produc-

tion parameters, such as heating and cooling

times or pressure curves and cycle times, can

be traced precisely. This enables fast identifi-

cation and elimination of causes of defective

parts. “In sectors such as automaking and

medical technology, DataXplorer meets im-

portant customer needs,” says Dr. Schiffers.

“Documentation of the manufacturing process

is especially important in ensuring the safety

and health of people.”

360° AT A GLANCE

Depending on the machineʼs

equipment, the new DataXplorer

displays up to 500 high-resolution

signal paths, visualizes these signal

paths and makes them available for

evaluation.

DATAXPLORER

CUSTOMER PROXIMITY

In the future, the E-Service of the

KraussMaffei Group will support

the processing of service calls in

day-to-day business.

E-SERVICE

7KraussMaffei Cover Story

MARKET DEBUT IN CHINA

Upon the market launch of the new all-electric PX series at K 2016,

KraussMaffei set new standards for all-electric injection molding

machines. Now, the new series is being introduced to the experts at

Chinaplas in Guangzhou, China.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

NĬ HĂO PX

he new PX series is the first

all-electric machine, which the

customers can tailor to specific

manufacturing needs (similar to

the modular design in the hydrau-

lic area). It was conceived and designed with

flexibility in mind, and this extends over the

entire service life from the purchase to every-

day production to retrofitting. The K trade

show featured the launch of the all-electric

toggle machine with clamping forces from

500 to 2,000 kN. At Chinaplas 2017 in Guang-

zhou, the new series is now celebrating its

market debut in China: Two selected produc-

tion lines produce groundbreaking applica-

tions from medical and surface technology in

real time at the trade show booth.

Soft with silicone, but reliable The buzzwords for medical technology re-

quirements are precision, process reliability

and compliance with clean rooms. The new

TPX 50-180 SilcoSet meets these exact require-

ments. At Chinaplas, it produces nasal venti-

lators made of liquid silicone rubber (LSR) for

babies. Silicone components are clearly gain-

ing ground due to their excellent physical and

chemical properties. Yet, as Jörg Wittgrebe

stresses, processing these materials is quite

demanding: “The consistency varies from

water to honey and demands absolute platen

parallelism to ensure that the mold closes

extremely tightly and the injection molding

PRECISION

STABLE PROCESSES

CLEAN ROOM-COMPLIANT

The PX 50-180 SilcoSet with

encapsulated ejector.

AHEAD Issue 01.20178 Cover Story

THREE QUESTIONS POSED TO JÖRG WITTGREBE,

SALES DIRECTOR AT KRAUSSMAFFEI IN CHINA

“ CUSTOMIZED FOR OUR CUSTOMERS”

What do your customers in China expect from

an all-electric injection molding machine?

Wittgrebe: Primarily, plug and play capability. This means system solu-

tions are ready for production immediately. They also expect increased

precision, high injection speeds, no oil leaks, less power consump-

tion and significantly higher process reliability compared to hydraulic

machines. We see plenty of potential in the 3C industry, the connector

industry, packaging for pharmaceutical and cosmetic products and

automotive applications.

What advantages does the new PX offer customers?

Wittgrebe: High flexibility over the entire lifecycle is the clear com-

petitive advantage of the new PX series. For example, our customers

benefit from a uniquely large variety of processes for clamping unit

and injection unit combinations. The selection also includes larger

platens, faster injection speeds, more ejector force and even the op-

tion of operation using food-grade NSF H1 lubricants, all with the

high precision and process reliability that are typical of an all- electric

injection molding machine. This combination makes the PX one of a

kind.

What experience have you gained with the new APC plus machine function?Wittgrebe: The feedback is excellent. Notably, customers that process

difficult materials or recycled materials benefit from the compensat-

ing properties of the Adaptive Process Control system. The topics of

process and production reliability and production costs are gaining in

importance in China because the wage costs have sharply increased

in the past.

process is engineered to the finest detail.” The

modular concept of the PX, which inherently

permits enlargement of the installation space,

proves to be beneficial here. The compact de-

sign provides lots of space for demolding and

peripheral equipment and good accessibility.

For clean room-compatible applications in

medical technology, the PX features encap-

sulated drive units and ejector and a closed

lubricant circuit.

The new APC plus function takes on a par-

ticularly important task as it compensates for

the batch fluctuations commonly encountered

when processing LSR. As the process pro-

gresses, APC plus monitors the viscosity of the

material and corrects the filling volume even

in the shot. The result: The process as a whole

is made even more precise; the part weight

remains constant. APC plus is even able to re-

liably compensate for any potential prelimi nary

cross-linking of the silicone.

As stylish as film, but more efficientExciting surface effects with precision struc-

tures and a hologram appearance are created

on a PX 160-540 with inductive DMH technol-

ogy (dynamic mold heating) that operates in

cooperation with RocTool at the KraussMaffei

booth. Components with premium-quality

surfaces are developed in the one-shot pro-

cess. As a result, additional in-mold decora-

tion steps such as preforming, punching and

feeding have been omitted. KraussMaffei is

presenting two different design variants at

Chinaplas using a finisher as an example of

an electronics box. The PX 160-540 pro duces

components with surfaces in a high-gloss fin-

ish using structure effects and a hologram

structure.

SUITABILITY FOR CLEAN ROOM USE

9KraussMaffei Cover Story

INDONESIAN PACKAGING MANUFACTURER INDRAGRAHA TRUSTS IN THE MX SERIES

THREE TIMES MORE EXPENSIVE – BUT STILL MUCH CHEAPERPackaging: In this highly competitive sector, the price counts above all. Articles are often standardized

or comparable, so suppliers can hardly distinguish themselves by technological competence. Success is

simply a matter of high output and low scrap volume. For this purpose, the Indonesian packaging manu-

facturer Indragraha has been using KraussMaffei machines since 2013.

TEXT: DR. SABINE KOB PHOTOS: INDRAGRAHA

QUALITY PAYS OFF

The Indragraha team in front of its MX 3200.

Brand & Markets

CONTAINERS AND PALLETS

FOR ASIA

MX machines are the go-to

machines at Indonesian pack-

aging specialist Indragraha.

YOUR CONTACT:

Klaus Zeiler

Head of Global Business

Development for Injection

Molding Machinery

klaus.zeiler@kraussmaffei.com

ndragraha, with approximately 250 em-

ployees, produces pallets, waste bins,

bottle crates and all types of contain-

ers in Jakarta. The company, which

was founded in 1970, sells its products

throughout Southeast Asia and is the market

leader in Indonesia. Especially in the area of

food, plastic pallets are increasingly replac-

ing the previously common wooden variant,

as this makes the elimination of pests easier.

