2 ¦ 2011 made by

Technology know-how for the customers of

PackagingMX machines for fruit andvegetable crates | Page 25

Construction KraussMaffei housing solutions | Page 29

AutomotiveHP-RTM for seriesproduction | Page 18

Life SciencesSterile plasticproducts | Page 26

ElectronicsCooperation withLG Electronics | Page 17

KraussMaffei

Competence

Forum enthuses

customers | Page 8

www.kraussmaffei.com

KraussMaffei is your system partner for fiber-composite processing. We have what it takes for successful solutions:

– High-performance machines and systems

– Application-specific processes to suit your product specs and batch size

– Our expert input to support your product development and manufacturing

There’s not much we don’t know about making lightweight components for automotive interiors, structural parts, bodywork and glazing – why not put our know-how to work for your business?

› INJECTION TECHNOLOGY › REACTION PROCESS MACHINERY › EXTRUSION TECHNOLOGY

Take a lookon the light side

made by KraussMaffeiPublished by: KraussMaffei Technologies GmbH,Krauss-Maffei-Straße 2, 80997 Munich, Germany,Phone +49/89/88 99-0, Fax +49/89/88 99-2206,www.kraussmaffei.comResponsible: Imre Szerdahelyi, Eva Münzenmaier

PUBLICATION DATAEditorial office: mk publishing GmbH,Döllgaststraße 7-9, 86199 Augsburg, Germany,Phone +49/821/3 44 57-0, Fax +49/821/3 44 57-19,www.mkpublishing.dePhoto credits: BYK Kometra, FKT, Fotolia/Finecki/Stefan Körber/Pei Ling Hoo/Radu Razvan, KraussMaffei Group, M|H|Fotodesign/Harald Mehnert, mk publishing/mk Archive, participants at the KraussMaffei Competence Forum 2011, P. E. Schall, Röchling SGT

Dear Readers,

I look back with pleasure on the KraussMaffei Competence Forum 2011 in Munich, to which we welcomed over 1,500 customers. Many of the people I talked with during the Forum congratulated me on the high caliber and communication value of the event and on the impressive number of innovations from our three technology areas. As an engineering company with our unique mix of expertise, we can help to improve processes along your whole value- adding chain. The positive feedback was a sign that our product portfolio plus our engineering and process know-how put us in a strong position to capitalize on future market potential. Among the global trends that will generate higher demand for plastics and rubber machine solutions I count rising demand for process and product efficiency among producers and increased concern for curtailing resource consumption. Today our three brands already offer energy- and resource-efficient machines, intelligent process technologies and multiprocess system solutions.Based on the proven performance of the entire KraussMaffei Group and the expertise and passion of our employees, we look ahead with confidence to the coming months. We’re aware that the current high level of demand in our markets is forecast to swing back to single-digit growth next year. Nonetheless we’ve set ourselves challenging goals and we’ll be aligning the strengths and skills within the KraussMaffei Group as well as reinforcing our enduring partnerships with other technology specialists to the ultimate benefit of our customers.

With best regards,

Dr. Dietmar Straub,CEO of KraussMaffei AG

EDITORIAL

DIALOG

Competence for future trends: lighter weights and fiber composites 04

FOCUS

Innovation in focus at the Fakuma 2011 06

Views and voices on the KraussMaffei Competence Forum 2011 08

NEWS 10–16

EUROMAP energy efficiency study 10/11

ELECTRONICS

Cooperation with LG Electronics 17

AUTOMOTIVE

HP-RTM for series production 18/19

Injection molding applications at Röchling SGT 20

The FiberForm process 21

New co-extrusion head for rubber profiles 22

Extrusion system for TPE/PP composite profiles 23

Integrated manufacturing cells at FKT GmbH 24

PACKAGING

Schoeller Arca Systems opts for MX machines from KraussMaffei 25

LIFE SCIENCES

Manufacturing cell for sterile medical products 26

Polyset applications at Mitras Composites Systems 27

CONSTRUCTION

BYK Kometra: customized extrusion solutions 28

World first – KraussMaffei housing solutions 29

WORLD OF KRAUSSMAFFEI

Subsidiaries celebrate milestones 30/31

Answers at the touch of a button: KraussMaffei Teleservice 32

Networking for success 33

CONTACT 34

CONTENTS

made by2 ¦ 2011

With best regards,

Dr. Dietmar Straub,CEO of KraussMaffei AG

MADE BY KRAUSSMAFFEI 2 ¦ 201104

made by KraussMaffei: With their potential for

weight-saving and high functional integration, plastics

are seen as a versatile solution to product challenges

in many sectors of industry – including the automotive

industry, which this year is celebrating its 125-year

jubilee. How would you say the trend to lightweight

composites is changing cooperation among developers,

processors and machine suppliers?

Frank Peters: German carmakers, for instance, are

spearheading the development of new technologies and

manufacturing processes, especially for lightweight

solutions. The carmakers build on the strengths of a

close-meshed network of trusted suppliers and inno-

vative partners. KraussMaffei is among the preferred

partners for almost all automotive manufacturers and

their components suppliers, thanks to its expertise in

the substitution of traditional materials by lightweight

plastic elements. At present, we have ties to customers

at various levels along the entire value-adding chain,

who are profiting from our lead in process technology.

We can help them to make the most of new opportuni-

ties and efficiency potentials in using reinforced plastics.

made by KraussMaffei: How is the trend to weight-

saving influencing plastics engineering?

Frank Peters: The challenge is to automate manual

processes in order to achieve reliable production on

medium and large series. KraussMaffei currently has

orders to supply machines and systems to manufacture

lightweight composite exterior and structural parts

for series vehicles. We can offer these customers

application-specific machine solutions, integrating

reaction and injection molding processes. I could cite

our SFT MX600 mold carrier in an HP-RTM system.

This configuration includes components which are

used in series-type injection molding machines. Our

customers profit from high-caliber technology, short

order lead times for mature machine technology and a

low capital investment.

made by KraussMaffei: How is KraussMaffei reacting

to changing market demands?

Frank Peters: With our integrated expertise in injection

and reaction molding, we’re able to offer each customer

the optimal machine and manufacturing solution –

whatever the material being processed or the type

of process. Our skill in combining processes helps

customers to reduce the number of process steps and

manufacturing cost through integrating functionality in

the component being manufactured. In Mold Painting,

for instance, offers huge potential for producing fiber-

composite parts with premium surfaces in a single-stage

process.

made by KraussMaffei: What do customers expect of

KraussMaffei as a technology partner?

Frank Peters: If we’re looking at solutions for high-

volume manufacturing of fiber-composite components,

UNIQUE COMPETENCE IN LIGHTWEIGHT COMPOSITES

KraussMaffei has built a strong reputation as a reliable solution partner for its customers. With our integrated technology expertise in systems and processes, KraussMaffei supports customers in their drive to realize efficiency potential along the whole supply chain. The company bundles its experience and know-how to deliver new developments that boost customers’ competitive advantage and help them meet new challenges as market trends change. Lightweight composite projects are a typical example. Frank Peters, a member of the KraussMaffei Managing Board explains how the company develops solutions for its customers.

“Multitechnology expertise is the key to

optimized solutions”

Frank Peters, member

of the KraussMaffei

Managing Board with

responsibility for Reaction

Process Machinery.

DIALOG

For further information pleaseclick here

DIALOG

Structural Component Spraying – are mainly used for

making interior components such as hat trays. LFI, on

the other hand, is ideal for large-format parts with high

glassfiber content, for example, bodywork parts for

trucks, buses and agricultural machinery. We’ll continue

to develop processing solutions for fiber-reinforced

plastics based on our expertise in injection and reaction

molding. We work closely with our customers to define

application-specific manufacturing solutions taking into

account the part size, batch size and specifications. p

then short cycles and fully-automated, reproducible

processes are high on the agenda. We work closely

with the automotive industry and with material and

equipment manufacturers to continuously improve

manufacturing processes. We already offer innovative

processes such as FiberForm, for back injecting

organic sheet, and HP-RTM, for high-strength

carbon-fiber parts. The ‘right’ process depends on the

mechanical specs for the product, the batch size and the

target manufacturing costs.

made by KraussMaffei: Can you give us some

examples?

Frank Peters: Polyurethane spray processes are already

being used in series production of cars and commercial

vehicles. FCS – Fiber Composite Spraying – and SCS –

Our new Fiber

Composites TechCenter

reflects KraussMaffei’s

engineering competence.

05

KraussMaffei is your

technology partner for

the whole spectrum

of fiber-composite

technologies with

their huge potential

(overview left). There’s

more information in

our brochure Fiber

composite solutions for

high spec, lightweight

parts; this English-

language brochure can

be downloaded from

www.kraussmaffei.com.

FIBER COMPOSITE SOLUTIONS

FOR HIGH SPEC,

LIGHTWEIGHT PARTS

Fiber composite

technologies at

a glance

Excellent Very good Good

IM-KGF

Injection molding,

short fiber reinforcement

IM-LGF

Injection molding,

long fiber reinforcement

IMC

Injection Molding

Compounder

FiberForm

Shaping and encapsula-

ting organic sheet

Polyset BMC/SMC

Injection molding

polyester BMC/SMC

R-RIM

Reinforced Reaction

Injection Molding

FCS

Fiber Composite

Spraying

LFI

Long Fiber Injection

SCS

Structural Component

Spraying

HP-RTM

High-Pressure Resin

Transfer Molding

Material properties Part and process specifications Cost

factors

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ab

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y

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MADE BY KRAUSSMAFFEI 2 ¦ 2011

FOCUS

FAKUMA 2011: KRAUSSMAFFEI PUTS THE SPOTLIGHT ON ENERGY AND RESOURCE EFFICIENCY

When the Fakuma opens in Friedrichshafen, Germany, from October 18 to 22, 2011, the KraussMaffei booth (booth 7303 in hall A7) will be giving visitors an insight into our energy- and resource-efficient manufacturing solutions. Evaluating the exhibits from Injection Molding Machinery and Automation, visitors will discover new solutions offering strong potential for savings in energy consumption and floor space.

Productive and efficient

manufacturing solutions

KraussMaffei’s BluePower concept bundles

the company’s varied offering of

energy- and resource-efficient

production solutions. “What

we’ve done is to optimize energy

efficiency right across our product

portfolio and also to introduce

additional BluePower machine

modules. The BluePower approach

kicks off with an analysis of the cus-

tomer’s production situation and details of the

manufacturing process. Using this data, we develop

a customized solution to boost energy efficiency,”

sums up Dr. Karlheinz Bourdon, the Managing

Board member with special responsibility for the

Injection Molding Division at KraussMaffei. “The

custom approach enables us to identify savings

potential very accurately and to slash energy con-

sumption by as much as 50%.” A prime example of

energy efficiency in injection molding

is our AX all-electric injection ma-

chine series, which covers 12 ma-

chine tonnages. On our Fakuma

booth, we’ll be demonstrating

what are currently the biggest and

the smallest AX machines in the

series – the AX 350 and the AX 50

respectively. With their huge choice of

modular options, AX machines can be

readily adapted for many specialized appli-

cations in different industries. At the Fakuma,

visitors will see how BluePower barrel insulation

reduces energy losses from the plasticizing unit. The

extensive functions of a BluePower energy analysis

give operators clear-cut assistance in optimizing ma-

chine settings to minimize energy consumption.

