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AHEAD

Engineering Passion

Fiber composite solutionsfor advanced lightweight components

www.kraussmaffei.com

RTM Technology

Structural and semi-structural

components such as underbody

structures, side frames or seat

structures

IMC Technology

Fiber-reinforced, structural

components such as front ends,

mounting supports, instrument

panel carriers

Surface RTM Technology

Fiber-reinforced, paintable surfaces

such as roof elements, door inner

panels, trunks or engine hoods

Wet molding RTM Technology

Semi-structural components

made of recycled carbon fibers,

e. g. hybrid components

FiberForm Technology

Continuous fiber-reinforced

components such as crash

elements, B- pillar

reinforcements or seat

structures

KM_Anz_Leichtbau2015_DE-EN_AHEAD_210x280+3_5c.indd 1 25.08.15 10:37

P

KraussMaffei

DRAFT

INCREASING COMPETITIVENESS

PRODUCTIVITY PLUS:THE FORMULA FOR SUCCESS

COVERFORM®

INTUITIVE TOUCHPADS FOR MULTIMEDIA SYSTEMS

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue 02.2015

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Dear Customers, dear Readers,

For the past several years, we have been completely committed to our one-of-

a-kind performance promise: “Engineering Passion.” Our decades of expertise,

our innovative ability and our passionate commitment to plastics engineering have

been your competitive edge. KraussMaffei has a tradition of being at the forefront

of groundbreaking topics of the industry.

This issue features several projects that highlight our expertise in “Trendsetting,”

some of which are in the areas of medical technology plastics, conservation of

resources, lightweight construction, functional integration, energy efficiency as

well as appearance. Not only are we taking a leading position here with our high-

performance machines, but we also see ourselves as innovative leaders for new

technol ogies. Prime examples include the SilcoSet, ColorForm, FiberForm and

CellForm (MuCell) processes developed by KraussMaffei. With the new Adaptive

Process Control System (APC), KraussMaffei has set a new benchmark in terms of

cosistently achieving zero-defect production.

Productivity PLUS is our 360 degree approach for your daily challenges in terms

of efficient production. It provides you with increased flexibility in manufacturing,

offers intelligent energy-saving solutions, extensive technology and upgrade

options as well as ease of operation and perfect accessibility to the machines.

Productivity PLUS combines the advantages offered by KraussMaffei through its

skills, knowledge and experience in machine building, automation and technology.

Productivity PLUS is also our motto at this year's Fakuma. Our dedicated team is

already looking forward to greeting you there and speaking with you about trends,

production and energy-efficient systems as well as the high quality and variety of

our products. It's just too bad that we will only be able to show you a small part

of our wide range of technologies at this large plastics trade show. These exchan-

ges with you, as well as the up-to-date information on new technologies that we

receive from universities and institutions, are an important part for our success

and daily work.

I hope you enjoy reading this edition of AHEAD and would like to take this opportunity

to turn your attention to the brief introduction of the new CEO of the KraussMaffei

Group on page 5. I look forward to working closely with Dr. Stieler!

Dr. Hans Ulrich Golz

Managing Director

President of the Injection Molding Machinery segment

CONTENTS

COVER STORY

6 Productivity PLUS: The formula for

success

PROCESSES & PRODUCTS

12 Combination technology: Three

processes in one production cell

14 Trendsetter silicone

16 Untapped potential

18 Easy and solid handle on all

peripherals

19 Additional savings potential in mold

changing

BRAND & MARKETS

20 Interview: “Fiber-reinforced

lightweight construction as

an innovation driver”

PARTNERS & PROJECTS

22 Operating without looking

24 Pipe fittings in XXL format

26 Resourceful technological leader

in Turkey

28 Continuous change provides stability

30 Always keep cool

32 Automotive glass: A brilliant outlook

34 Delivering successful solutions:

The new sprue picker SPX 10

KRAUSSMAFFEI GROUP

4 Strong together and unique all over

the world

5 New CEO of the KraussMaffei Group

35 Netstal: A win-win for all

35 KraussMaffei Berstorff: Ecology in

construction – a growth market

35 Trade show calendar

35 Imprint

EDITORIAL

IMPRINT

Publisher: KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2

80997 Munich

Germany

Phone +49 89 88 99-0

Fax +49 89 88 99-2206


Responsible: Imre Szerdahelyi (responsible for content

according to German media law)

Chief Editor: Ashenafi Shawl

Editorial team: Thomas Elfron, Michael Flurl, Dr. Sabine Kob,

Anna-Maria Meyer, Petra Rehmet, Stephan

Schierl, Dr. Reinhard Schiffers, Arne Schmidt,

Sven Schröbel, Joachim Weber

Photo credits: Colourbox, Daimler AG, Fotolia,

Fuyao, iStockphoto, KraussMaffei,

KraussMaffei Berstorff, Shutterstock

Concept and design: Kirchhoff Consult AG, Hamburg

www.kirchhoff.de

Printing: omb2 Print GmbH, Munich

The customer magazine is published twice a year

in German and English. The magazine may only be

reprinted with the written permission of the publisher.

Netstal and DaeSang are successfully collaborating in South Korea.

When two s trong

c om p a n i e s j o i n

forces, the result

is a win-win situa-

tion – and customers benefit from a

performance capability that neither of

the companies could have provided on

its own. In South Korea, Netstal and

DaeSang T&C are engaged in a reliable

partnership on equal terms. As a result,

the customers get the best of European

technology and Korean relationship

management.

FOCUS ON CUSTOMER NEEDS

A WIN-WIN FOR ALL

Extruded foams are the ace in thermal insulation.

Near ly 40 percent of German

energy consumption can be at-

tributed to the building sector.

About half of that is used for hea-

ting private homes. That means this area offers enormous sa-

vings potential. KraussMaffei Berstorff contributes to realizi-

ng them.

Partially spurred by lawmakers and partially by cost-conscious

home builders or buyers, the construction industry has made

energy savings one of its top priorities. Thermal insulation is

the name of the game. Buildings everywhere, new ones as well

as existing ones, are being covered with a second envelope for

thermal insulation. Less visible: The insulation of heating or hot

water pipes in order to avoid heat loss.

THERMAL INSULATION

ECOLOGY IN CONSTRUCTION –

A GROWTH MARKET

TRADE SHOW CALENDAR FROM OCTOBER 2015–MARCH 2016

Fakuma, Friedrichshafen, Germany 13.10.2015 – 17.10.2015 KraussMaffei Group

Composite Engineering Show NEC,

Birmingham, England 04.11.2015 – 05.11.2015 KraussMaffei

Expo Plásticos, Guadalajara, Mexico 04.11.2015 – 06.11.2015 KraussMaffei, Netstal

RubberTech, Shanghai, China 11.11.2015 – 13.11.2015 KraussMaffei Berstorff

Putech Eurasia, Istanbul, Turkey 12.11.2015 – 14.11.2015 KraussMaffei

Plast Eurasia, Istanbul, Turkey 03.12.2015 – 06.12.2015 KraussMaffei

Interplastica, Moscow, Russia 26.01.2016 – 29.01.2016 KraussMaffei Group

JEC World, Paris, France 08.03.2016 – 10.03.2016 KraussMaffei

ImprintKraussMaffei 35

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

22CoverForm® Technology enables the production of harder and

scratch-resistant three-dimensional surfaces.

Trendsetter silicone The best way to enter the silicone

growth market is with an experienced partner.

14

6

Prize awarded by

the Automotive

Award Society of

Plastic Engineers

2015

3KraussMaffei Contents

STRONG TOGETHER AND UNIQUE ALL OVER THE WORLDThe KraussMaffei Group is among the worldʼs leading suppliers of machinery and systems

for producing and processing plastics and rubber.