Indragraha owner and Managing Director

Pranoto Boedi controls the activities of his

company himself, and in 2013, when the pur-

chase of a new injection molding machine was

being planned, he decided not to buy an Asian

model as previously, but instead to change

over to the MX series from KraussMaffei.

At first glance, this seems like a financial

burden, as premium European makes cost

around three times more than low-budget

versions from Asia. However, thanks to fast

cycle times, low scrap rates and high machine

availability, the procurement costs were re-

couped within just a few years. Subsequently,

the company has been earning additional

money with its investment – depending on

the article, up to several hundred thousand

euros per year.

Speed makes the differenceTo the question regarding the greatest differ-

ence between the KraussMaffei machines and

the Asian equivalents, Pranoto Boedi there-

fore answers: “Speed. The MX machines are

extremely fast and very energy-efficient. In

addition, the precision. Scrap has decreased

from previously five percent to practically zero

percent. A Big Box weighs up to 30 kilograms.

If I have to throw away almost five percent

fewer parts, this immediately has a posi tive

effect on my earnings.”

After the successful commissioning of

the MX 3200 in 2013, Indragraha added an

MX 2300 to its machine pool in 2015, and

in 2016 another MX 1000. They all produce

boxes of different sizes, and the models with

a clamping force of 32,000 and 23,000 kN

additionally manufacture the most diverse

plastic pallets. As the demolding has a direct

effect on productivity, Pranato Boedi also

opted for a six-axis robot from Germany for

automation. He already has his eye on the

next opportunity for increasing efficiency: As

soon as he starts on a product with a longer

throughput time, he wants to use a European

mold. In comparison with molds purchased

locally, the cycle time will again be significant-

ly shortened, above all thanks to the consid-

erably more efficient cooling – again reducing

the amortization time for his machines.

I

11Brand & Markets

hether lids for cosmetics

packages, screw caps for

spray paint cans or tech-

nical components for the

electrical and electronics

industries, the portfolio of KTH Yildiz Kunst-

stoffverarbeitung and Werkzeugbau is highly

varied. In Heede, to the north of Hamburg,

the family-owned company produces com-

plex plastic components that are delivered

to their customers just-in-time in small to

large quantities.

“Our customers expect components of a high

quality. This requires extremely high preci-

sion during manufacturing, even when there

are frequent material and mold changes,”

explains Ali Yildiz, founder and Managing

Director of KTH Yildiz. That is why the com-

pany relies primarily on all-electric injection

Wmolding machines, which inherently boast

superior precision compared to hydraulic

machines. This state-of-the-art machine

pool currently consists of 15  machines.

One of the newest members is a PX 81–380

from the new KraussMaffei all-electric PX

machine series. KTH Yildiz commissioned

this machine in the summer of 2016 as one

of the first field test customers. “The new PX

impressed us right from the beginning. Its

one-of-a-kind modular concept in particular

complies with our promise of flexibility and

high availability,” states Yildiz. The modular

concept is not limited to configuration and

purchasing of the system. It is also used for

production and retrofitting. The tried-and-

tested modu lar concept of the KraussMaffei

hydraulic series was thus transferred suc-

cessfully to the all-electric PX series.

“ The enlarged mold installation space offers us clear added value.” ALI YILDIZ, FOUNDER AND MANAGING

DIRECTOR OF KTH YILDIZ

THE NEW PX SERIES

VERSATILE AND ALL-ELECTRICAt plastics processor KTH Yildiz, flexibility and precision are top priorities. The PX 81 – 380 of

the new all-electric PX series from KraussMaffei meets all of these requirements.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

AHEAD Issue 01.201712 Brand & Markets

YOUR CONTACT:

Frank Dalhaus

Head of the KraussMaffei Sales

and Service Center in Northern

Germany

frank.dalhaus@kraussmaffei.com

GOOD COLLABORATION

Ali Yildiz and Frank Dalhaus.

More space for the moldThe great adaptability is demonstrated by two

essential features of the series. First, the in-

jection and clamping unit can be combined in-

dividually from a wide range of variants. Sec-

ondly, versions of the PX come standard with

the larger mold fixing platens of the respective

next higher clamping force. The designation

numbers of these intermediate models are

odd numbers. KTH Yildiz opted for a variant

with larger platens – the PX 81. The larger

inside diameter means an increased maxi-

mum mold weight (in this case, approximately

1,000 kilograms compared to 750 kilograms

for a PX 80). “The enlarged mold installation

space offers us clear added value. The use of

heavier molds and fast mold changes support

us in flexible structuring of our day-to-day

production,” states Yildiz.

Modularity without additional costs also ap-

plies to the selection of ejectors. KTH Yildiz

opted for the servo-electric variant that en-

ables extremely precise transfer of parts to

the robot demolding area. In turn, this results

in exact and reproducible processes.

Space-saving and durableBecause the machine bed of the PX is divided,

clamping and injection units can be combined

as required. Large clamping units, small

injection units – in production, this means

that no more space is taken up than what is

absolutely necessary for the production or-

der. In addition to the space-saving concept,

Yildiz praises the durability of the machine.

The mechanical system in particular is easy

to move and has zero clearance.

Is anyone really surprised? Thanks to the

good reference the company wrote as one

of the first field test customers for the new

PX, it wasn't long before a follow-up order

for another PX was received. A second PX,

a PX  160–540, has been producing parts at

KTH Yildiz since late March of this year. The

company is set to receive two additional

PX machines this year. All machines feature

the new APC plus (Adaptive Process Control)

machine function that was launched during

K 2016. This function makes injection molding

even more stable and precise. “This ensures

that we support our high quality promise

over the long term. We are very satisfied with

the new PX machines and the service from

KraussMaffei,” states Yildiz. It is safe to say

that both partners will continue to collaborate

successfully in the future.

FLEXIBILITY AND PRECISION

ARE THE KEY

The design of the new, all-electric

PX series. Clamping unit and injection

unit in a modular design, plenty of

space for parts logistics, good accessi-

bility and ergonomic operation.

13KraussMaffei Brand & Markets

YOUR CONTACT:

Frank Dalhaus

Head of the KraussMaffei Sales

and Service Center in Northern

Germany

frank.dalhaus@kraussmaffei.com

Grohe is known for its premium-

quality sanitary fittings, spray

attachments and installation

systems. Oftentimes, optimum

processing and high-precision

technology are crucial in meeting the un-

compromising quality promise. This is also

the case at the Porta Westfalica location.