Efficient and compact

Another magnet for visitors at the Fakuma is likely

to be a CXW 200-380/160 SpinForm swivel-platen

machine demonstrating how integrated assembly

can boost production efficiency. “The lightweight,

three-part closures made of polypropylene (PP)

are produced on a machine using innovative cube

technology. They come out of the machine ready

to assemble,” emphasizes Frank Peters, head of the

Reaction Molding Division. Working together with

the moldmaker Zahoransky, KraussMaffei engineers

designed the whole system for highest productivity

and a small footprint. A BluePower servo pump

drive ensures maximum energy efficiency. The other

hydraulic injection molding machine in action will

be a compact two-platen CX 35-180 machine with

an integrated IR 50 I industrial robot. Noteworthy

is the fact that it takes up 25% less space than a

conventional automation solution.

Machine data on your

smartphone

All the machines on the KraussMaffei booth are

fitted with a central computer interface, allowing

production locations to be reliably networked. Also

Cost-competitive

machines from

KraussMaffei’s

AX series score on

precision and efficient

molding of a wide

range of products.

Swivel-platen machines

from the CX series are

engineered for high

productivity.

06

07

FOCUS

manufacturing cells incorporating all-electric

or hydraulic injection molding machines from

the KraussMaffei range. Exhibits like the CX

manufacturing cell with dynamic mold heating/

cooling on the gwk booth once again underline how

KraussMaffei works with specialist partners and

networks to ensure we have the system competence

our customers expect in a single-vendor supplier. p

on show is KraussMaffei’s Mobile Assistant, a

smartphone solution that lets owners and operators

check the operating status and production data of

their machines at any time and from anywhere in

the world. The Mobile Assistant is simple to use

and the data selected by customers are shown in a

clear and coherent format. KraussMaffei developed

the application in cooperation with a software

partner, T.I.G. Technische Informationssysteme

GmbH from Rankweil/Austria. The solution

installed at the Fakuma not only guarantees

fast access to production machine data, but also

safeguards customer data from illegal access and

meets all data security requirements likely to be

set by company IT networks. Other KraussMaffei

machines are on show with three of our partner

companies; in each case they will be demonstrating

KraussMaffei booth: Hall A7, No. 7303

AX 350-1400 with LRX 150 S Currently KraussMaffei’s biggest all-electric

machine. Making technical parts, application

example automotive industry

AX 50-180 Precision parts for the

electrical/electronics industry

CX 200-380/160 W SpinForm Swivel-platen technology and

integrated assembly

CX 35-180 with IR 50 I Manufacturing cell with far smaller

footprint than conventional automation

In addition to the Software solution for checking

machine exhibits: key production data via

the Mobile Assistant smartphone

Max Petek Reinraumtechnik booth: Hall A7, No. 7407

EX 80-380 SilcoSet with All-electric injection molding manufacturing

CleanForm cleanroom cell. Processing liquid silicone with

modules cleanroom technology for a clean mold area

gwk Gesellschaft Wärme Kältetechnik booth: Hall B1, No. 1205

CX 80-750 with IR 50 I Dynamic, ceramic mold heating

for exactly repeatable temperature

profiles

Kistler Instrumente GmbH booth: Hall A3, No. 3104

CX 50-180 Manufacturing technical parts in

multi-cavity, hotrunner molds

INJECTION MOLDING MACHINES IN ACTION

AT THE FAKUMA 2011

INFORMATION

Fakuma 2011 21st international specialist trade show for plastics processingNeue Messe FriedrichshafenOctober 18 to 22, 2011

KraussMaffei in Hall A7, Booth 7303

Opening times:Tuesday to Friday, 9.00 to 17.00 hSaturday, 9.00 to 16.00 h

www.fakuma-messe.de

EX cleanroom machines

are engineered for

precision and cleanliness

up to Class A GMP. See

one on the booth of

technology partner Max

Petek Reinraumtechnik.

For further information pleaseclick here

08 MADE BY KRAUSSMAFFEI 2 ¦ 2011

FOCUS

LOOKING BACK AT THE KRAUSSMAFFEI COMPETENCE FORUM 2011

KraussMaffei welcomed over 1,500 customers and visitors from 25 countries to our Competence Forum on May 19, 2011. On show and in action were more than 30 machines and systems from the portfolios of the KraussMaffei and KraussMaffei Berstorff brands with a clear focus on efficient and optimized process technologies and multitechnology system solutions.

“The reaction of customers and visitors was

totally positive. They were enthusiastic about

our wide range of high performance machines

and systems and our multitechnology process

expertise. These are two of the factors that enable

us to promise customers higher margins along

their whole value-adding chain,” commented

Dr. Hans Ulrich Golz speaking on behalf of

KraussMaffei. Comments from people there on the

day confirm this. Stuart Fry, Managing Director

of Linecross Ltd., UK, for example, was impressed

by the bandwidth of the engineering solutions

and processes. “Also important are the quality

of the products and the consulting skills of our

contacts at KraussMaffei. Linecross has already

given extensive consideration to the carbon-fiber

RTM process and the Competence Forum was a

great opportunity to swap ideas on technology

prospects with other people.” Steve Holwell, head

of Commercial Sales in the same company, added:

“I’m here primarily to find out more about PU

solutions. The Competence Forum as a whole and

the chance to talk with experts from KraussMaffei

have given me outstanding opportunities to do

just this.”

Automated solutions scored a hit

Multitechnology processes like the ones which

were demonstrated at the Competence Forum meet

the needs of our customers. Michael Haslinger,

Process Engineer at Johnson Controls Interiors

GmbH & Co. KG, agrees and cites the SkinForm

process as an example: “This technology and the

compact manufacturing cell was what fascinated

us. This new, space-saving application for automo-

tive interior components means that in future

we’ll be able to produce more efficiently and price

competitively.” KraussMaffei’s robot systems were

of special interest to Oliver Drefs, Managing Part-

ner at MKT GmbH: “As manufacturers of plastic

components for cars and commercial vehicles

we’re intensely interested in this type of solution.

In view of the global competitive pressure nowa-

days, we need advanced, fully automated manufac-

turing cells for our German plant in order to stay

competitive and protect jobs in the long term.”

Big interest in multiprocess synergies

At KraussMaffei’s Munich plant, KraussMaffei

Berstorff brand machines and technology were on

display in the Extrusion Hall, while the new joint

The venues for the Competence Forum

were the Extrusion Technology TechCenter

(below) and the new joint TechCenter for

Injection Molding and Reaction Process

Machinery (right) in Munich.

Michael Haslinger,

Johnson Controls

Interiors GmbH &

Co. KG.

Oliver Drefs, MKT GmbH,

Finnentrop, Germany.

Paolo Diena,

Dow Italia s.r.l.

Visitors impressed and

enthused by engineering

expertise

09

FOCUS

TechCenter operated by Injection Molding Machin-

ery and Reaction Process Machinery was the venue

for all KraussMaffei brand exhibits. The visitors

welcomed this approach. Paolo Diena, R&D Senior

Development Chemist Thermoset Systems at Dow

Italia, commented: “By showcasing the different

technologies side by side, KraussMaffei made it

easy to understand and appreciate the synergies. Of

the PU technologies on display, the ones that really

fascinated me were LFI, FCS and RTM.” Andreas

Villiger, Managing Director of Mythentec AG in

Switzerland, agreed and added: “The multiprocess

applications in action during the Forum clearly il-

lustrated KraussMaffei’s engineering lead – and the

huge effort that went into ensuring the success of

the event showed how much the company values its

customers. All this together with the good support

and service makes KraussMaffei a valuable partner

for us.”

Partnership is a top priority

Many customers commented on the idea of part-

nership which pervaded the Competence Forum.

As Maurizio Rachelli from Startec s.r.l., Italy,

points out: “It’s important for us to know that

we can work with a technology partner whose

engineering development and product solutions

are always state of the art. Our company has been

active in the field of technical injection molding

for 30 years. KraussMaffei is the only supply

partner who has stayed with us all through this

long time, supplying us with hydraulic and all-

electric solutions.” Especially welcome to many

visitors were the opportunities the Forum offered

as a specialist communication platform. Klaus

Bienstein, Operations Manager at KSM Kunst-

stofftechnik, explains: “We were able to get a very

good overview of the machine and service world

of KraussMaffei. In addition, we were able to

exchange ideas in a very concrete and practical way.

In particular, we were able to explore the whole

subject of adaptation in face-to-face discussions

with KraussMaffei experts.” So what’s the verdict

on the KraussMaffei Competence Forums 2011?

Dr. Ulrich Riedel from Johnson Controls GmbH

sums up many people’s opinion: “With a series

of compact talks on topics which included RTM

and automation, KraussMaffei has reinforced its

reputation for outstanding engineering expertise.

Linking individual process steps in a very compact

system is an important success factor along with

short process cycles and a low capital investment.

We also enjoyed the program of entertainment and

events and the evening get-together which rounded

off the Competence Forum. It was a real trade show

highlight.”p

Dr. Ulrich Riedel,

Johnson Controls GmbH.

Andreas Villiger,

Mythentec AG,

Biberist, Switzerland.

Maurizio Rachelli

and Anna Radman,

Startec s.r.l., San Vito al

Tagliamento, Italy.

Klaus Bienstein, KSM

Kunststofftechnik GmbH

& Co. KG, Meschede,

Germany.

10 MADE BY KRAUSSMAFFEI 2 ¦ 2011

NEWS

TALKING ABOUT THE EUROMAP ENERGY EFFICIENCY STUDY

The European Commission has set ambitious goals for improving energy efficiency. They’re going to affect the whole plastics and rubber industry. On the initiative of its president Bernhard Merki, EUROMAP, the European Association of Plastics and Rubber Machinery Manufacturers, has commissioned Urbanek Innovation Consulting to analyze the industry’s potential in this area. Talking to made by KraussMaffei, Dr. Otto Urbanek discusses the study’s findings to date.

made by KraussMaffei: Dr. Urbanek, the EU

commission wants to reduce energy consumption by

20% by 2020. You’re looking at the current situation

and the potential for savings. Can you tell us about

your results to date?

Dr. Otto Urbanek: The EU energy efficiency goals

will have an impact on the technology of plastics

and rubber machinery as well as on process

engineering. They’ll also influence market dynamics.

In the past 20 years, significant improvements

have been made to the energy efficiency of the

machines – although the main emphasis has been

on increasing productivity. Further innovations

have already been realized and there are more

in the pipeline. The continuous renewal of the

European machine population, aimed basically at

boosting productivity will make further significant

energy efficiency gains possible. European machine

technology is at a good level, but there’s still

potential for improvement.

“End-to-end optimization

is the game changer”

“By exploiting existing potential and with even more innovation, it is absolutely feasible to achieve the required reduction in energy consumption by the target date.”