2,000machines of the MX series

have been installed world-

wide to date.

celebration for the Viersen plant in

2015. Together with the location in

Georgsmarienhütte, Viersen forms

the business area of Automotive

Component Systems – trimming

and mold technology for

PUR components in cars.

-year anniversary

Purchase of the present-day pro-

duction center of KraussMaffei

Berstorff in Hanover (an der

Breiten Wiese).

1919

550 twas the clamping force of the first,

self-constructed injection molding

machine by KraussMaffei in 1959.

10

– thatʼs how many the ELION 4200

from Netstal can manufacture per year.

1.593 bill

ion

clos

ures

KraussMaffei Group

4 KraussMaffei Group AHEAD Issue 02.2015

With Dr. Frank Stieler, the KraussMaffei Group has gained a highly accomplished executive with

more than 20 years of international experience in renowned German industrial companies with a

global presence, especially in mechanical and plant engineering.

5KraussMaffei KraussMaffei Group

DR. FRANK STIELER,

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

NEW CEO OF THE KRAUSSMAFFEI GROUP

PERSONNEL NEWS

Dear Customers,

the KraussMaffei Group is a remarkable

company. It has three strong brands at its

disposal with a portfolio of a wide range

of premium-quality, high-performance

products and services, of which technological

expertise and the capacity to innovate form

the basis. I have formed a deep respect for the

wealth of knowledge, motivation and passion

of our workforce all over the world, who are

solely focused on you – our customers.

These strengths are an excellent foundation

for the continued development of the com-

pany and its portfolio of products and

services. As our valued customers, you are

at the heart of all our activities. It is for this

reason that I dedicated the first weeks to

numerous personal meetings with our long-

standing customers in Europe, China and the

USA, and I will continue to do so in the future.

This enables me to gain valuable insight into

your expectations and how we can assist

you in gaining and maintaining a competitive

edge in your markets.

It is a great honor for me to take on this chal-

lenge. I look forward to continue working with

our experienced and excellent management

team and our proud and committed

workforce.

It is my hope that I have been able to bring

across my enthusiasm. I look forward to

doing so in a personal conversation as well.

With best regards,

Dr. Frank Stieler

DR. FRANK STIELER – PROFESSIONAL CAREER

Since July 2015

KraussMaffei Group GmbH:

Chairman of the Executive Board (CEO)

until July 2015

Independent consultant;

Senior Advisor of Sun Capital Partners

Until 2012

HOCHTIEF AG:

Member of the Executive Board, lastly CEO

Until 2009

Siemens AG, various management positions

in the Power Generation Group, then CEO of

the Oil & Gas Division

Until 2001

Lurgi Bamag: CEO, also Senior Vice Presi-

dent of Azurix Corp.

Until 1997

Metallgesellschaft AG:

Head of Executive Board Office and Senior

Vice President

Until 1995

Lurgi AG (since April 2014 Air Liquide Glob-

al E&C Solutions Germany GmbH): Head of

Legal Affairs, lastly Chief Financial Officer of

Lurgi Energie und Umwelt GmbH

Education:

Doctor of Law

P

KraussMaffei

6 AHEAD Issue 02.2015Cover story


Maximum flexibility and efficiency are the key topics in state-of-the-art plastics processing for compa-

nies looking to assert themselves among international competition. Manufacturers have different tasks

depending on whether they are producing technical parts, medical products, packaging or automo-

tive components. The key to success is called Productivity PLUS – KraussMaffei supplies a tailor-made

system solution for every application purpose consisting of an injection molding machine, automa-

tion and additional peripherals, thus increasing productivity in your production. For example, injection

molding machines with small and medium clamping forces of up to 400 tonnes.

PRODUCTIVITY PLUS: THE FORMULA FOR SUCCESS

TEXT: DR. SABINE KOB, PETRA REHMET EDITORIAL SUPPORT: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI

ost pressure challenges The plastics industry is an international business and

production is increasingly moving directly into countries

that represent the markets for the products. This means

providers from high-price regions must be able to keep

up with competitors, that inherently have lower costs for energy, pro-

duction facilities and personnel. Therefore, the key to success is in-

creased productivity, either by decreasing the cost or increasing the

output quantity. In both cases, KraussMaffei opens up a wide range of

opportunities for its customers with its Productivity PLUS approach.

There are numerous factors influencing the injection molding process

and thus the product quality, such as temperatures and movements

on machines and molds or different material quality, either through

batch and moisture variations or changing proportions of recycled

material. This results in a different melt viscosity and the once-sta-

ble process configuration suddenly finds itself outside the specified

quality tolerances. Interruptions caused by mold changes and main-

tenance have a similar effect. This is where Adaptive Process Control

(APC), the only machine function of its kind on the market, effectively

steps in. The function measures the melt viscosity online and adjusts

– without delay – the point of changeover and the pressure level in the

holding pressure for every shot. Operation of the machine becomes

easier and the processor immediately obtains extremely uniform part

quality. The result: is fewer scraps and a higher return on investment.

Dr. Reinhard Schiffers, Head of Machine Technology, has this to say on

the topic: “Zero-defect production is possible with the Adaptive Pro-

cess Control System, and even difficult raw materials can be contin-

uously and efficiently processed into premium-quality components.”

Money can also be saved when investing in a new production plant

by using the cost-effective ClassiX product line from the CX series.

There are just under 450 basic clamp and screw diameter combina-

tions and plasticizing units available that can be supplemented by

over 500 options. The customer benefits from such a large selection

at an optimal price point.

The basic design of the small and medium-sized machines, such as

the CX series, already embodies the concept of high efficiency. Due

to the space-saving twin-platen design, the small and medium-sized

machines require less installation area and their cantilevered clamp-

ing units provide enough space underneath for mold temperature

controllers or removal equipment. This is ideal if capacities need to

be expanded in tight spaces or if a cleanroom is to surround the pro-

duction cell.

The CX is ready for anything. In the 35 to 160 tonne clamping force

range, the new CX is an impressive 15 percent faster, 30 percent

C

7KraussMaffei Cover story

> Exciting surface effects with laser or Exciting surface effects with laser or hologram appearance emerge from a hologram appearance emerge from a CX 160 using inductive DMH (Dynamic CX 160 using inductive DMH (Dynamic Mold Heating) Mold Heating) _ an efficient alternative an efficient alternative to film technology. The industrial robot is to film technology. The industrial robot is completely integrated into the protective completely integrated into the protective housing. housing.

> 40 percent weight reduction for airbag housing: 40 percent weight reduction for airbag housing: the FiberForm application on a CX 300 makes it the FiberForm application on a CX 300 makes it possible possible _ with a cycle time of 42 seconds. The APC with a cycle time of 42 seconds. The APC function also stabilizes the process here. The new function also stabilizes the process here. The new LRX-TwinZ multiple kinematics is integrated into the LRX-TwinZ multiple kinematics is integrated into the standard protective enclosure. This saves installation standard protective enclosure. This saves installation space and also costs.space and also costs.

> Incredibly versatile silicone: An all-electric AX 50 Incredibly versatile silicone: An all-electric AX 50 SilcoSet produces nasal respirator units made from SilcoSet produces nasal respirator units made from silicone in a 4-cavity mold. Premiere of the APC silicone in a 4-cavity mold. Premiere of the APC function for silicone applications, as well as for the function for silicone applications, as well as for the expanded functions of the sprue picker.expanded functions of the sprue picker.