Here a new, cost-effective production line

produces drain valves for toilet tanks from

the latest Grohe generation 24/7. The new

AV1 production line features efficient pro-

cesses, zero inventory and a high level of

automation. It is therefore all the more im-

portant that the injection molding machines

produce precisely and reliably, and with opti-

mum utilization of the installation area. The

view at Grohe is that, with the new CX series

and service from KraussMaffei, they are op-

timally set up.

100TH INJECTION MOLDING MACHINE FOR GROHE

SMART ANNIVERSARY MACHINE

A cause for celebration – in late January, KraussMaffei

delivered the 100th injection molding machine to Grohe.

The CX 80-380 is part of a new, streamlined production

line at the Porta Westfalica location.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

Adaptive Process ControlThe responsible parties at Grohe also see a

clear additional benefit in the APC function

(Adaptive Process Control). All KraussMaffei

machines are today equipped with this new

machine function. They have thus been able to

deal perfectly with the batch fluctuations of up

to 17 percent of the basic material. Also with

regard to the anniversary machine CX 80-380,

on which float flaps are made from the high-

tech plastic POM, the compensating proper-

ties of the APC function prove beneficial.

100 KraussMaffei machines for Grohe, 37 of

which are at the Porta Westfalica location –

a longtime success story celebrated by both

partners, who want to continue this collab-

oration into the future. “We have benefited

from the innovative products and the tailored

service provided by KraussMaffei for decades.

APPLAUSE FOR THE

ANNIVERSARY MACHINE

The Grohe and KraussMaffei

teams celebrate the 100th

injection molding machine.

CEREMONIAL HANDOVER OF THE ANNIVERSARY

MACHINE

Lars Thielke, (Grohe Production Manager, Plastic Injection

Molding), Hans-Martin Souchon (Grohe Plant Manager,

Porta Westfalica), Nadine Buhmann (Vice Presi dent Sales,

Injection Molding Machinery, KraussMaffei) and Thomas

Fuhr (Chairman of the Board of Grohe AG) (left to right).

Our 100th injection molding machine in Porta

Westfalica is a strong symbol of good collabo-

ration as well as sustainable growth and con-

tinuous further development of our location,”

explains Thomas Fuhr, a Member of the Board

at Grohe AG.

function after the components are held using

a vacuum ensures rapid depositing. “Overall,

the secondary process times can be signifi-

cantly reduced, which, in turn, shortens the

total cycle times,” says Marufke.

KraussMaffei pays special attention to en-

ergy-efficiency and cost-effectiveness in all

handling systems. This also applies to the

new LRX small robots. For example, the new

digital BluePower vacuum monitoring system

with integrated air-saving function makes it

possible to reduce compressed air require-

ments by up to 90 percent. The additional

function for leakage monitoring reports mal-

functions during operation, thus allowing the

planned maintenance of the system. Thanks

For the production of the new small

robot series, KraussMaffei uses

the new synchronized assembly

process for automation at the

Schwerin location. “We therefore

offer our customers fast delivery times, high

quality thanks to production from a single

source, and fast service and retrofitting ser-

vice, for example spare part stocking,” ex-

plains Thomas Marufke, Managing Director

of KraussMaffei Automation.

But the new synchronized assembly process

isn't the only remarkable feature. The entire

new generation of small linear robots features

a state-of-the-art industrial design with the

aim of increasing failsafe operation. The

decentralized switching cabinet design thus

ensures easy access and flexibility, for exam-

ple in event of maintenance or when retro-

fitting sensors or additional media circuits.

The revised thermal and protection concept

for the electronic components with protec-

tion class IP 54 ensures high availability and

safety. Furthermore, rack and pinion drives

instead of toothed belts result in a high level of

precision in rapid axis movements. A central

media portal allows for fast gripper changes

and supports you in production with frequent

product changeovers.

Forward-looking, high-performance, efficientAdditional high-performance components

complement the high level of accessibility

and productivity. The free-standing X axis

thus allows free access for plasticizing and

material supply. A new compact design of the

servo-driven wrist axes makes possible mini-

mal opening strokes, an additional blow-off

YOUR CONTACT:

Thomas Marufke

Managing Director at KraussMaffei

Automation

thomas.marufke@kraussmaffei.com

NEW GENERATION OF SMALL LRX LINEAR ROBOTS

SMALL HELPERS WITH A SIGNIFICANT IMPACTThe new LRX 50, LRX 100 and LRX 150 have been specifically designed to satisfy the cri-

teria of availability, precision and productivity. Thanks to the numerous new features, the

secondary process times and thus the entire cycle times can be considerably reduced.

TEXT: PETRA REHMET PHOTO: KRAUSSMAFFEI

to the new lightweight design of the robot’s

main axes, the mass to be moved by the re-

spective individual axes is also reduced. As

a result, the work can be performed with

smaller drive units, thus reducing energy

consumption.

LRX LINEAR ROBOTS

Rack drives for high precision

for fast axis movements.

15KraussMaffei Processes & Products

Processes & Products

PARTNERSHIP WITH A FRENCH MANUFACTURER OF CUBE MOLDS

CUBED – NOT SHAKENSize is relative. Sometimes all it takes is a small yet effective team to be extremely

innovative and cover the whole scope of a project. Just like the French mold manu-

facturer, DPI International, which developed a new pull tab for series production. All

thanks to a cube mold and a swivel plate machine from KraussMaffei.

TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI, DPI

Cube molds are “specialists”. They

are approximately 70 percent

more expensive than conventional

swivel plate stack molds and re-

quire special conditions in order

to be used effectively. However, these molds

enable an enormous boost in efficiency. They

are usually small components with a large

number of cavities, such as the pull tabs man-

ufactured by French company, DPI Interna-

tional (DPI), for beverage cans. They include a

2-component base body. Previously, this part

was produced in an 8+8-cavity mold in a cycle

time with a duration of approximately 20 sec-

onds. In the 48-cavity cube mold, which runs

on a GXW 550 SpinForm swivel plate machine

from KraussMaffei, the cycle time has been

reduced to less than ten seconds.

International customersThe 2-component pull tab is special in two

regards. It is the first resealable product for

cans and it is exceptionally tight. Even after

forceful shaking, the liquid does not spray out

like a fountain when the container is opened.

A customer had the idea and DPI, a young

French company with a rich store of expe-

rience, successfully implemented this idea.