Dr. Otto Urbanek

11

the economic relevance of energy consumption is

transparent, concrete measures can be planned to

reduce consumption. I am convinced that in all

machines and processes there is still unexploited

potential for saving energy and money – and

simultaneously increasing productivity.

made by KraussMaffei: In which areas of plastics

processing do you see the biggest potential for

reducing energy consumption – and is the target

actually reachable?

Dr. Otto Urbanek: In our study we evaluated four

main technologies – injection molding, extrusion,

blow molding and thermoforming – and we

surveyed a large number of manufacturers and

processors. Overall, it’s possible to identify bigger

potential for energy efficiency savings in machines

running cyclical processes. Summing up, my

assessment is that, for the machine technologies

we looked at, the target of a 20%

reduction in energy consumption

by 2020 will certainly be achieved

through further innovations. p

made by KraussMaffei: What do you see as the real

game changer in reducing energy consumption?

Dr. Otto Urbanek: We can look at energy

consumption in three main ways: consumption

for the whole factory, consumption for a specific

product or consumption for a specific machine. In

most companies, the only known value is energy

consumption for the whole factory. Because it is

not specific enough, this value is, at most, useful as

a reference against which to assess any reductions;

it’s no basis for planning concrete improvements.

The essential value is product-specific consumption,

ie, the total energy that goes into making a certain

product. The production machine will inevitably

account for some of this consumption, but typically

the machine itself is responsible for only a fraction

of the total product-specific energy consumption.

The real game changer is the ability to evaluate –

and then optimize – the entire process. In identifying

savings potential, it’s important to bear in mind

that there are some areas that cannot be influenced,

for instance, the energy input required to melt

the plastic before it is shaped. The use of energy

monitoring systems to capture product-related

consumption data is becoming important in the

effort to make processes more transparent. Once

INFORMATION

Dr. Urbanek Technologie

Management GmbH,

Ried im Innkreis, AustriaUrbanek Innovation Consulting:www.urbanek-consulting.com

“KraussMaffei has optimized the energy efficiency of its portfolio of injection

molding machinery across the board. In addition, we have introduced a

range of BluePower machine modules for application-specific adaptations.

We’ve also added the Energy Analyzer to the MC5 control system. This gives

customers a tool with which they can analyze the energy consumption of a

their machines in two ways: by process phase and by individual consumers.

Armed with this data, the machine operator can fine-tune the machine to

minimize consumption. With the Energy Analyzer,

customers can also compare energy consumption

and energy costs across different machine types

and versions for entire processing sequences.”

THE KRAUSSMAFFEI APPROACH TO OPTIMIZING

ENERGY EFFICIENCY

Dr. Karlheinz Bourdon, member of the

KraussMaffei Managing Board with

responsibility for Injection Molding Machinery.

NEWS

12 MADE BY KRAUSSMAFFEI 2 ¦ 2011

designed for extremely cost-competitive production.

Typical AX application areas lie in energy-efficient,

repeatable production for many industry sectors,

such as automotive, electrical/electronic, household

and garden. By contrast, KraussMaffei’s EX series

shows its strengths in high-spec applications requiring

the highest precision, cleanliness and performance.

These qualities are in demand in medical technology,

electronics and packaging products. Here too

KraussMaffei has filled a gap in the product spectrum,

this time with a 200 tonne machine. The EX series

is now available in six tonnages between 50 and

240 tonnes. They’ll soon also be available with the

optional Ultra injection units – for all applications

that make very high demands on injection speed. p

KraussMaffei customers investing in an AX series

machine now have a choice of 12 tonnages, ranging

from 50 to 350 tonnes. The latest addition is a

280 tonne machine. As with all machines in the

series, the AX 280 can be configured with different

plasticizing units and a range of optional add-ons. All

aspects of the all-electric AX machine concept were

Complete clamp force spectrum

NEW ALL-ELECTRIC INJECTION MOLDING MACHINE MODELS

With the launch of the new AX 280 and EX 200

injection molding machines, KraussMaffei has

expanded both of its electric product lines. Offering

the complete clamp force range means that we

can meet all customer requirements – both in the

standard and high-end areas – with application-

specific manufacturing cells.

KRAUSSMAFFEI BERSTORFF TECHNOLOGY FOR INLINE DIMENSION CHANGE

QuickSwitch on course for success

Rising raw materials prices and worldwide pressure

to cut resource consumption are driving demand for

cost-competitive pipe production systems. In this

environment, many major pipe producers in Europe

have invested in QuickSwitch systems, an energy-

and resource-efficient solution from KraussMaffei

Berstorff.

Recently KraussMaffei Berstorff booked four orders

for complete QuickSwitch lines within a few days. A

Belgian customer ordered two systems for the diameter

ranges 25 to 63 mm and 70 to 160 mm. The complete

systems included KraussMaffei Berstorff 36D single-

screw extruders, spiral distributor pipeheads and the

QuickSwitch calibration technology. Another complete

QuickSwitch production line for pipe in the 160 to

250 mm diameter range is being installed in the German

plant of one of the world’s major pipe producers. This

line also features KraussMaffei Berstorff’s Internal Pipe

Cooling (IPC) system enabling the producer to step

up output without the cost of a longer cooling zone. A

customer in Italy will soon be producing multilayer

PO pipe up to 160 mm on a new QuickSwitch system.

“We’re delighted that, especially in the European market,

our QuickSwitch system is making a major contribution

to efficient pipe production,” emphasizes Andreas

Kessler, Sales Manager, Extrusion Technology, at

KraussMaffei Technologies GmbH. p

NEWS

The only waste from

the dimension change

is a short piece of

tapering pipe.

QuickSwitch extrusion

line for polyolefin pipe.

The EX (above) and

AX series are being

extended.

13

and more of our customers are profiting from

the added value delivered by efficient manu-

facturing cells. These cells are made possible

through the intelligent convergence of robots

and injection molding machines,” points out

Dr. Karlheinz Bourdon. KraussMaffei’s Automa-

tion arm was founded by Josef Neureder in

1982, since then its core business has been

automating injection molding operations using

linear and industrial robots. “The extension will

enable us to meet growing demand and also to

ensure that customer’s confidentiality require-

ments are fully respected,” says Bourdon. The

new production area is due to be finished in

October and production is scheduled to start in

early November. p

The high-caliber reaction systems on show in

KraussMaffei’s new TechCenter include advanced

systems for fiber composite components. One unique

feature of the Reaction TechCenter is the close link

to the adjacent Injection Molding TechCenter.

KRAUSSMAFFEI OPENS THE WORLD’S BIGGEST FIBER COMPOSITES TECHCENTER

A place to check out

multiple options

On April 12, 2011, Dr. Karlheinz Bourdon and

Josef Neureder from KraussMaffei management

gathered with employees and local politicians for

the groundbreaking ceremony to launch

construction of a second production hall in

Schwaig. The new building will expand the floor

space from 670 to 1,570 square meters. “As

demand for automated injection molding cells

continues to grow, it’s become necessary to more

than double our production facility here. More

ESCALATING DEMAND DRIVES EXPANSION

More production space

for robots

KraussMaffei is doubling the production space at

the plant in Schwaig near Munich where we build

our robots and plan automation solutions. With

construction finished, work is focused on fitting out

the interior and the assembly areas.

On May 13, 2011, KraussMaffei opened the world’s

most versatile TechCenter for the production of

lightweight composite parts. There are substantial

benefits for customers in the proximity of the

two TechCenters and close cooperation between

KraussMaffei experts with specialist know-how in

reaction and injection molding bring. The official

ribbon-cutting to open the new facilities was a joint

effort by Dr. Karlheinz Bourdon, Frank Peters (both

Managing Board members of

KraussMaffei), Wolfgang Frehsdorf

(Operations Manager for Reaction

Process Machinery) and Nicolas

Beyl (Director Technology).

“We’re delighted that the new

combined TechCenter and the

unique juxtaposition of reaction

and injection molding machinery

will enable us to show customers

the widest possible range of

processing options. It enables us to define optimal

process solutions for a customer’s application and

to thoroughly test processes and part designs,”

explained the two Managing Board members. The

new joint TechCenter gives KraussMaffei around

4,000 square meters of floor space in which to

demonstrate its special engineering and market

know-how. p

Construction and

equipping the new

production building in

Schwaig is progressing

apace.

Frank Peters,

Wolfgang Frehsdorf,

Dr. Karlheinz Bourdon

and Nicolas Beyl

(l. to r.) at the opening

of the new TechCenter.

14 MADE BY KRAUSSMAFFEI 2 ¦ 2011

The latest physical foaming

technology

FIRST SCHAUMTANDEX LAB SYSTEM FOR FRAUNHOFER INSTITUTE

The ZE 30/KE 60 Schaumtandex line comprises a

ZE 30 UTX twin-screw extruder to melt and mix

the resin and a KE 60 single-screw extruder to

cool the melt. The ZE 30 UTX is a new machine

design premiered at the Chinaplas 2011. “With the

Schaumtandex ZE 30/KE 60, we’re in a position to

carry out leading edge research on a state-of-the-

art machine,” explains Dr. Jan Diemert from the

Fraunhofer ICT summing up the value of the new lab

system. One field of research for scientists at the ICT

is new physically foamed materials with customized

properties. The institute is also planning to develop

new processing concepts to produce sandwich

elements with foam cores and to work on new

composite materials using functional and reinforcing

agents.

“The Schaumtandex ZE 30/KE 60 adds another

high-caliber machine to our product portfolio,”

says Joachim Meyke, head of Foam Extrusion

at KraussMaffei Berstorff. “It enables us to

offer research institutes and development labs a

machine combination that is very interesting for

their purposes,” he adds. The modular twin-screw

extruder can process all standard polymers and

many high-temperature plastics up to a maximum

temperature of 350 °C. p

The new vacuum

degassing system can

increase productivity

and profit margins in

compounding.

KraussMaffei Berstorff’s new degassing system does

an efficient job of removing high volumes of air

from fillers such as talc, wood flour or light-weight

chalk grades. Depending on the apparent density

of the filler, output can be almost tripled compared

with side feeders without degassing.

VACUUM DEGASSING FOR GRANULAR OR POWDERED FILLERS

Boosting throughput rates in

filling and reinforcing plastics

ZE 30/KE 60 Schaumtandex lines offer a unique

machine concept for physical foaming of plastics

using environmentally compatible blowing agents.

The Fraunhofer Institute for Chemical Technology

(ICT) in Pfinztal, has ordered a laboratory-scale

line of this type.

At the Fakuma (Friedrichshafen, October 18 to 22,

2011), KraussMaffei Berstorff will be showcasing a

new vacuum degassing system for its ZSFE twin-screw

side feeder. The system can boost the profitability of

a compounding line through facilitating higher filler

content and improved output rates.

Schaumtandex

laboratory systems

from KraussMaffei

Berstorff are used

in R&D projects

to develop new

formulations and for

basic research.

The vacuum degassing system reduces the air

before the fillers reach the processing chamber

of the extruder and reduces the volume, thus

increasing the apparent density. “Profitability is

substantially improved by the higher filler content

and increased productivity. In most cases, the

investment pays off within a very short time,”

points out Gerhard Scheel, head of development

at KraussMaffei Berstorff in Hanover. The

vacuum degassing system is available for new

compounding line orders and can be retrofitted

on already-installed ZE UT and UTX machines

from KraussMaffei Berstorff. p

NEWS

15

Customers of KraussMaffei’s Reaction Process Machinery (RPM) division in

Columbia can now turn to KraussMaffei Andina in Bogotá for full support.