The exhibits at the Fakuma trade show showcase a variety of options for increasing The exhibits at the Fakuma trade show showcase a variety of options for increasing productivity with KraussMaffei in both small and medium-sized machine segments:productivity with KraussMaffei in both small and medium-sized machine segments:


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

quieter and 25 percent more efficient. A CX Hybrid solution is also

available now: Manufacturing is even more efficient and precise with

its electric injection unit.

The challenge of specializationUsing the new technologies presents a possibility for many proces-

sors to better position themselves in a very competitive environment.

A prime example is multicomponent technology, which enables a high

degree of functional integration. KraussMaffei also offers individu-

alized, flexible solutions here. Each KraussMaffei injection molding

machine can be conveniently expanded with a bolt-on unit. Surface

processes, such as film technology, offer similar potential for more

specialization. Thermoplastic lightweight construction solutions

such as the FiberForm process developed by KraussMaffei, which is

a combination of injection molding machinery and thermoforming of

composite sheets, also offer this potential.

KraussMaffei supports its customers on their path to discovering

new technologies from the beginning – from the project configura-

tion, test runs in the TechCenter up to the commissioning of the fin-

ished individualized production solutions and the after-sales service.

The investment pays off. Dr. Hans Ulrich Golz, Managing Director of

KraussMaffei and President of the Injection Molding Machinery seg-

ment of the KraussMaffei Group, adds: “The path to specialization is a

worthwhile endeavor. Those willing to take a chance will be success-

ful in the long run.”

The challenge of fl exibilityWhile traditional manufacturers have a certain amount of planning

certainty due to defined release order quantities and throughput times,

providers involved in contract manufacturing have to deliver flexibil-

ity first and foremost. As a result, their machinery needs to be de-

signed to meet a wide variety of different requirements. KraussMaffei

has them covered with optionally available clamping platen sizes and

distances, among other products. This is also true of the new CX se-

ries, which allows the platens to be up to 13 percent wider. The re-

sulting benefit is that applications requiring a 160 tonne machine

from the competition, run at 130 tonnes on a KraussMaffei machine

– an efficiency advantage of up to 15 percent, from requiring fewer

work hours to reducing operating costs to make the same piece. Even

molds up to 40 percent larger fit on the machine with XXL platens!

The adaptation for the plasticizing unit also enables enormous flexi-

bility. This facilitates the production of shot weights, which were too

small for the available machine and previously had to make due with a

large sprue (and thus wasted resources).

The new, intuitively operable MC6 Multitouch, which is being used in

all series, is a revolutionary highlight for the machine control sys-

tem. It is the only one on the market to use a capacitive 24 inch mul-

titouch screen and is as easy to operate as a smartphone. Even com-

plex processes can be run using gestures such as swiping or pinching

your fingers. To allow operators to control machine movements with-

out even looking at the screen, the SlideX guideway engraved on the

glass provides the necessary tactile orientation. The control of linear


TECHNICAL PARTS

Those who manufacture technical parts need

precision. Metal inserts are extrusion-coated,

a high percentage of recycled materials and

fiber-reinforced plastics are used and there

are frequently multiple color variants and

multicomponent applications, especially in

the consumer area.

Klaus Bange, Head of Business Unit TEC:

“Nearly every screwdriver from the DIY store

today already has a grip with hard-soft-

connections. Flexible bolt-on units allow our

customers to quickly and perfectly enter the

world of multicomponent technology.”

robots can easily and conveniently be integrated into the MC6 using

the WizardX programming wizard. Intuitive operator guidance sup-

ports the user and allows even beginners to create basic automation

processes in the shortest possible time.

The challenge of resource conservationResources are limited and raw materials are becoming ever more ex-

pensive. This makes reducing the amount of energy, oil and material

we use worthwhile in the long run. Therefore, the drive concept for

the new CX series has been energy-optimized so that the machine al-

ready requires ten percent less electricity than before due to intelli-

gent storage management. The optionally available BluePower Vario

Drive improves the efficiency even more, it saves up to 30 percent

compared to the typical hydraulic variant. The oil volume has also

been reduced by 20 percent and in the plasticizing area, KraussMaffei

stands alone as the leader for this type of design. Because injection

can take place in one line of action, even fully hydraulic machines

achieve a precision that other providers can only achieve with hybrid

or all-electric models. Moreover, the good homogenization perfor-

mance of the HPS-M screw really saves money. The color master-

batch, for example, can often be reduced by up to 30 percent, which,

at prices as high as 20 euros per kilogram, easily adds up to a few

thousand euros per year.

Intelligent KraussMaffei BluePower energy management systems

also support sustainable production. Such as the new weekly timer,

which prepares the injection molding machine with pinpoint accuracy

at the time of production start. This saves time and energy. Addition-

al energy-saving potential – up to 15 percent – is the result of active

storage management, with which the optimum operating pressure is

determined and the charge pressure is adjusted in the memory. The

“Eco-Button” function also compares the energy consumption before

and after optimization and thus determines the energetic optimum

setting values. The operator now decides whether the new values are

accepted or rejected.

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

MANAGING DIRECTOR OF KRAUSSMAFFEI

APC

The new APC (Adaptive Process Control)

machine function enables quick restart-

ing of the injection molding machine.

APC even lets you use difficult material

batches and high quantities of recyclate

to produce high-quality components.

HPS-M

The screw and non-return valve ensure

uniform color distribution in the com-

ponent. This allows the use of complex

materials. Achieve batch savings of up

to 30% and change colors up to 20%

faster!


CX STANDS FOR HIGH EFFICIENCY

Thanks to its smart battery management,

the machine uses ten percent less elec-

tricity than before.

AUTOMOTIVE

Automotive industry suppliers know the story:

Extremely narrow tolerances and high speci-

fications for the product quality. Highly visible

parts require absolutely immaculate surface

quality, because even the smallest defect often

only becomes apparent after a subsequent

refining step, resulting in the loss of even

more added value.

Bengt Schmidt, Head of Business Unit

Automotive, explains: “The APC function has

received a very warm reception from our cus-

tomers in the automotive sector, for instance

during cost-intensive procedures such as the

in-mold labeling (IML).” (For more information,

refer to: Foliotec user report on pages 28–29).

MEDICAL

Long throughput times and the cleanest pro-

duction situations: Many products in the medi-

cal industry are only subject to a few changes.

High quantities and long service lives are

sought after in disposable items. In addition,

silicone applications are becoming more and

more interesting (for more information, refer

to: article on pages 14–15).

Thomas Hörl, Key Account Management MED:

“KraussMaffei machines perform very well

with cleanroom capability by virtue of their

clean, compact design. In addition, applica-

tions can be run on smaller machines than

competing brands by using our wide platens.

This saves valuable cleanroom installation

space and reduces operating costs.”

LOGISTICS/PACKAGING

When quantities are approaching the millions,

two things in particular are key: speed and

raw material efficiency. In addition to rapid

cycle times, every last tenth of a gram of

saved plastic counts here because material

costs account for more than 60 percent in the

packaging industry.

Klaus Zeiler, Deputy Head of Business Unit

Logistics/Packaging: “The plasticizing unit

from KraussMaffei is the best on the market.

Alone with our unit and combined with the

HPS-M screw, our customers can save thou-

sands of euros a year.”


COMBINATION TECHNOLOGY: THREE PROCESSES IN ONE PRODUCTION CELL

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

Natural fibers have established their place in the automotive industry as a more lightweight and

cost-effective raw material for interior components. The mass production of components like

these is a part of everyday industrial life, up to this point; although, applying surface lamination

has been time-consuming in downstream working steps. The combination of processes is, how-

ever, a promising approach for shortening the process chain.