Founded in 2010 as a provider for engineering

services, the company grew into a complete

mold-making company within one year by

acquiring a company in the packaging sector

AHEAD Issue 01.201716 Processes & Products

YOUR CONTACT:

Andreas Handschke

Technology Manager Multinject/

SpinForm/CellForm (MuCell)

andreas.handschke@kraussmaffei.com

The cycle time in 48-cavity cube molds is reduced to less than ten seconds.

that was founded in 1966. In total, DPI now

employs 60 staff and generated a sales vol-

ume of around seven million euros in 2015. Its

customers include well-known brands such

as BIC, Danone, L’Oréal and Becton Dickin-

son. The portfolio includes thin-walled items,

flip-tops, cosmetic packaging and medi cal ar-

ticles. Here, DPI is able to offer its customers

turnkey systems including the injection mold-

ing machine, mold and installation and is able

to commission the systems. DPI recognizes

the benefit gained by planning and construct-

ing the entire production line around the heart

of production, the injection mold.

Parallel processesIn the case of the 2-component part, the mold

runs through the following cycle: The mold

closes and black polypropylene is injected into

the cavity from the first nozzle side, where it

forms the double-circle part body. The mold

opens and the cantilevered turn over unit of

the injection molding machine and rotates it

by 90° in only 1.1 seconds. The first preform

cools on its side while the next one is already

being formed. After another 90-degree rota-

tion, the first part body reaches the 180° posi-

tion where it is overmolded with TPE, thereby

obtaining its seal. To ensure the quality of this

seal, it is crucial that the material for GXW,

unlike the material for toggle machines, can

be fed in without detours and that the dwell

time in the melt channel is as short as pos-

sible. The finished 2-component part arrives

in the 270° position on the operator side at

the next station and it falls freely out of the

mold. Since the injection processes, cooling

times and demolding take place constantly

and concurrently, the mold produces a fin-

ished can closure in less than ten seconds.

Jean-Benoit Langlois says: “We see a clear

trend at DPI for our future projects in this high

productivity increase.” Due to the extremely

positive experiences in the collaboration, DPI

and KraussMaffei desire to cooperate more

closely in the future so that they can become

more active in the market of cube molds and

swivel plate machines.

THE VITAL COMPONENT OF THE PULL TAB

A 2-component base body made from black

polypropylene with a transparent TPE seal.

A LOOK AT A CUBE MOLD

The cantilevered turnover unit rotates the cube

mold 90° in just 1.1 seconds.

17KraussMaffei Processes & Products

HOW AUTOMATED GRIPPERS PROVIDE

VALUABLE SUPPORT IN PRODUCTION

PROVEN GRIPPING CAPABILITY

Gripper systems are the underestimated helpers in

production. Like human hands, they have to be delicate,

but also respond with the necessary force. In uniform

concepts, they reduce the cycle time and conserve

production space.

TEXT: DR. SABINE KOB, PETRA REHMET PHOTOS: KRAUSSMAFFEI

AHEAD Issue 01.201718 Processes & Products

YOUR CONTACT:

Michael Flurl

Product Manager for Automation

michael.flurl@kraussmaffei.com

he variety of sizes, weights and

equipment is enormous. Grippers

are required for bulky components

and for micro injection molding or

articles that are unstable, mak-

ing them hard to grip. Previously, the largest

KraussMaffei gripper measured 2.5 meters,

which resulted from the size of the insertion

parts. The components that were most diffi-

cult to move were the pipe fittings with a di-

ameter of up to 500 millimeters and a weight

of up to 120 kilograms. On the other hand, a

silicone membrane that was demolded at the

K 2016 KraussMaffei trade show booth was

only 0.03 grams, but had 32 cavities.

FiberForm technology demonstrates the com-

plexity of gripper topics within a single produc-

tion process. In FiberForm technology, organic

sheets (platen-shaped semifinished products

with continuous fibers made of glass, carbon

or aramid) are impregnated with a thermoplas-

tic matrix. To separate heating of the organic

sheet and demolding of the finished component

in terms of time, it is advisable to use two lin-

ear, twin robots (in other words, two kinematic

units/robots that each have up to six axes).

Kine matic unit 1 requires grippers that can pick

up the cold organic sheet and then the finished

article at a later stage. This process is carried

out using a gripper with suction devices. Kine-

matic unit 2 must handle the fixed and flex-

ible organic sheet. Then, thereʼs the matter of

temperature resistance during the process of

heating the organic sheet. A gripper with par-

allel gripper has proven to be ideal in this case.

Extensive experienceWith complex tasks such as this, it is useful

if there is plenty of experience in the project

team. Since the founding of the KraussMaffei

Automation division in 1982, it has been active

in the construction of grippers and, as a result,

delivers customized automation solutions for

injection molding technology, from design all

the way to project engineering, including the

peripherals. Robot types for linear and indus-

trial robots and SPX 10 sprue pickers form the

basis of this product port folio. Especially when

using complex systems, it pays to configure the

automated grippers for use with the mold and

component.

The ever-increasing networking of machines

and production processes is also increas-

ing requirements for part handling. Some

KraussMaffei customers who carry out pro-

duction with almost no employees also order

gripper stations for their removal grippers. If

multiple articles are traveling on a system and

the mold change is fully automated, this must

also be possible for the gripper.

Conserving weight with 3-D printingAnother trend is grippers production using

a 3-D printer. This enables weight conser-

vation, unusual designs and often simplifies

the function of the component. It is easier to

integrate cables and hoses into the gripper,

which bene fits the function-oriented design

and opti mizes the dimensions of the grip-

per. Thomas Marufke, Managing Director

of KraussMaffei Automation, views this as

MODULAR AND ENGINEERED

The modular gripper design

consisting of simple standard

components is suitable for small,

simple models, and the customized

engineered variants (pictured here)

for complex versions.

Ta growth market. “We are producing more

and more components in additive processes

because they allow us to optimize the design

and weight of our grippers during production.”

Printing a gripper instead of building it from

individual components can also reduce re-

plenishment times.

Gripper systems have earned their reputation

as small helpers with a significant effect. That

is because only these systems enable the im-

plementation and combination of a wide varie-

ty of working steps. They implement complex

demolding processes, feature sensors that

detect components and can help to reduce

cycle times and conserve production space

for uniform concepts. Ultimately, the main

dilemma is how best to grip and hold parts

with various designs, materials, temperatures

and other ambient influences. The solution

may be a gripper with suction, a clamping,

parallel, needle, or internal gripper, a grip-

per finger, gripper with demolding stroke, or

a number of other possibilities.

19KraussMaffei Processes & Products

specifically adjusted to the properties of the

end products,” explains Josef Renkl, Head of

Pultrusion Development. In addition, the cur-

rent, conventional open resin bath is omitted.

The system becomes more compact, and the

production even faster.