The latest sales and service merger continues the company’s “one face to the

customer” strategy.

directly to the Munich spare parts system, we can

access stock information on line, trigger shipments

and complete import formalities – including

customs clearance,” explains Cadavid. This slashes

order lead times, so that local customers get their

spare parts as fast as possible. The change in

Columbia, Venezuela and Central America is part

of KraussMaffei’s systematic expansion of its

global presence as an expert and trusted systems

and solutions supplier. p

“Joined up know-how and bundling our products

and services are strengthening our market

presence,” says Carlos Cadavid, Managing

Director of KraussMaffei Andina. “We create

value for our customers by advising them without

a process bias and because of our unique capacity

to supply efficient multiprocess solutions as single

vendors.” Rapid response to service calls and

spare parts needs are extremely important for all

customers, including producers of parts for motor

bikes and buses, white goods, rigid foam and

panels for the construction industry. “Linked

STRONGER SALES STRUCTURES IN SOUTH AMERICA

KraussMaffei Andina

welcomes RPM customers

The KraussMaffei

Andina team: Manuel

Weindl, Carolina

Salcedo, Managing

Director Carlos

Cadavid and Angelica

Quiceno (from left).

CUSTOMERS CHOOSE QUALITY

laboratory machines and a ZE 75 production line

for compounding thermoplastic elastomers. The

lines were shipped in August 2011.

Before the K 2010, PRET, a compounder located

in the Shanghai area, had already contracted with

KraussMaffei Berstorff to supply 18 twin-screw

extruders. The company used the trade show time to

finalize the details of the orders. Two years earlier,

PRET had bought two machines from KraussMaffei

Berstorff – to add to the already installed production

machines from Asian machine suppliers companies.

Building on the positive experience with the first two

machines, the company is again opting for quality

made in Germany by buying 18 new lines to populate

a second production plant. p

During the K 2010, the lead trade show for the

global plastics and rubber processing industries,

KraussMaffei Berstorff booked new orders from

China and concluded negotiations on some

pending offers.

22 twin-screw extruders for China

Kingfa has been operating KraussMaffei Berstorff

extrusion lines for several years now. The Chinese

company, headquartered in Guangzhou, has a

total of 200 lines in operation; by this measure it’s

the world’s biggest plastics compounder. Kingfa

representatives, in Germany for the K 2010, took the

opportunity to pay a visit to KraussMaffei Berstorff

in Hanover and then signed a contract at the K for

the delivery of four more extruders – three ZE UTX

Demand is surging

in China for twin-

screw extruders from

KraussMaffei Berstorff,

such as the ZE 30 UTX.

MADE BY KRAUSSMAFFEI 2 ¦ 2011

NEWS

16

CONTACT

Jochen Mitzler

Manager Product and Technology Management Injection Molding MachineryPhone +49/89/8899-4410jochen.mitzler@kraussmaffei.com

The MX 650+ injection

unit is capable of

injection speeds up

to 700 mm/s.

Above right:

The MX 650+ clamp unit,

engineered to move

very heavy molds, is

one of the machine’s

outstanding features.

One of the big advantages of the MX series is the

immense flexibility it offers for managing mold

variants. With the new MX 650+, wide variation

in mold installation heights is no problem – and

nor is running very heavy molds. Launching the

MX 650+, KraussMaffei has incorporated both

these advantages in a new tonnage machine. The

smallest machine size in the MX series used to be

850 tonnes, now it’s this new 650-tonne machine.

Target production tasks for the MX 650+ are

applications running stack molds and other molds

NEW HIGH-SPEED MX 650+ MACHINE

With this new machine size, KraussMaffei is

responding especially to the requirements of

customers and market segments running heavy

molds with very high cavity counts.

with high cavity counts. In other words, it’s the

perfect solution for the packaging industry, which

is strongly represented in the USA and other

countries. Paul Caprio, President of KraussMaffei

Corporation, explains: “Multicavity molds

are widely used to produce screw caps and

other closures and for profitability this type of

application demands ultra-short cycles. The

MX 650+ exactly meets these requirements.”

Key features of the new machine are outstanding

plasticizing performance and an energy-saving

electric screw drive for parallel plasticizing. p

• 2-platen technology: great flexibility to manage mold

variants, especially wide variations in mold installation

heights

• Ultra-high plasticizing performance thanks to the

HPS-UN screw and electric motors for parallel

plasticizing

• Run very heavy molds: stack molds are supported on

the machine bed, no load on the tiebars

• Highly consistent shotweights in all cavities and

stacks

• Very fast turn-out for short cycles – parallel functions,

each stack moves independently

• Most compact floor space compared with competitors

• Customization options, e.g. high-flow valves for cores/

turn-out units

KRAUSSMAFFEI MX 650+: CUSTOMERS

PROFIT FROM INNOVATIONS

Events through

to spring 201204.10.–07.10. Plastimàgen Mexico City, Mexico

18.10.–22.10. Fakuma Friedrichshafen, Germany

08.11.–11.11. Andinapack Bogotá, Columbia

14.11.–18.11. Equiplast Barcelona, Spain

15.11.–17.11. Waterproof Membranes Cologne, Germany

28.11.–01.12. Saudi Plas Riad, Saudi Arabia

13.12.–14.12. WPC Congress Cologne, Germany

17.01.–19.01. Swiss Plastics Lucerne, Switzerland

24.01.–27.01. Interplastica Moscow, Russia

01.02.–06.02. Plastindia New Delhi, India

14.02.–16.02. Tire Technology Expo Cologne, Germany

21.02.–23.02. ACMA Las Vegas, USA

29.02.–02.03. Plastics & Rubber Vietnam Ho Chi Minh City, Vietnam

27.03.–29.03. JEC Composites Show Paris, France

01.04.–05.04. NPE Orlando, USA

17.04.–20.04. Tires & Rubber Moscow, Russia

A huge gain for

packaging applications

17

know-how in injection and reaction molding.

They set a high priority on our ability to integrate

processes from both these fields of technology

in multiprocess solutions such as CoverForm,

SkinForm or ColorForm.”

Engineering competence for entire

process chains

The depth of LG

Electronics’ trust

in KraussMaffei’s

engineering skills and

process know-how

was clear at the official

signing ceremony in

Munich, where LG

Electronics ordered

three more MX injection

molding machines from

KraussMaffei for its

Mold Tech Center in

Korea. The machines

are fitted with modular

packages for processes

such as SpinForm (for

multicomponent products), giving LG Electronics the

scope to tackle a wide range of future development

projects. KraussMaffei’s process engineering

expertise will be available to support LG’s technical

development throughout the life of a project. p

In terms of the agreement, KraussMaffei and LG

Electronics agreed to work together to develop

innovative manufacturing processes based on

reaction and injection molding. The main focus

will be on new solutions for cost-competitive,

efficient and variable production of plastic parts

for electronics equipment. The agreement is a

logical further step in a working partnership which

began three years ago with the shipment of MX

injection molding machines to LG Electronics.

“With our positive experience of the high caliber

of KraussMaffei machines and the company’s

comprehensive process know-how, this cooperation

represents major progress in our development

work,” emphasized Jae-Woong Yun, head of the

Mold Technology Center at LG Electronics, adding

that, “ KraussMaffei is a single-source supplier for

the entire process engineering.” Frank Peters from

the KraussMaffei Managing Board is delighted to

be working with LG Electronics: “The cooperation

shows that our partner values our engineering

ELECTRONICS

COOPERATION WITH LG ELECTRONICS, KOREA

LG Electronics and KraussMaffei recently signed a cooperation agreement setting out plans to work together to research and develop new plastics processing technologies. Some of the work will be done on new injection molding machines from KraussMaffei’s MX series ordered by LG Electronics during the visit to Munich.

Shoulder to shoulder in

the Far East

CONTACT

Marco Zorn

Sales Injection Molding MachineryPhone +49/89/8899-2269marco.zorn@kraussmaffei.com

Cooperation in R&D for new processing technologies.

• Application-specific MX injection molding machines

• Processing expertise

• Joint R&D for new production solutions

• Process engineering support over the whole life of

the project

KRAUSSMAFFEI MACHINERY,

PROCESSES & SERVICE

Successful cooperation:

Jae Woong Yun, Director

of the LG Mold Tech

Center (left), and

Frank Peters, from the

KraussMaffei Managing

Board, signed the

cooperation agreement.

A SpinForm swivel-platen

machine.

MADE BY KRAUSSMAFFEI 2 ¦ 2011

AUTOMOTIVE

HP-RTM IN SERIES PRODUCTION

also feasible to produce sandwich structures, with

cores inserted between the fiber layers.

Scaling up for big, cost-competitive series

Up to now, RTM has been used predominantly

for small production runs or special series. The

constraints are the high manufacturing and material

costs, the long cycle times and the fact that the

process is labor-intensive due to the high level of

manual input. It can take several hours for the parts

to cure fully. Removing the sprues and risers after

the part is removed from the mold is also time-

consuming. Regular cleaning cycles, for example,

for the low-pressure mixing heads, further reduce

productivity. All these time-consuming, labor-

intensive aspects impact on the production flow and

count against efficient large-volume production.

Successful cooperation for innovative

processes

In our endeavor to develop a fully automated, RTM-

based process to make lightweight, high-strength

composite parts which will be cost-competitive

for large series, KraussMaffei collaborated with a

number of partners – Dieffenbacher GmbH & Co.

KG in Eppingen, the Chair of Carbon Composites

(LCC) at Munich’s Technical University, and the

Fraunhofer Institute for Chemical Technology

(ITC) in Pfinztal. The outcome is the innovative

Fiber-composite parts, combining extremely

light weight with high strength, are playing

a growing role in industries from automotive

to aerospace and from power engineering to

environmental technology. One method widely

used to manufacture these parts is Resin Transfer

Molding (RTM). A preformed fiber mat or fabric is

inserted in the mold and saturated with resin which

is allowed to cure. RTM is used to manufacture

large-format, high-strength elements for rotor

blades, airfoils and tail components, and also for

automotive components such as side walls, floor

pans and bumper carriers. Fiber composite parts

for these applications are between 25 and 40%

lighter than the equivalent steel or aluminum

parts. They are also characterized by high stiffness

and strength. These

properties derive

from the type and

length of the fibers,

their orientation,

the fiber content and

the matrix material.

Different reinforcing

materials can be

combined in arbitrary

configurations in

order to meet part

specifications. It’s

High pressure for lightweight composites

Demand for fiber-reinforced plastic parts is growing steadily in many industries. Together with cooperation partners, KraussMaffei

set about improving on the conventional Resin Transfer Molding (RTM) process, which is fine for small production runs and special series, to make it viable for high-volume production. The outcome was a High

Pressure RTM process (HP-RTM). HP-RTM opens the way to highly-automated, cost-competitive high-volume production of lightweight, high-strength composite parts.