TEXT: JOACHIM WEBER EDITORIAL SUPPORT: STEFAN SCHIERL PHOTO: KRAUSSMAFFEI

T his is likely a dream come true

for many automotive suppli-

ers: a new process for manu-

facturing natural fiber-rein-

forced components has been developed by

the Institute for Lightweight Structures and

Plastic Processing at the Chemnitz Univer-

sity of Technology in close collaboration with

KraussMaffei and Hugo Stiehl GmbH Plas-

tics Processing. It brings three process

steps under one roof: thermoforming, injec-

tion molding and surface application using

reaction process machinery.

Up until now, the state of the art has been

pressing natural fiber mats interspersed

with plastic fibers into the desired shape

by first applying heat (thermoforming).

High percentages of long fibers can be pro-

cessed in the press method, which acts as

the basis for components that can withstand

high mechanical stress with relatively low

wall thickness and low structural weight.

The materials are then processed further

in downstream working steps. They are first

provided with fasteners and then laminated

with decorative materials. Until now, all of

the process integration efforts had to be fi-

nalized before surface decoration.

Now, the developer community has broken

down this barrier. Through the communityʼs

efforts, all three production steps have been

combined into a single production cell. A

standard injection molding machine was all

that was needed. The process is amazing-

ly well suited to mass production, as cycle

times of 60 seconds on a manufacturing cell

can produce more than half a million compo-

nents in a year.

Combinations of methods shorten the pro-cess chainAs in the previous standard process, a tex-

tile semifinished fiber fleece product made

of polypropylene fiber (PP) and natural fiber

Processes & Products

CURRENT TRENDS

Automakers are increasingly

relying on the use of natural

fibers in cars.

312 AHEAD Issue 02.2015Processes & Products

(NF-PP mat) with a defined weight per unit

area is the starting point of the procedure.

NF-PP mats with a weight per unit area be-

tween 1,400 g/m² and 2,000 g/m² are usually

used depending on the mechanical require-

ments. In the first process step, this semifin-

ished product is first heated to approximate-

ly 200 °C and fixed in the mold of a standard

injection molding machine. The mold clos-

es and the semifinished product is reshaped

into a thin-walled NFRP lightweight carrier

(NFRP: natural fiber-reinforced plastic).

The second process step occurs in injection

molding and takes place in the same mold as

the first process step. The lightweight carri-

er is back-injected with function elements or

structural reinforcements made of PP. In the

previous pressing process, the back injection

areas were omitted. This way, the PP melt

can be screwed into the heated NF-PP mat

during the injection process. This creates

a reliable connection between the semifin-

ished product and the molded-on structures.

Both components cool together – internal

stresses are minimized in the component.

As soon as the applied melt is cooled, the re-

action process machinery comes into play.

Numerous material systems are available

for coating. Surfaces with a soft-touch effect

and scratch-resistant paint surfaces can be

applied depending on requirements. Both

coatings are two-component materials. They

are introduced into the closed mold with a

mixing and metering system and react from

there.

Effectively decreasing cycle timesCarrying out this process directly on the in-

jection molding machine requires expand-

ing the mold by the corresponding coating

thickness. This is handled by mold systems

from well-established multicomponent vari-

ants, such as sliders, turntables, indexing

and spin platens. The component can be re-

moved from the mold after the reaction time

has elapsed.

A swivel-platen machine makes it possible to

significantly reduce cycle times even further.

“ We are convinced that

partnerships with univer-

sities can substantially

accelerate innovation.”

MARTIN WÜRTELE, HEAD OF TECHNOLOGY

DEVELOPMENT FOR KRAUSSMAFFEI

This requires reforming and back-injecting

the next semifinished product into the other

cavity at the same time as the coating pro-

cess is happening in the second cavity. Ini-

tial close-to-production tests demonstrated

the bond strength of the three components

as well as the processʼ potential in industrial

applications.

Martin Würtele, Head of Technology Develop-

ment for KraussMaffei, believes this has de-

finitively proven the value of the development

strategy, “Weʼve always been convinced that

partnerships with universities can provide a

significant boost to innovation. This project

has reinforced our decision to continue down

this successful path in the future as well.”

11

THERMO-

FORMING

+

2

INJECTION

MOLDING

+

3

SURFACE

APPLICATION3inYOUR CONTACT:

Martin Würtele

Head of Technology Development

[email protected]

13KraussMaffei Processes & Products

mailto:[email protected]

TRENDSETTERSILICONE

Components made of silicone – whether as stand-alone products or in conjunction with

common thermoplastics – are gaining ground. Medical technology and the automotive

industry in particular are increasingly interested in the outstanding physical and chemi-

cal properties of the material. The best way to enter the silicone growth market is with

an experienced partner such as KraussMaffei.

TEXT: DR. SABINE KOB EDITORIAL SUPPORT: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI

CONFIDENTLY TAKING YOUR FIRST STEPS INTO SILICONE PROCESSING WITH KRAUSSMAFFEI


t is very resistant to aging and chem-

icals, highly flexible, flame resis-

tant and free of plasticizers. And itʼs

a trendsetter: New areas of applica-

tion are bringing double-digit growth

to silicone processing around the world. This

growth stems from technical developments

such as more and more powerful motors, as

well as the increasing population in Asia and

the increasing importance of lighting tech-

nology in everyday applications. These are

all good reasons to delve into the topic of sili-

cone in greater detail.

New paths to precision If you compare processing silicone to pro-

cessing thermoplastics, two things become

immediately apparent: The material is cre-

ated from two individual components in a

reaction process and temperature control

in the plasticizing unit and injection mold is

precisely the opposite of conventional appli-

cations, i.e., cold in the screw (approximate-

ly 20 °C and hot in the mold (approximately

160 °C). As part of its SilcoSet product line,

KraussMaffei makes hydraulic, electric and

hybrid machines with clamping forces from

35 to 650 tonnes designed to process sili-

cone – even post-manufacturing processing.

Turnkey solutions even provide a complete

system – including the injection mold and pe-

ripherals. Doing this for the mold is quite a

challenge. Because liquid silicone (LSR: liq-

uid silicone rubber) has a consistency rang-

ing from honey to water, the mold must

clamp extremely tight and the creation of a

vacuum is often necessary. KraussMaffei

has proven partners for silicone molds with

up to 256 cavities and excels on the machine-

side with its plasticizing unit. On proven in-

line injection units, the force is transferred to

the screw via the piston along a direct line of

action. This allows even fully hydraulic ma-

chines to achieve the precision necessary for

processing silicone.

Exceptional physical and chemical propertiesThe enthusiasm for materials that can be

used in extreme temperatures continues to

rise in the automotive industry. As engines

become increasingly more powerful, TPEs

just cannot handle the heat under the hood.

Silicone, by contrast, is stable from –110 to

+250 °C and even up to 300 °C in special for-

mulations. In addition, self-adhesive types

cling tightly to coverings made of polyamide

(also with glass fiber content) or other ther-

moplastics as a seal in two-component ap-

plications. A production and transfer pro-

cess is recommended for two-component

parts, which can involve handling within the

machine, can occur between two separate

trends. First, the population in Chine is aging

at a rate similar to Europe. Second, the num-

ber of very young users of silicone products

is increasing due to the easing of Chinaʼs one

child policy.

In addition to liquid silicones (LSR), there

are also solid silicones (HTV: high-temper-

ature vulcanizing), which comes in rectangu-

lar blocks before it is processed into its final

shape. Due to their insulating properties and

even higher dimensional stability, they are

particularly well suited to applications in the

electronics industry or with high mechanical

stress. KraussMaffei also offers the equip-

ment needed for processing HTVs, includ-

ing patents for the automatic feed unit AZ.

Plastics processors considering the idea of

entering the silicone area are in good hands

with KraussMaffei.