In addition to speed, flexibility is another great

strength of the new iPul pultrusion systems.

Linear profiles and profiles with complex

YOUR CONTACT

Wolfgang Hinz

Business Development

and Sales Management Pultrusion

wolfgang.hinz@kraussmaffei.com

igh-strength, lightweight and

corrosion-resistant – pultruded

plastic profiles are ideal for ap-

plications in the construction and

wind power industries. However,

the most important decision criterion for

cost-effective series production is short cy-

cle times and a high degree of automation.

This is exactly what KraussMaffei Reaction

Process Machinery experts are leveraging.

“The typical tub and pull-through processes

on the market generally aim for speeds of 0.5

to 1.5 m/minute. Our target for the new iPul

pultrusion systems is a significant increase

to more than 3 m/minute,” explains Wolfgang

Hinz, Business Development and Sales Man-

agement Pultrusion at KraussMaffei. This

opens up entirely new applications and mar-

kets for pultrusion.

The new pultrusion systems combine the direct

injection of the matrix material and the radius

pultrusion process of Thomas Technik GmbH

in a unique way. The technical and economic

advantages are clear. “The metering technol-

ogy optimized specifically for the pultrusion

process carries out direct and continu ous in-

jection of the matrix material into the injection

box. This means the matrix systems can work

with a higher reactivity, which in turn can be

NEW IPUL PULTRUSION MACHINE SETS GLOBAL STANDARDS

MORE SPEED DURING PULTRUSION

KraussMaffei Reaction Process Machinery is utilizing a new approach to revolutionize the pultrusion

process for continuous production of highly filled, fiber-reinforced plastic components. A new efficient

system solution with significantly higher production speeds is the focus of the development.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

Hcross-sections, as well as 2- or 3-dimen-

sional bent profiles, can be produced. A wide

array of matrix materials such as epoxy, poly-

urethane or, in the future, polyamide 6 can be

processed. Fibers made from glass, carbon,

basalt and aramid are primarily used as re-

inforcing fibers. It is also possible to directly

work in additives such as mineral fillers, pig-

ments or flame retardants.

Global system providerKraussMaffei is working closely with renowned

partners from the chemicals industry to

develop the new pultrusion technology. Poly-

urethane-based profiles for large-format win-

dows with simultaneously narrow frames are

one of the topics of collaboration with Covestro.

The second project (Evonik) with epoxy material

and glass fibers also comes from the construc-

tion industry. The third application (Huntsman)

comes from the wind power industry. Here it

is about the production of pultruded reinforce-

ment elements for particularly large-format

rotor blades in wind turbines.

Leading expertise in metering technology for

fiber composite applications and decades of

experience as a system provider are represent-

ative of KraussMaffei Reaction Process Ma-

chinery. This is supplemented by a wide global

sales and service network. “This combination

is unique in the world in the area of pultrusion.

We are thus offering our customers significant

added value,” adds Renkl in summary. UNIQUE COMBINATION

The new iPul pultrusion machine

combines the advantages of direct

injection of the matrix material

with the advantages of the radius

pultrusion process.

IPUL

KraussMaffei will be presenting exciting

applications and the new iPul pultrusion

machine together with its partners at

“Pultrusion” Competence Day in Munich on

June 28, 2017. We invite customers and other

interested parties to attend this event.

www.kraussmaffei.com/pultrusion

injected. innovative. integrated. industrialized.

Pultrusion Technologies

Partners & Projects AHEAD Issue 01.201720

Partners & Projects

“ Our target for the new iPul pultrusion machines is a significant increase to more than 3 m/minute.” WOLFGANG HINZ, BUSINESS DEVELOPMENT AND SALES MANAGEMENT PULTRUSION

Partners & ProjectsKraussMaffei 21

THE PRODUCT DEFINES THE TECHNOLOGY

LIGHTWEIGHT CONSTRUCTION WITH PERSPECTIVES BEYOND VEHICLE MANUFACTURING Recently, development of lightweight plastic construction has been increasingly dynamic. Initially,

the parts that were produced were primarily large-format components for vehicles and plastic

household appliances. In the meantime, new materials and manufacturing processes have

increasingly enabled cost-effective manufacturing of load-bearing parts made from composite

materials. KraussMaffei supports this trend with combined expertise from the areas of injection

molding technology and reaction process technology.

TEXT: GERHARD KONRAD PHOTOS: KRAUSSMAFFEI, FORWARD ENGINEERING

BOOST IN EFFICIENCY

FiberForm components are light-

weight, stable and cost-effective.

AHEAD Issue 01.201722 Partners & Projects

oday, technologies such as FiberForm, wet molding,

T-RTM, S-RTM, HD-RTM technology and now, pultrusion

(more on page 20), are offering new perspectives on for-

ward-looking products and applications. In this area, we

are a pioneer for sustainable development. Even with tech-

nologies such as LFI, FCS or SCS (sandwich technology using loaders),

KraussMaffei can draw on its longtime experience in many fields of

application.

Lightweight and cost-effective“The triumph of fiber composite technology is well-deserved because,

compared to steel or aluminum, carbon is 80 to 50 percent lighter

respectively,” explains Erich Fries, Head of the Composites/Surface

Business Unit at KraussMaffei. Lightweight plastic construction also

provides advantages when it comes to costs. Depending on the geome-

try of the component, cost savings of up to 15 percent can be achieved.

In addition, the lightweight components such as door modules for vehi-

cles can be produced in an integral design. Surface finishing can also

be integrated into the manufacturing process.

The process is defined by cost-effectiveness and function To determine the best process for series production of a component,

the desired product properties are just as important as the productivity,

material costs and investment. KraussMaffei is the only company in

the industry to offer a choice between all common injection molding,

extrusion and reaction process machinery technologies and intelligent

combinations of these technologies. At KraussMaffei, plastics proces-

sors find expert contacts for these issues. “We work with the customer

to create an optimum, customized production and automation solution

from a diverse KraussMaffei portfolio of machine series and processes

in the TechCenter,” stresses Fries.

KraussMaffei is the only provider on the market manufacturing

machines and systems for all types of plastics processing in-house:

Mixing/metering systems, compression molding and milling centers

for reaction process machinery as well as classic injection molding

machines. Automation solutions and material supply are also included

in our product range.