18

The KraussMaffei HP-

RTM system is capable

of producing big runs

of lightweight, high-

strength components in a

reliable, cost-competitive

process.

Lightweight, high-

strength structural

components are

in demand in the

transport sector.

For further information pleaseclick here

19

AUTOMOTIVE

High Pressure Resin Transfer Molding (HP-RTM)

process. “At the heart of the system is a very

flexible, but nonetheless compact KraussMaffei

injection unit with its self-cleaning mixing head,”

explains Josef Renkl, Director of RPM Research

and Development at KraussMaffei. “The key

difference to a conventional RTM process is that

the resin components are mixed at high pressure;

this allows a very high level of automation in

manufacturing fiber-reinforced plastic parts.”

High-precision repeatability

In HP-RTM the two components, resin and

hardening agent, are injected at high pressure (up

to 200 bar), via defined nozzles, into the mixing

chamber of the mixing head. Component pressure

and throughput remain constant throughout every

shot, even as cavity pressure increases. In other

words, the high-precision mixing and metering

machine adapts the output volume to the increasing

filling height in the mold. The ability to maintain

a defined pressure in the mold is a key factor in

achieving a precisely repeatable process. It ensures

that every single filament is completely wetted with

the resin and that all cavity zones are reliably filled.

After each shot, the control piston automatically

cleans the mixing head ready for the next shot. Self-

cleaning makes it feasible to use the mixing head to

process fast-curing resins. Operation and control

is via a PUC08 process

data capture system.

It visualizes the whole

process, giving operators

a full overview of the

system status at all

times.

Single-vendor solutions for series production

“High pressure RTM stands for stable processes

with high repeatability plus shorter cycle times,”

points out Josef Renkl. The mold fills faster, the

fiber preforms are wetted much more effectively,

and tolerances for shape and layer thickness are

tighter. As part of a well-engineered system, the

HP-RTM system meets the highest

expectations in producing big

runs of lightweight, high-strength

components. KraussMaffei is a

single-vendor supplier of complete

turnkey systems. p

Carbonfiber-

reinforced

automotive

components are

up to 40% lighter

than the equivalent

parts made of a

conventional material

such as steel.

• Shorter cycle times, faster mold filling

• Fibers more effectively wetted

• Self-cleaning mixing head

• Tight tolerances for shape and layer thickness

• Very stable process, high repeatability

ADVANTAGES OF HP-RTM

Automated

preform production

is extremely

cost-effective.

CONTACT

Josef Renkl

Director Development and Application Engineering RPMPhone +49/89/8899-3288josef.renkl@kraussmaffei.com

20 MADE BY KRAUSSMAFFEI 2 ¦ 2011

AUTOMOTIVE

High-spec automotive components for under-the-hood applications – but made of plastic: these are at the core of the product spectrum at Röchling SGT. When it comes to production machinery, the company puts its trust in hydraulic and all-electric injection molding machines from KraussMaffei. It has just added an AX to its machine park.

KRAUSSMAFFEI CUSTOMER RÖCHLING SGT SPRITZGIESSTECHNIK GMBH

sensor. A handling device removes the parts from

the side and counts them into small load carriers

sorted by type. Klaus Pietsch, production manager

at Röchling SGT, emphasizes: “Short cycle times –

18 seconds in the case of the AX – are one of the

dominant requirements for our highly automated

manufacturing cells.”

For the present, the AX 100-180 rounds off the

machine park of all-electric injection molding

machines at Röchling SGT. These include two

EX series machines from KraussMaffei. Apart

from delivering short cycle times, they provide the

extreme precision necessary in the manufacture of

high-spec parts, such as components for antilock

brake systems in cars. The plastic parts are

replacing aluminum ones. They have to withstand

high operating pressures and temperatures and as

such they represent a highlight in the manufacturing

spectrum of Röchling SGT. p

Röchling SGT Spritzgießtechnik GmbH is a

company in the Röchling Group headquartered

in Mannheim. Röchling SGT was set up in 1992

in Weidenberg in Upper Franconia, Germany.

The company’s main focus is on fully automated

production of metal-plastic composites and on

products made of high-performance plastics such

as PEEK, PPS or PPA. Further production arms

are micro-injection-molded, multicomponent and

thermoset parts. 11 of the 55 injection molding

machines in the Weidenberg plant sport the

KraussMaffei brand, including an all-electric AX

100-180 delivered in the summer of 2011. “For

precision and repeatability, electric machines take

some beating,” says Rudolf Hösch, Managing

Director of Röchling SGT Spritzgießtechnik

GmbH. “This, plus the cost-effectiveness which is a

hallmark of the AX, were the factors that decided us

in favor of our latest buy.”

Short cycle times a must

Röchling SGT will be using

the AX 100-180 to produce

parts made of PPA. These

are produced in a 4+4 cavity

mold with a cavity pressure

CONTACT

Hans-Günther Kammermeier

Area Sales Manager Injection Molding Machinery Phone +49/9264/968 850hans-guenther.kammermeier@ kraussmaffei.com

High-performance

plastic replaces metal

Hydraulic and all-electric CX, EX and AX series

injection molding machines.

• AX 100-180 standard machine to round

off the machine park

• To process PPA high-performance plastic

in a 4+4 cavity mold

• Economical machine solution for short

cycle times

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

Case halves for the

automotive industry

produced in a 4+4 cavity

mold.

The AX joins two existing

KraussMaffei EX series

machines (see photo).

21

AUTOMOTIVE

components, encapsulated or back-injected with

a rib structure. The integral edging protects the

component against moisture ingress.

Huge application potential

“By combining injection molding and

thermoforming in a single-sequence process,

FiberForm reduces the number of production

steps, cuts cycle times and delivers assembly-

ready components in large quantities,” says

Jochen Mitzler, Manager Product and Technology

Management Injection Molding Machinery.

“The compounder is also capable of processing

individual formulations for the matrix to increase

the scope for custom component designs.” With

FiberForm KraussMaffei is offering an innovative

and cost-competitive manufacturing process for

fiber-reinforced hybrid components, with an

application potential far beyond the automotive

sector. Partners in this development were Audi,

Bond-Laminates, Georg Kaufmann Formenbau,

gwk Gesellschaft Wärme Kältetechnik, Heraeus

Noblelight, Jacob Composite, Kistler Instrumente

and Lanxess Germany. p

Automotive companies and their component

suppliers want innovative, lightweight

production concepts for very light and yet highly

resilient structural components. Up to now, such

parts have been made using long-fiber granulates

in a proven injection molding process which

is both efficient and economical. This process,

however, reaches its limits as increasing demands

are made on component strength. In response

to the need for an injection molding process

capable of producing even higher strength

components, KraussMaffei and its partners

developed the FiberForm process. FiberForm

combines injection molding with thermoforming

to make organic sheet intermediates from fabric

reinforced with endless fiber impregnated with a

polymer matrix.

Fully monitored production cell

KraussMaffei designed a special manufacturing

cell for running the FiberForm process on

an industrial scale. It basically comprises a

300-tonne CX 300-1400 IMC injection molding

compounder and an LRX 150 linear robot, plus

an infrared oven. Under automatic control, the

composite fabric inserts are formed in the mold

and then encapsulated in glassfiber-reinforced

polyamide in a single-sequence process. The

whole production process is continuously

monitored. The result is edged structural

CONTACT

Jochen Mitzler

Manager Product and Technology Management Injection Molding MachineryPhone +49/89/8899-4410jochen.mitzler@kraussmaffei.com

FiberForm process for

ultra-strong, fiber-composite

components.

• Injection molding and

thermoforming in a single

process step

• Series and high-volume

production of ready-to-

assemble components

• Short cycle times with fewer

production steps

• Economical production also

of particular component

designs

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

KraussMaffei’s FiberForm is an innovative and economical process for manufacturing plastic hybrid components. The combination of injection molding and thermoforming of organic sheet makes it feasible to produce large volumes of assembly-ready parts for a very wide range of applications, in a single-sequence process.

INTEGRATED PRODUCTION PROCESS FOR PLASTIC HYBRID COMPONENTS

Cost-competitive

production with FiberForm

AUTOMOTIVE

onomical nts. The ing of organic f assembly-n a single-

OMPONENTS

Exceptionally high strength

is a hallmark of plastic

hybrid components

produced by the FiberForm

process.

For further information pleaseclick here

22

NEW CO-EXTRUSION HEAD FOR RUBBER PROFILES

reduces retooling time or downtime for cleaning

compared with screw-on flange connections.” The

co-extrusion head can be retrofitted on virtually

all KraussMaffei Berstorff extruders.

The extrusion die is key to top quality

The flow channels are engineered in such a way

that the molten rubber is completely and precisely

distributed around the profile cross-section.

A wide selection of inserts in a building block

system are used to adjust the flow speed of the

melt stream in the channels to different profile

cross-sections. Easy access for machine operators

is part of the overall design concept. Especially

when the profiles have complex cross-sections,

the extrusion die in the head has a key role to

play. The process parameters – temperature, flow

speed and deformation – must be adjusted to the

tight tolerances specified for the finished profile.

For this reason alone, die design demands high

levels of proficiency and experience – yet another

reason to rely on solutions from KraussMaffei

Berstorff. p

The extrusion head plays a central role in the

production of seal profiles. The KraussMaffei

Berstorff co-extrusion head guarantees

outstanding product quality. At the same time,

because it’s engineered for fast die changes

and short cleaning times, it stands for high

productivity. The co-extrusion head, for rubber

extruders from 60 mm to 120 mm, is the ideal

solution for extruding multicomponent profiles

made of EPDM (ethylene propylene diene

monomer) rubber with or without a carrier

material. The head is mounted on the extruder

using a C-clamp connection which is pressure

tight up to 450 bar. “The effort involved in

releasing or tightening the clamp connection is

minimal,” explains

Helmut Lüders,

Product Manager

Profile Production

Systems. “This sharply

Fast retooling and short

cleaning timesThe new co-extrusion head from KraussMaffei Berstorff improves productivity in manufacturing rubber seal profiles. It’s especially attractive for producers of multicomponent profiles in the automotive sector who can cut retooling times and keep start-up waste to a minimum.

AUTOMOTIVE

CONTACT

Helmut Lüders

Product Manager Profile Production SystemsPhone +49/511/5702-237helmut.lueders@krausmaffei.com

The new co-extrusion

head was optimized for

fast retooling for rubber

profiles.

MADE BY KRAUSSMAFFEI 2 ¦ 2011

Co-extrusion head for rubber seal profiles for

automotive applications.

• Pressure-tight C-clamp connection

• Fast retooling and minimal start-up waste

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

23

AUTOMOTIVE

CONTACT

Harald Hepke

Technical Manager Rubber TechnologyPhone +49/511/5702-102harald.hepke@kraussmaffei.com

KraussMaffei Berstorff in Hanover has been

building production lines for composite profiles

for many years. As part of its drive to increase

system productivity and reliability still further, the

company has bundled skills and expertise from the

two KMB locations Hanover and Munich. The new

lines are the outcome of the company’s expertise in

system engineering and outstanding competence in

designing extrusion dies and building production

systems for a great diversity of seal profiles. For the

first time, they also incorporate KME single-screw

extruders from Munich, which were previously used

only in pipe, window profile and sheet extrusion.