I

FAKUMA: SILICONE PROCESSING LIVE

Ensuring the flow of oxygen:

KraussMaffei is demonstrating the

production of nasal respirator units

made of silicone at Fakuma. The

product runs on an all-electric AX

with 50 tonnes of clamping force

in a four-cavity mold. The SPX 10

sprue picker with extended function

takes the parts, separates them and

deposits them. The AX SilcoSet is

cleanroom-compliant and qualified

for the manufacturing of medical

products.

YOUR CONTACT:

Cordula Regensburger

Product and Technology Management

[email protected]

machines or, if space is at a premium, can be

achieved using a rotary table. In any case, the

silicone is sprayed onto the still-active ther-

moplastic surface to produce the finished

product.

The new highly transparent silicone is of in-

terest for applications throughout vehicle

production and in other areas where the de-

mands on lighting technology continue to in-

crease in complexity. They enable the pro-

duction of extremely thin and precise lenses,

such as for LEDs. The low viscosity of LSR

makes it possible to create light-scattering

textures that are hardly even feasible with

thermoplastics. The material has additional

advantages: It does not yellow and is resis-

tant to aging.

Leading know-how in the growth marketSilicone is most frequently associated with

the health sector. These products include

cannulae, baby pacifiers and breast pumps

– all ideally made on all-electric machines

with cleanroom equipment. This use fo-

cuses on the biocompatible, hypoallergen-

ic properties of the material and the fact

that bacteria-resistant types are also avail-

able. Access to medical care is increasing in

many countries around the world – and de-

mand along with it. In the booming market in

China, growth is also influenced by two other

New areas of application are bringing double-digit growth to silicone processing around the world.



Sophisticated programming, large quantities of sensory data: These provide the basis for a

wealth of setting options that state-of-the-art injection molding machines offer. Their opera-

tors, as well as the manufacturer, can access a vast amount of parameters and information

to optimize the process. However, many of these areas available for optimization remained

underutilized until now.

UNTAPPED POTENTIAL

TEXT: JOACHIM WEBER EDITORIAL SUPPORT: DR. REINHARD SCHIFFERS PHOTO: KRAUSSMAFFEI

dmittedly, not every employee is permitted to make ad-

justments. Access works on various levels. The operator

can directly input one part of the optimization processes.

But this requires in-depth familiarity with the machine.

Another area of machine parameters cannot be reached

from the outside. It depends directly on the process involved and is

set to safe, general values defined by the manufacturer. And final-

ly, there are interactions that can only be made while the machine is

running.

The control system in the injection

molding machine holds this built-in

intelligence. It has process “knowl-

edge” in two forms. Information about

the machine itself – you could say its

configuration and options are fixed by

the software blueprint. On the other

hand, the measured values from the

ongoing process vary, are dynami-

cally processed and regulated as

needed. At the same time, they help

the control system acquire addition-

al process knowledge, essentially al-

lowing it to learn.

Complete controlEntirely new options for achieving the perfect machine optimization

result from this setup, particularly the option of operating it in an en-

ergy-efficient manner. The measured values include information such

as the hydraulic accumulator charge pressure and the injection pres-

sure limit. KraussMaffei has integrated an electronic specialist in the

MC6 machine control system to adjust them automatically: The Eco

Button.

Activating it sets it to work determining the optimum energy values

for various setting parameters. The operator then has the choice of

either accepting or refusing the suggested parameter settings. This

gives the operator full control over component quality and makes it

possible to achieve maximum energy savings – the machine handles

the task of finding the optimum parameters here. The Eco Assistant

is a standard function for all hydraulic machines with an MC6 control

system.

Intelligent pausingThe option of minimizing the energy use during planned downtime,

such as during pauses in production, is also interesting. The drives

can usually be switched off during these standby times while the

barrel and mold heating are dropped down to a certain level. This

level changes depending on which plastic material is being used.

Polyethylene can cool down com-

pletely; polyacrylic or PMMA, on the

other hand, would likely damage the

machine if they solidified complete-

ly. The operator can also leave this

function to this control system; the

operator just needs to specify the

times for the idle mode.

The weekly timer offers another op-

portunity for savings. This function

– long a part of KraussMaffei con-

trol systems – makes it possible to

switch on the heating and the pump

motor on a timer. How much time be-

fore the beginning of production do

warm-up processes need to be started so that the machine can be

ready on time but doesnʼt use an unnecessary amount of energy?

This is where the learning effect comes into play. The control system

already has empirical values after powering up a system for the first

time and can calculate how long such a process will take based on

the current (temperature) conditions.

At that point, the operator just has to enter the desired times for the

daily start of production. The processes of warming-up the hydrau-

lic fluid and heating up the barrel start automatically. The machine is

warmed-up at the desired time and can immediately start production

at the lowest energy expenditure. The weekly timer for start of pro-

duction is available on every MC6 control system.

A

THE INTELLIGENT MC6 CONTROL SYSTEM FOR SAVING ENERGY

“ The Eco Assistant is stan-

dard for all hydraulic ma-

chines with the MC6 con-

trol system.”

DR. REINHARD SCHIFFERS, HEAD OF MACHINE TECH-

NOLOGY FOR KRAUSSMAFFEI


YOUR CONTACT:

Dr. Reinhard Schiffers

Head of Machine Technology

[email protected]

Load peaks under controlEvery machine can also be integrated into external energy manage-

ment systems (EMS) through the MC6 control system. The reason

stems from energy provider rates, which make load peaks expensive.

Coordination when powering up the machinery is necessary to avoid

these kinds of peaks. An integrative EMS can prevent machines from

all operating in peak-load phases at the same time.

Using stored priorities and performance data as a basis, this system

individually signals all of the MC6 control systems in operation when

they should show a low profile. The control system continues prevent-

ing additional loads such as pump drives, heaters or connected pe-

ripheral units from being switched on until the machine is cleared to

operate again. As a result, individual machines can be ramped up via

time-delay and load peaks can be prevented.

Considerable savingsLimiting peak loads can also be enabled during ongoing production

to temporarily throttle the energy draw of the machinery. In this case,

the EMS also gives the control systems a start/stop signal. The con-

trol systems continue inserting a cycle pause if this is permitted by

the mold and product quality.

“The extensive bundle of intelligent functions built into the MC6 con-

trol system creates many ways for processing companies to save

energy to the tune of several kilowatt hours. In total, when calcu-

lated over the year, this can add up to considerable amounts,” con-

cludes Dr. Reinhard Schiffers, Head of Machine Technology for

KraussMaffei. “This is why we want to help all of our customers dis-

cover and utilize additional functions in the control system.”

MC6 MULTITOUCH

The intuitive control

system of the future.




The dream of every operator is to have the ability to simultaneously

operate and program up to seven peripheral processes with a hand-

held robot – from moving to sorting to packaging. This is possible

with the Multisubmit control function from Kuka integrated into the

KraussMaffei MC6 control system. This keeps KraussMaffei one

step ahead of the competition.

EASY AND SOLID HANDLE ON ALL PERIPHERALS

TEXT: JOACHIM WEBER EDITORIAL SUPPORT: MICHAEL FLURL PHOTOS: KRAUSSMAFFEI

MULTISUBMIT CENTRALIZES THE OPERATION OF THE ENTIRE LINE

“The new Multisubmit programming func-

tion provides the perfect complement to our

proven MC6 operating concept. Centralized

system operation, control and programming

can be carried out via the handheld terminal

of the robot. In addition, the complex integra-

tion of an additional programmable logic con-

troller (PLC) is made obsolete in a wide range

of applications. Basically, system operation

is being centralized and, in turn, simplified,”

states Thomas Marufke, Managing Director

of KraussMaffei Automation GmbH.