Materials for any requirementCarbon fiber is the top of the line when it comes to fibers used for

composite components. The use of carbon fibers in finished com-

ponents provides an advantageous ratio of weight to mechanical

characteristic values. As a result, these components are primarily

used for structural components. But due to the comparatively high

costs, carbon fibers are often only cost-effective for certain appli-

cations. Components that have fiber-glass reinforcement instead of

carbon-fiber reinforcement still offer excellent properties at sub-

stantially lower costs. Hybrid applications such as those presented

by KraussMaffei at the K trade show also enable cost-effective pro-

duction of components as fiber composite parts, such as roof frames

for vehicles. In addition, other fibers such as natural fibers may be

useful depending on the application.

Capable of being recycled and thermally utilizedAnd last but not least, lightweight components made from compo-

site materials can be reused. This means that products made from

poly amide 6, which is processed in a T-RTM process, can be used

as a secondary material or filler in injection molding. This is highly

cost-effective, particularly for premium-quality carbon fibers. Thermal

utilization for energy generation is another option.

T

HIGH LEVEL OF AUTOMATION

Grippers handle organic sheets quickly and precisely.

15% Up to

cost savings.

23KraussMaffei Partners & Projects

FiberForm offers advantages in the automotive sectorStructural components made from fiber-reinforced composites are

quite popular, particularly in vehicle manufacturing. Less mass cuts

back on fuel consumption and CO₂ output. Solutions that can offset

the high weight of batteries are important to the booming electro-

mobility sector.

FiberForm combines the thermoforming of organic sheets with in-

jection molding. Components with customized mechanical properties

are produced through a combination of lightweight construction with

respect to both the material and design. In addition, a high level of

functional integration is possible. Recently, KraussMaffei set new

WET MOLDING

Energy-saving operations,

cost-effective investment.

standards for productivity and quality in this area. “It’s all happen-

ing with FiberForm technology at the moment. By the end of 2017,

KraussMaffei will have installed approximately one dozen FiberForm

systems in Europe and Asia,” explains Technology Manager Stefan

Fenske with pride.

The reason is easy to understand. “In designs suitable for fiber com-

posites, FiberForm components can reduce weight by 30 to 50 percent

compared to conventional materials,” explains Fenske. “And thanks to

this weight reduction, the components can usually be produced at no

additional cost.”

High quantity elasticityPreviously, the manufacture of lightweight components based on reac-

tion process machinery processes was primarily useful for premium-

quality applications. Thermoplastic FiberForm manufacturing, on the

other hand, utilizes organic sheets. It offers the potential of efficiently

producing components in large quantities (e.g. four million units per

year) for applications in mid-class vehicles. FiberForm is even cost-

effective for batches with 5,000 units.

Series modules for future-proof investment The KraussMaffei FiberForm process is also very cost-effective as an

investment. Through the use of horizontally clamping standard injec-

tion molding machines, this process can also be used for conventional

injection molding orders, even after the FiberForm project. Very short

organic sheet transfer times can be achieved with FiberForm because

the infrared heating station is typically located on the fixed platen.

“Quick transfer of the hot, flexible organic sheet into the mold is vital.

The close proximity of the infrared heating station to the mold allows

us to achieve very short transfer times,” stresses Fenske.

Wet molding reduces weight, energy and timeThe wet molding process is another alternative to the series produc-

tion of fiber-reinforced lightweight components. “Conditioning of the

magazine largely eliminates the need to carry out complex preforming.

AWARD

As a partner of Forward Engineering, KraussMaffei

received the JEC Award 2017 in the Automotive/

Structural category for the T-RTM process.

50% Up to

weight reduction com-pared to conventional

materials.

AHEAD Issue 01.201724 Partners & Projects

YOUR CONTACT:

Erich Fries

Head of the Composites/Surfaces Business Unit

erich.fries@kraussmaffei.com

Stefan Fenske

Technology Manager for FiberForm & IMC

stefan.fenske@kraussmaffei.com

In the wet molding process, certain design guidelines must be applied

that relate to the component and mold. But the process is carried

out with low mold cavity pressures, meaning that the press tonnage

is relatively low. This reduces energy consumption and investment,”

explains Sebastian Schmidhuber, Head of Development for Reaction

Process Machinery at KraussMaffei.

On request for surfaces: S-RTM KraussMaffei made the S-RTM process available in 2013. Here,

S stands for surface. The process consists of two steps. In the first step,

a dry semifinished fiber product is infiltrated in a C-RTM process. In the

second step, the semifinished product is flow-coated with a specific,

UV-stable surface material. This provides the desired surface, which

will boast various colors and properties if necessary.

The third dimension: T-RTMAnother new development is the T-RTM process, which was presented

at the K 2016 trade show. This consists of an in-situ polymerization

from ε-caprolactam to polyamide 6 in an RTM process. A material

hybrid (fiber composite and metallic loaders) and a fiber hybrid (glass

and carbon fiber) were shown in this application.

“ In designs suitable for fiber composites, FiberForm components can reduce weight by 30 to 50 percent compared to conventional materials.” STEFAN FENSKE, TECHNOLOGY MANAGER

ightweight, stable and safe. These

are requirements for the electric

vehicles of the future. As part of

the LEIKA research project, sci-

entists and industry partners fo-

cused on the use of new hybrid materials

made from metal and fiber-reinforced plas-

tics (FRP) as well as their processing for

large series production. The new lab sys-

tem at ILK demonstrates how lightweight

construction in auto body components, or

LEIKA, can function. This system allows

FRP-metal hybrid materials to be formed and

back injected in one step. The advantages are

clear. The process and structure quality are

excellent, the cycle times of significantly less

than two minutes support the potential of

DISCOVERING NEW MATERIALS AND PROCESSES

THE HYBRID IS THE FUTURE OF E-MOBILITY Hybrid processes and materials made from fiber-reinforced plastics

and metal for the automotive lightweight construction of tomorrow

are the focus of the LEIKA research project. KraussMaffei is devel-

oping this project along with the Institute for Lightweight Engineer-

ing and Polymer Technology (ILK) at Dresden University of Techno l-

ogy and with other partners.

TEXT: PETRA REHMET PHOTO: TU DRESDEN (ILK)

Lsuch hybridization on both the material and

production end.

Another great advantage of the new test sys-

tem is its flexibility. This system is suited both

for the manufacturing of components by injec-

tion molding and for the back injection of semi-

finished products. Furthermore, plastics can

be used for reinforcement for local areas in the

component. “The new test system lets us pro-

ject a large number of incredibly varied pro-

cesses on a single system. This lets us offer

significant added value to our partners from

the automotive industry,” says Dr.  Michael

Krahl, Project Manager and person in charge

of LEIKA at the Institute for Lightweight Engi-

neering and Polymer Technology.