The new line is designed to process PP and TPE

in different hardness grades, both compact and

foamed. Modular engineering makes it possible

to configure flexible solutions, from conventional

mono systems to hybrid profile systems with flock

tape application, or steel reinforcement. With

these features, the new system will be of special

interest to customers who produce a wide range of

different profiles and who put a high priority on

flexibility. “Strong demand

from customers confirms that

our strategy of expanding our

portfolio of profile solutions

with a hybrid profile line

was the right one. We’re

seeing an expansion of the

seal profile market

segment,” comments

Harald Hepke, Technical

Manager of the Rubber

Profile business unit at

KraussMaffei Berstorff.

The right solution

every time

“With this composite

profile line, we can offer

our customers the right

production solution whatever profile properties

or productivity level they are aiming for –and

regardless of whether they are producing

for the automotive or for the

construction industry,” sums up

Harald Hepke. p

CUSTOM EXTRUSION LINES FOR TPE/PP COMPOSITE PROFILES

KraussMaffei Berstorff has joined up engineering expertise from its locations in Hanover and Munich to develop an extrusion system for TPE/PP composite profiles. The profiles produced on the new line are light, temperature resistant over a wide temperature range and show good pigmentability as well as being recyclable.

Bundled expertise for a

new system concept

Custom TPE/PP composite profile extrusion line for the

automotive and construction industries.

• Versatile – capable of processing a wide range of

materials

• More energy efficient thanks to tried-and-tested up-

and downstream equipment

• Central line control at the operator panel

f

con

Ha

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

Optimized for

automotive and

construction sector

applications: the new

TPE/PP composite

profile extrusion line.

24 MADE BY KRAUSSMAFFEI 2 ¦ 2011

AUTOMOTIVE

FKT GmbH is the partner of choice for many car

manufacturers when it comes to systems for car

sunblinds, for cargo management, wind blockers

for convertibles and various accessories. In the

past, the company used external suppliers as an

extended workbench. The issues of increasing

vertical integration and capturing more added

value in-house is

of great strategic

importance for

FKT. The company

decided to change

strategy and expand

its own production

capacity. The decision

has now resulted

in the purchase

and installation of

a total of five new

manufacturing cells.

Two of these consist

of an AX 50/180

injection molding

machine with an

INTEGRATED MANUFACTURING CELLS AT FKT, PFÖRRING, GERMANY

FKT GmbH, in Pförring near Ingolstadt, Germany, is a certified development and system supplier for the automotive industry. In mid-2011, the medium-sized company expanded production capacity with five AX injection molding machines complete with standard automation. Three of the machines are configured as integrated manufacturing cells.

Integration saves space

Two of the manu-

facturing cells at

FKT, each with an

AX 50/180 injection

molding machine and

an integrated LRX 50

linear robot.

integrated LRX 50 linear robot while a third cell

has an AX 80/180 machine, again with an LRX 50

linear robot. FKT also ordered two larger AX

machines with standard automation. FKT will use

these machines to manufacture small parts such as

hinge plates for wind blockers in convertibles and

mounting profiles for seat belt anchorage systems.

“We decided on the integrated manufacturing cells

from KraussMaffei, because this compact solution

takes up far less space than others we considered,

and because we liked the overall logical machine

concept”, explains Guido Günthner, in charge

of production at FKT. “During the purchase and

installation phase, the standardized manufacturing

cells were modified to fit in with special requirements

at FKT,” says Benjamin Weinzierl, Product Manager

at KraussMaffei Automation. “Together with

the customer, we developed different parts drop

and packaging concepts.” Alexander Weidinger,

responsible for mold management at FKT, summed

up the benefits of the new solution: “Despite

increasing vertical integration, we’ve been able

to realize substantial cost savings with the new

manufacturing cells. At the same, our production

has become more flexible. And we’re no longer

dependent on the quality and delivery performance

of subcontractors.” pCONTACT

Benjamin Weinzierl

Product Management KraussMaffei AutomationPhone +49/8122/9782-217benjamin.weinzierl@kraussmaffei.com

Integrated manufacturing cells for automotive

component suppliers.

• Extremely compact system solutions with

a 25% smaller footprint

• Mechanical integration of the robot in the

injection molding machine housing

• Shared data storage for linear robot and

injection molding machine

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

For further information pleaseclick here

25

Kentucky, the US subsidiary of the

KraussMaffei Group. KMC

President, Paul Caprio

commented, “SAS has

gone for machine

technology from the

market leader for

high-speed machines in

the upper clamp force

range. The decision to

invest in these machines

was based on the

outstanding performance

of the injection units and

the fast-acting clamps.”

The high-caliber machines

together with KMC’s

outstanding local service

and support give SAS a

strong basis for maintaining target production

volumes of 40,000 crates a day in a continuous,

highly automated operation, 24 hours a day,

seven days a week. p

ary of the

MC

PACKAGING

Fresh from the field and moved rapidly through the

retail channels to reach the consumer soon after

picking – that’s the logistics challenge for agri-

cultural produce like fruit, vegetables and salads.

There’s nothing better for transporting this type of

produce than plastic crates. Among the benefits is

the fact that they last far longer than conventional

wooden crates. Easy to clean, they meet all hygienic

criteria and the collapsible versions are the answer

to saving space. At the end of long service lives,

plastic crates can be reground and processed to

new plastic products. World number one in the

field of reusable and recyclable plastic packaging

and transport solutions is SAS, headquartered in

the Netherlands. SAS is currently equipping a new

plant in Goodyear/Arizona, USA to manufacture

collapsible fruit and vegetable crates using injection

molding processes.

High-volume production on precision

machines

The new SAS production plant is being set up on an

area of almost 13,000 square meters in an existing

industrial complex with a 2011 investment of

32 million dollars. Initially, the plant is being

equipped with nine 1,150-tonne precision machines

from KraussMaffei’s MX series of big injection

molding machines. SAS ordered the machines from

KraussMaffei Corporation (KMC), Florence/

NINE MX INJECTION MOLDING MACHINES FOR NEW SAS PLANT

Big tonnages and

fast cycles

CONTACT

Paul Caprio

President, KraussMaffei CorporationPhone +1/859/28 30 200paul.caprio@kraussmaffei.com

SAS ordered nine

machines from

KraussMaffei’s MX

series for the new plant.

Supply nine MX injection molding machines to

manufacture collapsible plastic fruit crates.

• Big machines (1,150 tonnes) for high shotweights

• Technology from the market leader for fast-

cycling machines

• To manufacture environmentally-friendly trans-

port crates, which are reusable and recyclable

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

Thanks to their superior properties, plastic transport and display crates for fruit and vegetables are inexorably taking over from their conventional wooden counterparts. World leader in manufacturing plastic crates is Schoeller Arca Systems (SAS). The company is currently setting up a new plant in the USA for high-volume production of plastic crates. KraussMaffei has the machine solutions to meet the challenge of high productivity and big shotweights.

For further information pleaseclick here

MANUFACTURING CELL FOR STERILE MEDICAL PRODUCTS

Medical products injection molded from plastic are normally sterilized in a separate process prior to packaging. KraussMaffei’s new clean manufacturing cell concept cuts out the sterilization step – parts leave the mold sterile and are packaged immediately.

Steady sterile state

Precision planned zone concept

The central feature is an all-electric EX CleanForm

injection molding machine specially adapted for

cleanroom manufacturing and with an integrated

automation solution. The other major component

is the cleanroom in which the manufacturing cell is

installed. Finally, a complete system would include

a packaging system and possibly other equipment,

depending on the application. After identifying

the product- and technology-related requirements,

our engineers went on to define product zones

and system zones which were allocated to specific

cleanroom areas. System zone 1 is the heart of the

aseptic manufacturing cell. It comprises all the

production equipment (mold, clamp, robot and

packaging system) which is directly involved in

making and packing the product. Zone 1 complies

with GMP class A. System zone 1 is located inside

either a system zone 2 (a GMP B cleanroom) or

a system zone 3 (a GMP C cleanroom). Stable

processes are essential in aseptic manufacturing

in order to eliminate, or at least minimize,

human intervention which is a major source of

contamination. KraussMaffei guarantees this with a

very high level of automation. p

LIFE SCIENCES

MADE BY KRAUSSMAFFEI 2 ¦ 201126

CONTACT

Hans Malinowski

Product and Technology ManagementPhone +49/89/8899-3937hans.malinowski@kraussmaffei.com

Most medical products made of plastic are

manufactured in a cleanroom environment

that complies with GMP Class C or D and

then sterilized in a separate process step. This

sterilization step is superfluous, for example, for

simple bulk products such a syringe barrels. The

high melt temperatures and pressures generated

during the injection molding process reliably kill

all microorganisms, so that when the mold opens,

the parts are sterile. If the parts can be packaged

in this state, it would be possible to eliminate the

post-mold processing step – assuming, of course,

that the entire process satisfies GMP standards for

aseptic manufacturing. On this basis, KraussMaffei

Technologies GmbH

has called on its

long experience

in cleanroom

technology to design

a manufacturing cell

capable of running

an aseptic process to

manufacture sterile

medical products.

The EX CleanForm

concept includes a

cleanroom enclosing the

whole manufacturing

cell.

Aseptic manufacturing system for sterile medical

products without post-mold sterilization.

• Production cell with all-electric EX CleanForm

injection molding machine

• Outstandingly stable process thanks to high

automation level

• Carefully planned zoned cleanroom concept with

GMP cleanroom classes A, B and C

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

For further information pleaseclick here

WELT VON KRAUSSMAFFEI

View into the two-cavity

mold mounted on the

1,300-tonne machine. This is

the biggest injection molding

machine KraussMaffei

has supplied to date for

processing BMC/SMC.

27

Mitras Composites Systems GmbH in Radeburg/

Saxony, specializes in plastics products for

industrial applications outside the automotive

sector – for example, in power distribution, data

transmission and medical technology. The company,

with 160 employees, has a core competence in high-

spec products, sometimes produced in small series,

which demand extensive support for customers

in the product design phase and in the mold

procurement process. Kai Steinbach, Development

Manager at Mitras Composites Systems, mentions

two technical highlights in the company’s current

product spectrum. One is housings for moisture-

proof lighting fixtures which are 1,850 mm long,

but have a wall thickness of only 1.4 mm. The

second is a range of housing, operating and tray

elements for high-end dentist’s chairs. Kai Steinbach

explains: “Both applications push the material and

the automated manufacturing cells close to the

very limits of the possible.” KraussMaffei met this

challenge successfully, supplying the machine and

robot technology for both applications.

Producing durable surfaces

Mitras Composites Systems makes the very large

luminaire elements on a 1,300-tonne injection

molding machine from KraussMaffei’s MX series,

while the dentist’s chair components are produced

on CX machines. All four machines have been

specially equipped to run the PolySet process. The

three CX machines were installed in 2010. The

material used in these

applications is bulk

molding compound

(BMC), optimized for

highest surface quality,

some of which is

supplied by Menzolit.

Surfaces with high

scratch resistance are

an absolute must for

dentists’ consulting

rooms where hygiene is

a top priority. Resistance

to disinfectants, cleaning

materials and other chemicals is also essential.