The new function has been available in com-

bination with the KUKA KR C4 control system

version 8.3 since the beginning of 2015. Above

all, the system operator notices the additional

convenience. The operator can monitor, con-

trol and, where necessary, program both the

injection molding machine and all of the func-

tions and parameters of the peripheral de-

vices from the familiar control unit. Almost

nothing indicates that third-party software is

responsible for this.

No new expertise necessaryKraussMaffei is expanding the standard of

the available MC6 ProgTechX command li-

brary with the new Multisubmit program

function. The diagnostic and pneumatic func-

tions, as well as variable monitoring, are dis-

played via the MC6 VisuX visualization. Ad-

ditional programmable logic controllers and

PLC operating expertise are no longer re-

quired. This lowers the time and expense

required for training machine operators as

well as the amount of investment required.

The option of retrofitting an existing system

with additional peripherals is also a major

key feature.

For those interested in IT: An interpreter is

a computer program that – instead of con-

verting program source code into an execut-

able file directly on the system like an as-

sembler or compiler – reads in, analyzes and

runs the source code. Kukaʼs Submit Inter-

preter is a logic program that runs in paral-

lel with the robot program. While the previ-

ous robot control system from the company

only had one Submit interpreter each, the

new KUKA KR C4 has eight interpreters run-

ning independently (Multisubmit). The most

important application of Multisubmit is the

activation of external peripheral components

operated at the same time, such as conveyor

belts with separators, assembly stations or

drawer systems and magazines.

PROGRAMMER HELP

Generating a command line free of

errors. Drop-down selection list for

more functionality.

A LIBRARY FOR EVERYTHING

Multisubmit implemented in the

ProgTechX command library.

A1

A2

A3

A4

A5

A6


COMPLETELY UNDER CONTROL

The MC6 look and feel using the

VisuX program interface.

YOUR CONTACT:

Rudi Brand

Technology – Control Technology

[email protected]



“INSERT, MAGNETIZE – DONE”

TEXT: JOACHIM WEBER EDITORIAL SUPPORT: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI

C

Large leaps are not the only path to more productivity for injection molding. It is oftentimes the small

steps that lead to success and have an overall large effect. KraussMaffei showcases two essential work

steps that can further optimize the complex process of mold changes.

ADDITIONAL SAVINGS POTENTIAL IN MOLD CHANGING

hanging a mold more often

means more time devoted to

setup: the interlocking connec-

tion between the machine ejector

and the mold. In order to accel-

erate this work step without impacting safety

or service life, KraussMaffei has developed a

new mechanical ejector coupling.

The result is a new ejector coupling that gives

the user noticeable time savings. It is char-

acterized by the fact that it is flexible when

coupling. This ensures the minimum possi-

ble axis offset between machine and mold.

After locking, a positive connection is created

on both sides. This not only guarantees a pre-

cise ejection but also a long service life.

The coupling releases easily, opens quick-

ly, easily couples back together and clamps

quickly. Owing to its streamlined design, it is

very readily accessible, which makes these

steps easier. As a whole, convenient opera-

tion leads to a significant decrease in setup

time for mold changing.

Magnet instead of screws The magnetic clamping plates from techno-

logical leader Stäubli add a bit more weight

to the scales – both in terms of the produc-

tivity boost and physical weight. Instead of

unscrewing and reattaching at least eight

mounting clamps for changing the mold as

on a conventional clamping plate, all the

mold setter needs is two commands for ex-

tending and retracting the molds: demagne-

tize and magnetize. The operator does not

require any additional equipment. As a re-

sult, the magnetic plate offers the fastest and

most flexible solution for clamping molds.

KraussMaffei adds even more to the equa-

tion. The Stäubli magnetic clamping plate (for

35 to 5,500 tonnes) is fully integrated into the

KraussMaffei MC6 control system, including

its highly intuitive programming and user in-

terface with touchscreen.

is reduced to five minutes with the magnet-

ic clamping plate. The same process on a

1,600 tonne system previously required two

persons to spend 30 minutes working on it.

Mag netic clamping lets one worker finish

this task in ten minutes. This results in a po-

tential increase in machine operating time of

15 minutes in the first scenario, or even 20

minutes in the second.

“Insert, magnetize – done. This is clearly

the fastest, universal type of mold chang-

ing,” states Jochen Mitzler, Head of Strategic

Product and Technology Management at

KraussMaffei. “The user gains a high level

of flexibility and productivity with the com-

bination of the control system and magnetic

plate. In the highly competitive markets for

plastic injection molded parts, this always

entails an increase in competitiveness

as well.”

YOUR CONTACT:

Götz Scheibe

Product and Technology Manager

[email protected]

All the data at a glance This means that the clamping plate does not

require its own control unit; all of its func-

tions can be controlled directly using the

MC6 control system. The operator does not

need to become familiar with another system

(and the corresponding training expenses),

does not have to swap control panels during

ongoing operation and has all the data rel-

evant to the process – such as holding force

and the temperature of the clamping plate

– available at a glance automatically on the

same interface as usual. All specific com-

mands, such as “magnetize” or “demagne-

tize” are input using the control system di-

rectly. The operator can find the previous

working steps stored in the memory as usual

when checking the process or looking for er-

rors. The combination of MC6 plus magnetic

clamping plate ensure noticeably smoother

processes.

This is not the only reason that investing

in a clamping plate such as this is worth-

while. There are other, tangible reasons:

For one, the service life is very long; more

than 20 years is not uncommon. The effi-

ciency gains are also measurable. On aver-

age, a machine setter requires 20 minutes

for setup (insertion, centering and clamp-

ing) on a 300 tonne machine with a conven-

tional mechanical clamping device. This time

SIMPLE AND QUICK

Mold changeover with flexible

ejector coupling.

19KraussMaffei


Brand & Markets

The trend towards lightweight construction suitable for series production is noticeably spurring develop-

ment in reaction process machinery. Development does not stagnate in an industry with new machines

and procedures that allow for the production of high-performance composite components from epoxy

resins alongside polyurethane raw materials and other materials, such as cast polyamide. AHEAD spoke

with Nicolas Beyl, President of the Reaction Process Machinery Segment of the KraussMaffei Group,

about the current trends and developments.

“ FIBER-REINFORCED LIGHTWEIGHT CONSTRUCTION AS AN INNOVATION DRIVER”

INTERVIEW: PETRA REHMET PHOTOS: KRAUSSMAFFEI

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

AHEAD: BMW led the way with the i-series: Lightweight con-

struction ready for series production with carbon-fiber rein-

forced plastic. The other automakers, on the other hand, are

still holding back. What can we expect in this area in the future?

Beyl: The development and acceptance of carbon-fiber reinforced

plastic in the automotive industry is almost exactly like that of

aluminum 20 years ago. In 1994, Audi produced the first sedan se-

ries with a self-supporting car body made of aluminum. The ex-

perts were skeptical at first, but the material caught on at other

manufacturers due to its good properties. Today, BMW is the

NICOLAS BEYL:

The HP-RTM (high

pressure RTM) process

developed by Krauss-

Maffei significantly

shortens cycle times.

pioneer of carbon-fiber reinforced plastic. Composite construc-

tion will catch on in large-scale series production, with CFRP

making up bigger and bigger portions of the mix.

AHEAD: The high costs of carbon fibers and the long cycle times

used to be the largest obstacles to the use of CFRP. What poten-

tial do you see here?

Beyl: It is important to look at the big picture when looking at

costs. For CFRP components in the automotive industry, fibers,

processes and rework costs are all cost drivers, each accounting

20 AHEAD Issue 02.2015Brand & Markets

for about one-third of the cost. The costs for fibers and cycle times

will drop. In the HP-RTM process (high-pressure resin transfer

molding), times as low as two minutes are already possible. And

automation is expanding further in the process as a whole.