AHEAD Issue 01.201726 Partners & Projects

YOUR CONTACT:

Martin Würtele

Head of Technology Development

martin.wuertele@kraussmaffei.com

THE NEW LAB SYSTEM

Enables hybrid FRP-metal materials to be formed

and back injected in one step.

Combined expertise in injection molding and extrusionFlexibility is also a subject of major interest

in the implementation of individual system

components. This is why KraussMaffei de-

signed a bolt-on unit of reduced height which

is completely integrated with the production

line including a press, infrared oven, robot

and conveyor belt. The unit is capable of both

injection molding and extrusion, portioning

the injection volume in the process. As stated

in the requirements specifications, up to five

areas can be reinforced locally in one cycle.

Another feature of note is the conveyor belt’s

full integration into the system to make it

possible to deposit the individual portions of

plastic. “The speed of the conveyor belt re-

sults directly from the process parameters,

such as injection speed or throughput. This

is a clear advantage for employees at the In-

stitute for Lightweight Engineering and Poly-

mer Technology because there is no longer

any need to set the conveyor belt manually

beforehand and there is no discharged melt.

In the event of a change in discharge speed,

the conveyor belt speed adapts automatical-

ly and with deliberate control,” says Martin

Würtele, Head of Technology Development at

KraussMaffei.

Mass reduced by 25 percentUsing the floor structure for electric vehicles

as an example, the partners demonstrated

the suitability of real-world implementation

in series production for the innovative hybrid

materials and their processes. For the center

tunnel, the scientists combined metallic outer

layers of steel with a core of CFRP. “The first

test results are impressive.” The mass is re-

duced by 25 percent compared to an all-metal

lightweight construction solution. Simultane-

ously, it was possible to demonstrate compa-

rable performance under the most important

load conditions with regard to stiffness and

crash situations for components with signifi-

cantly lower mass.

The groundwork has been laid for the use of

hybrid materials and their processes in large

series production. There seems to be nothing

standing in the way of hybrid lightweight con-

struction in the electromobility sector.

27KraussMaffei Partners & Projects

eat cushion production is quite

complex from a process tech-

nology standpoint,” explains Carl

Alaerts, Corporate Plant Engi-

neering Manager at Proseat. “To

achieve optimum comfort and stability, the

cushions are equipped with multiple hardness

zones. For example, the polyurethane foam

in the bulges, or the border areas in other

words, has to be harder than in the middle

of the seat, i.e. what is known as the mirror.”

The setup of the respective foam thickness

is determined by the various mixture ratios

S

FOAMED SEAT CUSHIONS

High-tech from KraussMaffei for

optimum comfort.

of the components isocyanate and polyol. “In

practice, the intervals from shot to shot can,

in part, be below 0.8 seconds. This means the

mixing head has to be able to switch between

up to six different components very quickly

to ensure that each article zone has precise-

ly the desired foam thickness,” adds Ralf

Moser, Head of Mixing Head Development at

KraussMaffei.

Proseat uses an oval conveyor system

equipped with two RimStar Compact series

six-component metering systems and com-

patible multi-component mixing heads during

production. It gets challenging when another

hardness zone is reached, and the quantity

ratios in the mixing head change. “The pres-

sure at which the components flow into the

mixing chamber must be kept as uniform as

possible. This is the only way to guarantee the

correct mixture ratio and optimal mixing,” ex-

plains Ralf Moser.

Stable pressure ratiosThis is why Proseat opted for the newly de-

veloped KraussMaffei Vario nozzle that of-

fers substantially higher repeatability over

a longer period compared to previously used

spring-loaded nozzles. “With the Vario nozzle,

the pressure is stable even over the course of

YOUR CONTACT:

Ralf Moser

R&D Mixing Head

ralf.moser@kraussmaffei.com

VARIO NOZZLE INCREASES PROCESS RELIABILITY FOR SEAT FOAM

PREMIUM-QUALITY UPHOLSTERYComfort and well-being even on long trips – seat cushions and backrests made

from polyurethane that cleverly combine soft and hard foam make this possible.

At Proseat, an upholstery specialist located in the Spanish town of Santpedor,

the Vario nozzle from KraussMaffei has been providing stable pressure ratios in

mixing heads and therefore high levels of reproducibility during foam production.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI, PROSEAT, ISTOCK

several production shifts and days, not just

during the foaming process.” This allowed

us to increase system availability and reduce

maintenance costs,” states Carl Alaerts. The

technical plant manager sees another advan-

tage of the Vario nozzle in the replacement

of mixing head elements such as blocks and

nozzles. In these processes, the pressure in

the mixing head also remains completely uni-

form thanks to the Vario nozzle.

As a result of the extremely positive experi-

ence, Proseat is now using the Vario nozzles

on other production systems at the Santpedor

location and at the Mladá Boleslav plant in the

Czech Republic.

AHEAD Issue 01.2017Partners & Projects28

Thanks to the Vario nozzle, the pressure in the mixing head remains completely uniform.

SMALL NOZZLE WITH A LARGE IMPACT

The Vario nozzle from KraussMaffei keeps the pressure

constant in the mixing head, even during fast replace-

ments in the output rate of the polyurethane components.

This means it is possible to produce components of vari-

ous sizes and hardnesses with consistently high quality.

It offers clear advantages compared to spring-loaded

nozzles. The Vario nozzle features an air cushion which

counteracts the component pressure. The nozzle needle

moves back and forth in such a way that dampens

pressure changes that occur if there is a variation in the

component throughput. The design without moving seals

also reduces cleaning and maintenance costs.

KraussMaffei Partners & Projects 29

KraussMaffei Group

AHEAD: What do you view as the role of the KraussMaffei Group in the plastics and rubber industry?Dr. Stieler: Our industry is growing worldwide and offers numerous

opportunities. We’re in a good position, and want to take advantage of

the positive momentum from 2016, which was a record year.

AHEAD: What do you view as the specific strengths of the company?Dr. Stieler: We have strong roots and a long and successful tradition in

machine engineering. Today, we have a global structure as one of the

market leaders. Therefore, we are very familiar with and understand

well the wide array of customer needs in many regions of the world.

Our innovative ability with respect to products and systems with lasting

value is the result of the great passion of our engineers and service

technicians. Our technologies set standards for premium quality in

the industry.

GROWTH FROM OUR OWN EFFORTS

KraussMaffei, KraussMaffei Berstorff and

Netstal look back at a long success story. CEO

Dr. Frank Stieler in an interview about the future

of the KraussMaffei Group and its brands.

AHEAD: What can plastics processors expect from the KraussMaffei Group?Dr. Stieler: It is our ongoing mission to offer our customers prod-

ucts and services that give them a competitive advantage. Therefore,

we will continue to expand our product range by adding innovations.