“Apart from the ability to deliver products with

outstanding surface quality, PolySet is also the

process of choice when good heat resistance is

required,” says Martin Palik, Technology Manager

at KraussMaffei. “Our patented feed system and,

in fact, our thermoset system as a whole, satisfy

customer requirements for short cycle times,

outstanding product quality and a high level of

automation.” p

POLYSET APPLICATIONS AT MITRAS COMPOSITES SYSTEMS

Hot compression and injection molding are the core competences of Mitras Composites Systems, a KraussMaffei customer. The company makes high-spec plastic components, for example, for the medical technology sector, using the PolySet process on KraussMaffei injection molding machines.

Tough tasks

for polyester resins

CONTACT

Martin Palik

Product and Technology ManagementPhone +49/89/8899-2385martin.palik@kraussmaffei.com

Supply large- and medium-tonnage injection molding

machines to process non-free-flowing polyester

molding compounds.

• Three CX series machines, 200 to 650 tonnes

• One MX series machine, 1,300 tonnes

• Producing medical technology and other

components

• Deliver on specified properties: high quality

surfaces, scratch and chemical resistance

KRAUSSMAFFEI MACHINERY,

PROCESSES & SERVICE

From left: Andreas

Schreiber (Technical

Manager), Patrick

Stumpler (Technical Work

Preparation) and Kai

Steinbach (Development

Manager; all from Mitras

Composites Systems) with

Maik Hölscher and Martin

Palik (both KraussMaffei).

For further information pleaseclick here

MADE BY KRAUSSMAFFEI 2 ¦ 2011

CONSTRUCTION

28

BYK KOMETRA GMBH, SCHKOPAU, GERMANY

Within the Altana specialist chemicals group, BYK Kometra is the specialist for plastics modifiers. The company produces special surfactant copolymers that are used in many applications as bonding agents and impact resistance modifiers. In their production, BYK Kometra uses three identical ZE 50 UTX twin-screw extruders from KraussMaffei Berstorff.

Since March 2011, BYK Kometra has been part of

BYK Additives & Instruments, one of four divisions

of the specialist chemicals group Altana. Joining the

group, the new subsidiary contributed its competence

based on many years’ experience in the production of

plastics modifiers used to enhance standard plastics.

These are needed primarily in technical applications

and ensure, for example, very good bonding between

polymer and filler in WPC production. Among other

qualities, customers in the compounder business

appreciate the high grafting density of BYK Kometra

products that is important for the efficacy of bonding

agents. For the extrusion process, the company opted

for twin-screw extruders from KraussMaffei Berstorff.

“We liked the price, plus the fact that we ended up

with solutions that from a technological point of view

exactly met our requirements”, emphasizes Klaus

Dieter Besser, General Manager of BYK Kometra.

“Together with the KraussMaffei Berstorff experts,

for instance, we identified the best screw

configuration for our requirements. The extruders are

not engineered for ultra-high output, but rather to

guarantee the dwell time necessary for our

applications.” No other vendor of extruders was able

to realize the special screw coating, which was part of

the machine specification, in the required way.

Fully redundant and flexible

It is no coincidence that the three twin-screw

extruders are all the same type – ZE 50 UTX. “Our

systems must be fully redundant, because we

exchange system components between them”,

explains Klaus Dieter Besser. “Because we change

configurations fairly often, we work, for instance,

with five complete screw pairs; we always hold a

couple ready configured in reserve.” For this reason

alone, it is on the cards that a fourth machine, which

is already being planned, will once again be a ZE 50

UTX twin-screw extruder. p

Customized

extrusion solutionsOne of the three identical

ZE 50 UTX twin-screw

extruders that BYK

Kometra uses to produce

plastics modifiers.

CONTACT

Gerhard Schmitt

Sales Manager Twin-screw Extruders D/A/CHPhone +49/511/5702-515gerhard.schmitt@kraussmaffei.com

Reactive extrusion of plastics modifiers and

additives for compounder operators.

• C-clamp cover connection save time when

changing covers

• Direct influence of processes thanks to the

modular design of the processing unit

• Operator-friendly thanks to Process Control

• Joint development of the optimal machine

configuration

KRAUSSMAFFEI MACHINERY, PROCESSES & SERVICE

For further information pleaseclick here

29

CONSTRUCTION

The world population today is close to 7 billion

and, according to the United Nations 2010 Revision

of World Population Prospects, it is set to grow to

around 9.3 billion by the year 2050.The growth will

be mainly the result of rapid population increases

in Asia and Africa. This means that emerging

economies and third world countries will have

to find affordable homes for over 2 billion more

people by 2050. KraussMaffei has drawn on its

many years of sector-specific experience to come

up with an innovative concept for prefab houses

as part of the solution to this challenge. The walls

and ceilings of the houses are made of sandwich

panels – the outer layers are steel or aluminum sheet

with an insulating layer of polyurethane or mineral

wool between them. The materials used in a specific

project will be selected for easy local availability.

Low-cost, adaptable and mobile

The basic dimension can be taken from a local

building material (for example, typical brick

size or door and window widths) and the panels

manufactured to match. Because the houses are

built using just a few different elements, a large

number of homes can be manufactured and erected

quickly, easily and cheaply. The low-cost basic

house can be upgraded, for example, by facing

interior walls with plasterboard or cladding the

outer walls. Our flexible manufacturing concept

makes it possible to produce the sandwich panels

on-site where a new housing complex is being

built. This can be a great advantage, for instance,

if the homes are needed for rehousing people after

a natural disaster. The production system is always

ready to go and, because it’s modular, it can be

transported quickly to a disaster location and start

production immediately. In other words, mobility

is almost limitless. p

WORLD FIRST – KRAUSSMAFFEI HOUSING SOLUTIONS

A major goal of development policy in the 21st century has to be the creation of affordable housing for millions of people. KraussMaffei has developed an innovative concept for producing very large numbers of low-cost prefabricated homes.

New-look prefabs

create low-cost homes

CONTACT

Dr. Michael Loferer

Manager Business Unit ConstructionPhone +49/89/8899-2364michael.loferer@kraussmaffei.com

Complete solution for prefabricated homes.

• Efficient, low-cost production of sandwich panels

for housing

• Continuous production of house sections in a factory

• Mobile production systems

• Quick and easy build on-site

• Flexible adaptation to local preferences and

conditions

KRAUSSMAFFEI MACHINERY,

PROCESSES & SERVICE

Wall and roof elements

for the prefab houses

(above) are made of

sandwich panels.

The first low-cost prefab

house was opened at the

KraussMaffei Competence

Forum.

For further information pleaseclick here

30 MADE BY KRAUSSMAFFEI 2 ¦ 2011

WORLD OF KRAUSSMAFFEI

reaction process machinery, our success is founded

on our ability to offer customers flexible solutions

– from stand-alone machines to equipping complete

factories. Customers in all sectors know they

can rely on KMC to deliver complete production

solutions, which are optimally matched to the

customer’s specific requirements. Paul Caprio has

good reason to be both proud and optimistic:

“This year we’ll be supplying their 100th injection

molding machine to two of our customers.”

A tradition of success in Switzerland

KraussMaffei’s Swiss subsidiary was set up in 1996

with active participation from Bruno Schleiss who is

still running the company today. From the centrally

located headquarters in Rotkreuz/Canton Zug, he

and his team have marketed our machines across

the whole country and achieved steady growth.

Parallel to order growth in injection molding

machines, the number of employees increased to

today’s total of 13 people. Thanking them for

their dedication and hard work, Bruno Schleiss

summed up the company’s core business like this:

“The Swiss market is a fairly even mix of different

applications. Medical technology, automotive,

packaging, electronics and apparatus engineering

are all represented. Our customers operate machines

ranging from 35 to 2,300 tonnes. And the processes

are equally varied, including thermoplastic and

Paul Caprio, President of KraussMaffei Corporation

(KMC) in the USA, looks back at the early years:

“When KMC was founded in 1966, it was the

first company to market extrusion lines in North

America.” Today, extrusion technology from

KraussMaffei Berstorff still holds an unchallenged

lead position with customers. We’ve supplied our

single-screw extruders for PE pipe production, for

instance, to the major pipe producers in the market.

KraussMaffei Berstorff also leads the market in

compounding systems. Paul Caprio says: “Our

customer base here reads like a Who’s Who for this

application area.”

Marketing machines from three technology

areas in North America

KraussMaffei began marketing injection molding

machines in the USA in the early 1980s. Especially

the automotive industry came to value the know-

how of our experts, for example, in multicomponent

injection molding. Tail light clusters were among the

first products produced on KraussMaffei injection

molding machines in the USA. We soon progressed

from being a niche supplier to a partner for a great

number of industries, for instance, packaging,

medical technology and electronics. Today

KraussMaffei’s engineering capability is supporting

any number of companies in many industry sectors

to slash their production costs. When it comes to

Paul Caprio, President

of KraussMaffei

Corporation in the USA.

Bruno Schleiss,

Managing Director

of KraussMaffei

Switzerland.

INTERNATIONAL SUBSIDIARIES CELEBRATE MILESTONES

45 years in the USA, 15 years in Switzerland, 10 years in China and 5 years in Japan: all over the world KraussMaffei subsidiaries are celebrating special anniversaries in 2011. On a congratulatory tour, made by KraussMaffei collected some interesting views on company history and future prospects.

Surging ahead

with confidence

31

thermoset molding and LSR applications.” Bruno

Schleiss sees KraussMaffei’s greatest strengths in

Switzerland as its coherent customer and service

orientation together with the company’s role as a

full-liner. “Since 2006, we’ve integrated automation

in our portfolio and it’s there to stay! Today every

second machine we sell has an integrated robot.”

On the high road to growth in the Far East

“In China, the KraussMaffei Group has made

great strides in recent years in positioning the

names KraussMaffei, KraussMaffei Berstorff and

Netstal as key brand names in potential markets.

Our brands are known to stand for the highest

quality and innovative engineering,” explains

Michael Müller, responsible for injection molding

machine sales in China. Many large companies with

international operations have become customers of

KraussMaffei in China. KraussMaffei has built a

strong reputation as a technology leader. Michael

Müller is hugely proud of the employees in China:

“Many of them have been with us from the start and

their tireless hard work and strong identification

with the company has made our success possible.”

The KraussMaffei Group today employs over

60 people in our sales and service companies in

China. The imminent move to bring the teams

from KraussMaffei and Netstal together under

the organizatorial umbrella of the KraussMaffei

Group will give a strong new impetus to our market

position. KraussMaffei has an excellent basis for

the future growth of all three brands, because our

customers can only profit from having a much

bigger product and service portfolio to choose

from. With demand increasing, KraussMaffei is also

planning to expand its Haiyan production plant in

the future.

In Japan, where KraussMaffei has had a subsidiary

since 2006, reaction systems take pride of place.

Jens Rappold and Erich Fries, the responsible area

sales managers, can look back with satisfaction

on progress to date: “We didn’t have long to wait

before we booked the first orders for mixing heads,

lab systems and oval production lines. The teams

from Munich and Japan have worked extremely well

together. In short, KraussMaffei Japan has been an

ongoing success story for five years. Acceptance with

customers is high and there’s considerable potential

for growth.” p

The highly-motivated team of KraussMaffei Japan.