AHEAD: You talk about the HP-RTM process as an important

trendsetter for series production. What sort of advantages does

the process offer compared to extrusion-coating and back-in-

jection of inserted composite sheets with similar, very short

cycle times?

Beyl: Unlike the conventional RTM process, the HP-RTM variant –

that is to say, high-pressure injection – allows processing of fast-

reacting resin systems. This significantly shortens cycle times.

Extremely lightweight structural components can be made with

the HP-RTM process. Today, a fiber content of up to 70 percent

can be achieved and the fibers can be aligned with load paths.

This allows us to achieve strength and stiffness that exceeds the

performance of steel components. The HP-RTM process clearly

outpaces the injection molding process.

AHEAD: But there is still the argument that it has comparatively

long cycle times...

Beyl: We set the highest priority on having manufacturing pro-

cesses that are suitable for automation. That is the decisive factor

for cutting costs. HP-RTM can be fully automated and is suited

for series production from the manufacturing of preforms up to

post-mold processing. Of course, we still need to look at the cycle

times in the mold, but these continue to get shorter and shorter

with faster curing matrix materials and new mixing and metering

technology.

AHEAD: How is KraussMaffei advancing the technological devel-

opment of HP-RTM?

Beyl: The T-RTM process is especially interesting. T-RTM stands

for thermoplastic resin transfer molding. Polymerizing thermo-

plastic systems, such as cast polyamide, are used in place as

matrix material here. These reactive caprolactam systems have

three important advantages. First, they have very low viscosity,

almost like water, and therefore offer fast impregnation of the

semifinished fiber components and short process times in pro-

cessing. Second, they can be welded; additional functional parts

can be injected onto the component. And third, they can be re-

cycled as epoxy resin or polyurethane more easily. The first ref-

erences for KraussMaffei are B-pillar reinforcement prototypes

manufactured in the Volkswagen FVK TechCenter. The spec-

trum of all five different HP-RTM processes from KraussMaffei

is diverse and offers a lot of potential – we are planning to pur-

sue every avenue of development for them in the future.

FRONT-END CARRIER

Maximum structure load capacity

and approximately 50 percent lighter

than a metal structure.

“ The spectrum of all five different HP-RTM pro-

cesses from KraussMaffei is diverse and offers a

lot of potential – we are planning to pursue every

avenue of development for them in the future.”

NICOLAS BEYL, PRESIDENT OF THE KRAUSSMAFFEI GROUP REACTION PROCESS MACHINERY SEGMENT

21KraussMaffei Brand & Markets

EXTREMELY SCRATCH-RESISTANT TOUCHPAD SURFACES THANKS TO COVERFORM®

OPERATING WITHOUT LOOKINGIntuitive touchpads for multimedia systems ensure more operating convenience and safety on the

road for current Mercedes models. Continental manufactures the advanced plastic upper shells using

the CoverForm® process from KraussMaffei and Evonik. This lets the automotive supplier benefit from

extremely scratch-resistant and chemical-resistant surfaces in series production.

TEXT: PETRA REHMET (KRAUSSMAFFEI), ARNE SCHMIDT, SVEN SCHRÖBEL (EVONIK) PHOTOS: DAIMLER AG

TOUCHPAD

Extremely scratch-resistant,

providing a long service life:

The manufactured top cover of

the three-dimensional molded

Touchpads from Continental in

the CoverForm® process.

Partners & Projects

22 AHEAD Issue 02.2015Partners & Projects

wiping, zooming, scrolling – the

touchpad integrated into the

center console in the current

Mercedes models enables intui-

tive operation of the multime-

dia system just like a smartphone. In addi-

tion, the touchpad confirms the action of the

driver with haptic feedback just like a button.

This lets the driver operate the system with-

out looking down, keeping the driverʼs focus

on the road. This is an important aspect for

more comfort, convenience and safety while

driving.

Naturally, the more contact there is with a

personʼs hand, the higher the stress of the

touchpad surface. Therefore, the top cover of

the touchpad has to be even more resistant

than a conventional plastic surface, that is to

say extremely scratch-resistant and chem-

ical-resistant. But those were not the only

strict design and quality requirements that

Daimler placed on the automotive supplier

Continental. “The touchpad had to work in a

temperature range of minus 40 °C to above

80 °C, and withstand loads of 80 kilograms

as well as two million operations,” says Jür-

gen Diefenbach, Head of Haptic Devices Proj-

ect Management at Continental, while nam-

ing some of the test criteria from Daimler.

With the CoverForm® technology, it was pos-

sible to meet these criteria perfectly. “We

developed a premium product for premi-

um customers,” says Diefenbach of the new

touch panel. “The technology allows the pro-

duction of harder, more chemical-resistant,

more scratch-resistant and more transpar-

ent three-dimensional surfaces than with

other processes.” The

production site locat-

ed in Babenhausen is

expected to achieve

maximum produc-

tion volume of over

one million top cov-

ers with two injection

molding machines by

2016. This makes the

automotive supplier

and Daimler the first

to bring CoverForm®

into automotive series

production togeth-

er with KraussMaffei

and Evonik.

Injection molding and scratch-resistant coating in one systemCoverForm® is both a material and a pro-

cess technology. It is for this reason that

KraussMaffei and Evonik worked so close-

ly together on development right from the

start. The key to success on the material

side is a specially developed material sys-

tem from Evonik for this process: A very

hard PMMA ( polymethyl methacrylate) bond-

ed with an additional coating for particular-

ly high requirements. But the material alone

is not everything. The conventional manu-

facturing process for a three-dimensional

component with these exceptional qualities

would require injection molding followed by a

separate lacquer coating – a procedure with

a total of 14 steps. A costly and time-con-

suming method. The CoverForm® process,

on the other hand, substantially speeds up

manufacturing while making it more cost-ef-

fective. It enables injection molding and ap-

plication of a scratch-resistant coating in a

single, fully integrated process. This solu-

tion is the only one of its kind in the world:

PMMA directly flow-coated in the injection

mold with a reactive system. This flow-coat-

ing in the mold extends the cycle time by

roughly ten to 15 seconds compared to the

standard injection process, but it eliminates

S

YOUR CONTACT:

Martin Würtele

Head of Technology Development

[email protected]

many downstream steps such as cleaning

the component surface or applying and air-

ing out the primer and hardcoat. In short,

this makes it possible to have significantly

more compact systems than in typical man-

ufacturing processes.

Hand-in-hand developmentDaimler and Continental took an early in-

terest in the new technology. KraussMaf-

fei and Evonik had already subjected Cover-

Form® to numerous standardized tests and

demonstrated its superior material prop-

erties. However, KraussMaffei and Evonik

had to bring this young technology to the

commercial stage. In the automotive indus-

try, for example, it is typical for a compo-

nent to cycle through

three to four sam-

ple phases in which

the design require-

ments can change

significantly. For all

of these intermediate

steps, KraussMaffei

and Evonik needed to

demonstrate time and

again that the altered

design requirements

could be met with

CoverForm®.

In close collaboration,

everyone involved

succeeded in putting

the process into action on time and in accor-

dance with the specifications from Continen-

tal and Daimler. This makes Daimler the first

automaker that can offer a touchpad with a

curved surface for the operation of infotain-

ment system in its vehicles. All other auto-

makers are still using flat surfaces. For Udo

Gayer, Team Manager Interior-Materials

Technology at Daimler, the new touchpad is

not only a technical marvel, but also an eye-

catching addition to the new interior design.