Customers should be in a position to produce the best end product at

the lowest unit costs with our system solutions. We also offer standard

machines and provide our customers with advice on solutions for spe-

cial requirements.

AHEAD: What are the main areas of focus for technical develop-ment in the coming years? Dr. Stieler: The requirement for quick, cost-effective production of new

products in large quantities and for high quality is a daily reality in the

plastics and rubber industry. Digitalization and automation of produc-

tion are increasing in importance. In this area, I see great potential for

added value for our industry.

AHEAD: How is the KraussMaffei Group preparing for the coming challenges?Dr. Stieler: We will continue to grow through our own efforts and accel-

erate growth elsewhere, primarily in China and other Asian countries.

Additional manufacturing and development capacity bring us closer to

our customers there. The brands and locations in Germany and Europe

will be strengthened over the long term with respect to personnel and

technology. This provides security for our customers. They can be sure

that we will continue to work with them to actively shape the future.

“ Our technologies set stan dards for premium quality in the industry.” DR. FRANK STIELER, CEO

30 AHEAD Issue 01.2017KraussMaffei Group

IMPRINT

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

Persons responsible: Imre Szerdahelyi (responsible for content

according to German media law)

Editor-in-chief: Gerhard Konrad

Editorial team: Frank Dalhaus, Stefan Fenske, Jens Fiedler,

Michael Flurl, Erich Fries, Wolfgang Hinz,

Dr. Sabine Kob, Gerhard Konrad, Ralf Moser,

Petra Rehmet, Dr. Reinhard Schiffers, Martin

Würtele, Klaus Zeiler

Photo credits: DPI, Indragraha, iStock, KraussMaffei,

Proseat, Dresden University of Technology

(ILK), Forward Engineering

Concept and design: Kirchhoff Consult AG, Hamburg,

www.kirchhoff.de

Printing: omb2 Print GmbH, Munich

In order to make the magazine easier to read, we

have mostly dispensed with gender-related double

designations (e.g. “male and female readers” – this

is more relevant for the German text) for mixed

groups of persons. The male gender form is used as a

collective term.

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.

THE PET-LINE FROM NETSTAL

First choice for the production of

PET preforms.

THAI BEVERAGE USES THE PET-LINE FROM NETSTAL

The Thai Beverage Public Company Limited (“Thai Beverage”) counts among

the largest beverage bottlers in Thailand and the ASEAN region. The company

distributes numerous popular beverage brands in the region, including beer,

distilled beverages, soft drinks and water.

Now, Thai Beverage is expanding production by setting up its own production lines for PET pre-

forms. With its subsidiary BevTech Co., Ltd., the company has invested in high-performance

injection molding systems from the Netstal PET-LINE series.

Superior technology“Based on our excellent experience, and after the careful consideration of other options, we

have decided to manufacture our own preforms using state-of-the-art and highly efficient sys-

tems from Netstal,” explained Thapana Sirivadhanabhakdi, President and CEO at Thai Beverage.

At the contract signing ceremony in Bangkok, Renzo Davatz, CEO of Netstal stated, “We’re

delighted to be able to success-

fully assert ourselves over the

competition with our superior

technology in terms of perfor-

mance and energy efficiency.”

TRADE SHOW CALENDAR FOR MAY 2017 – DECEMBER 2017

Plastpol, Kielce, Poland 23.05.2017 – 26.05.2017 KraussMaffei Group

Automotive Engineering Exposition (AEE),

Yokohama, Japan 24.05.2017 – 26.05.2017 KraussMaffei

Molding Expo, Stuttgart, Germany 30.05.2017 – 02.06.2017 KraussMaffei

FIP, Lyon, France 13.06.2017 – 16.06.2017 Netstal, KraussMaffei

PSE Europe, Munich, Germany 27.06.2017 – 29.06.2017 KraussMaffei

Competence Day Pultrusion, Munich, Germany 28.06.2017 KraussMaffei

PU Tech Eurasia, Istanbul, Turkey 11.07.2017 – 12.07.2017 KraussMaffei

China Composites Expo, Shanghai, China 06.09.2017 – 08.09.2017 KraussMaffei

Drinktec, Munich, Germany 11.09.2017 – 15.09.2017 Netstal, KraussMaffei

Competence Day, Munich, Germany 14.09.2017 KraussMaffei

Composites Europe, Stuttgart, Germany 19.09.2017 – 21.09.2017 KraussMaffei

RubberTech, Shanghai, China 20.09.2017 – 22.09.2017 KraussMaffei Berstorff

Compounding World Asia Congress, Singapore 21.09.2017 – 22.09.2017 KraussMaffei Berstorff

Interplas, Birmingham, England 26.09.2017 – 28.09.2017 KraussMaffei

Iranplast, Tehran, Iran 26.09.2017 – 29.09.2017 KraussMaffei Berstorff

Kunststoffen, Veldhoven, Netherlands 27.09.2017 – 28.09.2017 KraussMaffei

Equiplast, Barcelona, Spain 02.10.2017 – 06.10.2017 KraussMaffei Group

MSV, Brno, Czech Republic 09.10.2017 – 13.10.2017 KraussMaffei

Fakuma, Friedrichshafen, Germany 17.10.2017 – 21.10.2017 KraussMaffei Group

Gulfood Manufacturing, Dubai,

United Arab Emirates 31.10.2017 – 02.11.2017 Netstal, KraussMaffei

Plastimagen, Mexico City, Mexico 07.11.2017 – 10.11.2017 KraussMaffei Group

Andina Pack, Bogotá, Colombia 07.11.2017 – 10.11.2017 Netstal, KraussMaffei

Waterproof Membranes, Cologne, Germany 14.11.2017 – 16.11.2017 KraussMaffei Berstorff

Plast Eurasia, Istanbul, Turkey 07.12.2017 – 10.12.2017 KraussMaffei

KraussMaffei 31Imprint

Engineering Passion

www.kraussmaffei.com/px

The new PX seriesPower meets fl exibilityPower and lifetime flexibility join together in the all-electric PX series.

Individually tailored and expandable at any time, it defines the state of the art

for any industry and any application – all-electric, all-flexible.

The advantages will strike you like lightning!

– Perfectly tailored machine thanks to large number of modular components

– Maximum efficiency and productivity in all sizes

– High-precision dynamic drive technology

– Ergonomic design with maximum flexibility and optimum accessibility

KM_Anz_PX-Teaser4_DE-EN_210x280+3_AHEAD_5c.indd 1 20.04.17 13:27