This building is home to KraussMaffei

in Shanghai.

32 MADE BY KRAUSSMAFFEI 2 ¦ 2011

It must be the dream of

every plastics processor

– to press a button

or touch a computer

screen and immediately

be in contact with a

KraussMaffei expert

team. This is exactly

how KraussMaffei’s

Teleservice operates.

Users get a quick

response and a fast,

targeted service solution

– specific to their

machine, anywhere in the world and whatever their

query. An optional Web Servicebox integrated in a

manufacturing cell is the route to the KraussMaffei

Teleservice support team who are ready to help

with any number of routine – and non-routine –

situations. These can be as disparate as a quick

operating instruction, problem diagnosis, support

with a specific application, process control or the

prompt installation of special software.

Know-how from the network

Fast, efficient and secure – that’s the KraussMaffei

Teleservice. “Many of our customers are showing

a lot of interest in this service,” reports Josef

Hammerschmid, Product Manager Service.

“Because with the Web Servicebox as the interface

to their technology partner KraussMaffei, they have

a clear added value with regards to operating costs

and system uptime. It offers enormous potential for

expert support with daily production challenges.”

The moment the machine operator activates the

Teleservice connection via the machine control

panel, he is connected directly with the KraussMaffei

hotline for remote diagnosis or troubleshooting.

The integrated firewall and VPN (Virtual Private

Network) technology guarantee fast, secure data

transfer. As the KraussMaffei service expert opens

the Teleservice query, all the machine information

he needs is displayed on his screen, called up

automatically from the KraussMaffei database. If he

needs to call on expertise from other KraussMaffei

specialists, they can be linked in directly via the

in-house network. The combination of up-to-date

technical information, access to current operating

data and the ability to intervene directly in machine

operation, plus the experience of the highly trained

hotline specialists almost invariably result in fast,

efficient solutions. Processors and their machine

operators benefit enormously because they’re

reinforcing their high-performance machines with the

know-how of a global expert network. p

TELESERVICE FROM KRAUSSMAFFEI

Customers using KraussMaffei’s Teleservice en-joy a big advantage, because they can contact a KraussMaffei expert immediately with any problem, from process control to machine diagnosis. Quick answers boost the overall efficiency of production systems.

Support at the

touch of a button

With Teleservice,

operators can set up

a contact with their

technology partner

KraussMaffei within

seconds.

WORLD OF KRAUSSMAFFEI

CONTACT

Josef Hammerschmid

Product Manager ServicePhone +49/89/8899-2558josef.hammerschmid@kraussmaffei.com

For further information pleaseclick here

WORLD OF KRAUSSMAFFEI

33

“Plastics processing is a huge field and includes

highly complex technologies where simply

exploiting existing technology options and available

expertise is not enough,” says Martin Würtele, New

Technologies Manager at KraussMaffei. “What is

needed are strong networks capable of bundling a

range of resources and interdisciplinary expertise.”

This type of network maximizes the opportunities

to expand in-house expertise through exchanges

with other experts, to identify new trends at an

early stage and to develop productive solutions.

Cooperations with universities and research

institutes keep industry in touch with the very latest

scientific findings. This information can flow into

new product development.

Driving technological progress

KraussMaffei long ago recognized the importance

of interdisciplinary cooperation and has set

up many networks of different kinds to bring

organizations together. They include the

interdisciplinary PRIMUS network and the Center

for Integrative Lightweight Composites. “These

networks bundle the development resources of

our Injection Molding, Extrusion and Reaction

Machinery divisions with the research facilities

of universities, research institutes and industrial

partners,” says Martin Würtele. “The outcome has

been innovations with very high success potential.

They give all the partners a valuable technology

lead and a strong and sustainable competitive

advantage.” The most recent partnership was

agreed recently with the BioProcess Engineering

department at the Hanover University of Applied

Science (FHH). The goal is to develop biobased

polymers and industrial-scale processes to produce

viable plastic products. The special focus will be

on characterizing the connections between the

composition of the materials and the technology

required to injection mold them. Working closely

together, the partners aim to lay the foundation

for wide use of sustainable, biobased plastics.

Researchers in the new Plastics Laboratory at the

FHH will have available a twin-screw ZE 34 Basic

extruder from KraussMaffei Berstorff and an all-

electric EX 160-750 injection molding machine

from KraussMaffei. p

CONTACT

Martin Würtele

Manager New TechnologiesPhone +49/89/8899-3508martin.wuertele@kraussmaffei.com

Cooperations with

scientific researchers

and with industry bring

together a range of

specialist know-how to

generate powerful, new

solutions.

SCIENCE AND INDUSTRY HAND IN HAND

KraussMaffei bundles our own expertise with know-how from universities, research institutes and industry partners in many networks and cooperations. The innovations that are developed in this way contribute to the long-term success of all the parties involved.

Networking for success

CONTACT

Our worldwide service teams and hotline numbers

KraussMaffei Technologies GmbH

Munich, Germany

Customer Service

Phone +49/89/8899-2273 (electrical systems)Phone +49/89/8899-4380 (mechanical systems)service-ext.de@kraussmaffei.comProcess Engineering

Phone +49/89/8899-4094 Fax +49/89/8899-2161 processing-ext.de@kraussmaffei.com

KraussMaffei Berstorff GmbH

Hanover, Germany

Customer Service

Phone +49/511/5702-533service-ext.ha.de@kraussmaffei.comHotline rubber technology +49/172/5119620Hotline plastics technology +49/172/5119621Service hotline +49/172/5119623

Extrusion Technology division

Berstorff Krauss-Maffei OOO

Moscow, RussiaPhone +7/495 9377554 Fax +7/495 9701731 service-ext.ru@kraussmaffei.com Krauss-Maffei Extrusion

Technology (Zhejiang) Co., Ltd.

Jiaxing City, China Phone +86/573 86973888 Fax +86/573 86967111 service-ext.cn@kraussmaffei.com

KraussMaffei Co. Ltd.

Shanghai, ChinaPhone +86/21 5868-2662Fax +86/21 5868-1173service-ext.sha.cn@kraussmaffei.com

KraussMaffei Technologies India Pvt. Ltd.

Pune, IndiaPhone +91/20 41404610Fax +91/20 41404699service-ext.in@kraussmaffei.com

KraussMaffei (U.K.) Ltd.

Warrington, United KingdomPhone +44/1925 644100 Fax +44/1925 234284 service-ext.uk@kraussmaffei.com

KraussMaffei Corporation

Florence, USA Phone +1/859 2834307 Fax +1/859 2830290 service-ext.us@kraussmaffei.com KraussMaffei de Méxiko Mexico City, MexicoPhone +52/55 53082383 Fax +52/55 53081727 service-ext.mx@kraussmaffei.com

Krauss Maffei do Brasil Ltda. São Paulo, Brazil Phone +55/11 46129171 Fax +55/11 46128366 service-ext.br@kraussmaffei.com

Krauss-Maffei Italiana S.r.l. Abbiategrasso, Italy Phone +39/02 94963181Fax +39/02 94699482 service-ext.it@kraussmaffei.com

Team America/Spain

Injection Molding Service Teamservice-imm.america@kraussmaffei.comInjection Molding Spare Parts Team spareparts-imm.america@kraussmaffei.com

Injection Molding Machinery division

Team Europe

Injection Molding Service Teamservice-imm.europe@kraussmaffei.com Injection Molding Spare Parts Teamspareparts-imm.europe@kraussmaffei.com

Team Asia/Middle East Injection Molding Service Teamservice-imm.asia@kraussmaffei.com Injection Molding Spare Parts Teamspareparts-imm.asia@kraussmaffei.com

KraussMaffei Technologies GmbH

Munich, Germanybernd.friedrich@kraussmaffei.comViersen, Germanyudo.hafer@kraussmaffei.comGeorgsmarienhütte, Germanyrainer.janotta@kraussmaffei.com

KraussMaffei (U.K.) Ltd. Warrington, United Kingdomstephen.lambert@kraussmaffei.co.uk

KraussMaffei Corporation

Florence and Detroit, USAdlanham@krauss-maffeicorp.com

Reaction Process Machinery division

KraussMaffei Corporation Mexico City, Mexicojuan-pablo.trejo@kraussmaffei.com

KraussMaffei do Brasil Ltda.

São Paulo, Brazilanselmo.costa@kraussmaffei.com.br

KraussMaffei Andina

Bogotá, Colombiacarlos.cadavid@kraussmaffei.com

KraussMaffei Italiana S.r.l.

Abbiategrasso, Italy gianmario.bossi@kraussmaffei.com

KraussMaffei Berstorff

Moscow, Russiajuri.mitschurin@kraussmaffei.com

KraussMaffei Korea

Seoul, Koreaalex.lee@kraussmaffei.com

Shanghai KraussMaffei

Machinery Co. Ltd.

Shanghai, China yutang.xu@kraussmaffei.com

KraussMaffei Japan Corporation

Okazaki, Japan k.toda@krauss-maffei.jp

MADE BY KRAUSSMAFFEI 2 ¦ 201134

Page 1 Solutions for the automotive industry

All-round service

Choose the service and support solutions that are

right for your business. We’ll configure your

system, install and commission it, train your staff,

advise on minimizing downtime and maximizing

productivity, and carry out maintenance, repairs

and upgrades.

Hands-on training for operators

and service technicians

We’ll train your operators and technicians in our

Training Centers or on your premises anywhere in

the world. Our graded course programme covers

machine operation, process control and mainte-

nance. We’ll also organize special courses on

customer-specific topics.

Service, support and spare parts – when you need them, where you need them

Europe: · Germany – Munich, Hanover, Verl, Renningen, Oberding-Schwaig, Viersen, Georgsmarienhütte, Treuchtlingen, Schwerin, Schkopau · Austria – Vienna · Denmark – Roskilde · France – Genneviliers Cedex · Italy – Abbiategrasso · Netherlands – Breda · Russia – Moscow, Kazan · Slovakia – Martin, Zilina · Sweden – Jönköpping · Switzerland – Rotkreuz · United Kingdom – Warrington

Asia: · China – Shanghai, Zhejiang, Shenzhen · India – Pune · Japan – Aichi · Korea – Seoul · Taiwan – Taichung · Thailand – Bangkok

Americas: · Brazil – São Paulo · Columbia – Bogotá · Mexico – Estado de México · USA – Florence KY

www.kraussmaffei.com

KraussMaffei Berstorff is your system supplier. We plan and deliver complete systems for processing natural-fiber-reinforced plastics. The natural fiber – wood, hemp, rice husks, flax or similar materials – is processed with the polymer in corotating or counter-rotating twin-screw extruders to produce composite materials. Composites such as WPC (Wood Plastic Composite) have excellent properties, including durability and moisture resistance.

We supply – you benefit:

– Energy-efficient manufacturing due to innovative engineering

– Active wear protection for screws and barrels

– Flexibility to process a wide range of different formulations

– Innovative system solutions

On track for NFC – Natural Fiber Composites

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