“Overall, I am impressed by both the high re-

sistance to scratches and chemicals as well

as the amazing collaboration with the com-

panies involved: Continental, KraussMaffei

and Evonik,” says Gayer.

80 kgand

2 moperations.

The touchpad can

withstand a load of

1st Place and the Grand

Award, Electronic/Opti-

cal Parts Category, Au-

tomotive Award Society

of Plastic Engineers

(SPE) 2015

No. 1

“ We developed a

premium product

for premium

customers.”JÜRGEN DIEFENBACH,

HEAD OF HAPTIC DEVICES PROJECT

MANAGEMENT AT CONTINENTAL

KraussMaffei Partners & Projects 23


The pipe fittings of GF Piping Systems in Schaffhausen are true heavyweights with a diameter of up

to 500 mm and a weight of up to 120 kg. The connecting pieces for the water supply are being manu-

factured on an MXH 3200 from KraussMaffei. With the option of freely selectable shot weight, the

largest injection molding machine ever installed in Switzerland offers maximum flexibility on a large

machine.

PIPE FITTINGS IN XXL FORMAT

ven the technical data of the MXH 3200 – 101.000/101.000

is impressive: A clamping force of 3,200 t, maximum shot

weight of 120 kg, screw diameter of 2 x 265 mm. “A large

machine with these values in this combination is unique

on the market. This lets us underscore our leading posi-

tion in the development and implementation of large injection mold-

ing machines of the MX series,” says Bruno Schleiss, Managing Di-

rector of the Swiss subsidiary. The products made on the machine

are just as large and complex – pipe fittings with a diameter of up to

500 mm and a weight of up to 120 kg. These are used as connecting

pieces for the public water supply. “The investment and implemen-

tation of a new injection molding system of this size was certainly

a special challenge for us. In addition to the technical parameters

such as a high shot weight and high quality at every point, the sys-

tem also had to meet other criteria with regard to flexibility in mate-

rials and geometry selection. KraussMaffei is the professional, re-

liable partner at our side with whom we succeeded in making this

challenging project a reality,” explains Claude A. Fischer, Head of

Business Unit Utility at GF Piping Systems.

TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

E

THE LARGEST INJECTION MOLDING MACHINE IN SWITZERLAND OFFERS MAXIMUM FLEXIBILITY

The result of the collaboration is an MXH 3200 – 101.000/101.000.

A clamping force of 3,200 t and a shot weight from 5 kg to a maximum

of 120 kg makes it the largest injection molding machine in Switzer-

land. An IR KR500 L340 industrial robot ensures reliable handling of

the pipe fittings, which can weigh up to 120 kg. This is another record,

because – with a maximum payload of up to 340 kg – this is the larg-

est industrial robot that has ever been installed on an injection mold-

ing machine.

Best quality and high shot weightsThe size and weight of the pipe fittings, as well as high quality at every

point, were the customerʼs central requirements for designing a suit-

able MX machine. Large machines of the MX series from KraussMaf-

fei are ideally suited for these applications. They feature a high melt

quality and shot weight consistency, thereby ensuring continuous-

ly high product quality. One special challenge was the high-viscosity

polyethylene 100 material to be processed on the large machine. The

solution involves optimized screw geometries and drives for the plas-

ticizing unit, which are specially designed for processing demanding

LARGE MACHINE WITH LARGE CAPACITY

Solemn commissioning of the MXH 3200 – 101.000/101.000

from KraussMaffei, the largest injection molding machine in

Switzerland, at GF Piping Systems. 340 kgmaximum payload

3,200 tclamping force

120 kgmaximum shot weight

24 AHEAD Issue 02.2015Partners & Projects

material. “The controlled melt temperature during plasticizing pre-

vents the melt from overheating during the plasticizing, preventing

thermal decomposition of the material as a result. At the same time,

high plasticizing output with outstanding melt qualities are possible,”

Schleiss adds.

Maximum fl exibility on a large machineYet this large machine must do more than just produce large compo-

nents with high quality. The customer also wants high flexibility with

regard to material, size and geometry when producing the pipe fit-

tings. For this reason, the large machine is equipped with two injec-

tion units that can be interconnected as needed. “We offer our cus-

tomer, GF Piping Systems, use of a shot weight they can freely choose

from 5 to 120 kg, thereby providing maximum flexibility on a large ma-

chine,” Schleiss says. Furthermore, each injection unit can be oper-

ated independently. This results in high application-specific flexibility

in the process control.

The adapter modules of the plasticizing unit provide additional flex-

ibility in the production of pipe fittings. For example, GF Piping Sys-

tems can install a smaller SP 33000 injection unit; this makes it pos-

sible to quickly change to production with other materials. What

makes this so special is that the material and melt geometry are per-

fectly matched to one another.

The IR KR500 L340 industrial robot used has an additional axis for lin-

ear motion (7th axis), provides additional freedom of movement and

more flexibility as a result, especially when handling heavy compo-

nents. The special gripper technology permits precise interaction of

removing and gripping. The multifunctional gripper is designed for the

various nominal diameters of the fittings. A special padding on the jaws

protects the fittings from getting damaged. “The skilled and close co-

ordination with the persons responsible at KraussMaffei, both lead-

ing up to the project and during the project phase, made a strong im-

pression on us. The result is an automation solution that is perfectly

matched to our requirements,” states Claude A. Fischer.

Save electricity with the BluePower drive conceptBluePower Servo Drive Technology from KraussMaffei supports an

energy-efficient manufacturing process. For the energy-related op-

timization of hydraulic drives, it uses the high dynamics of servomo-

tors to adapt the rotational speed of the hydraulic system pump to

constantly adapt to the actual requirements. The same dynamics are

used to reduce idling losses to almost zero by reducing the speed,

such as during cooling times and during demolding. As a result, the

energy consumption of the machine can be significantly reduced.

YOUR CONTACT:

Daniel Notter

Project Planning

[email protected]

WHEN THE CHEMISTRY IS RIGHT

The teams from GF Piping Systems

and KraussMaffei worked hand in

hand from the start.


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

RESOURCEFUL TECHNOLOGICAL

LEADER IN TURKEYYou can find plastic parts made by Farplas, a customer of KraussMaffei based in Gebze, Turkey, every-

where inside, outside and under the hood of cars. Technical innovations and high-speed machines have

made the company the technological leader in the automotive sector in Turkey, and the company also

delivers parts to the US, UK, Mexico and all over Europe.

TEXT: DR. SABINE KOB, PETRA REHMET EDITORIAL SUPPORT: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI

arge-scale parts like inner

door panels, dashboards, front

grills, cable ducts and finish-

ers for the engine and water

tank form the core focus of busi-

ness. Farplas recently made a concerted ef-

fort in developing its portfolio further with

continuous increases in the production of

what are known as Class A products – vis-

ible parts with premium-quality surfaces.

In the past, these were painted parts, but

the future also holds promise for decora-

tion using film. Accordingly, the range of pro-

cesses that have been employed and imple-

mented together with KraussMaffei is very

broad. While weight-saving technologies like

MuCell and FiberForm show their prowess

under the hood, a greater emphasis is placed

on the quality appearance provided by in-

mold decoration (IMD) in the carʼs interior.

KraussMaffei will soon provide a turnkey

system for this technology. Farplas continues

to specialize even further, and KraussMaffei

is supporting the company along the way.

GX high-speed machine shows its strengthsHolding your own among international com-

petition and opening up new sales markets

require exceptionally efficient production.

Farplas was able to start taking advantage

of potential savings in this area by invest-

ing in a new GX 600-4300 from KraussMaffei

with 600 tonnes of clamping force. The in-

novative GearX and GuideX systems enable

Lthe implementation of exceptionally high-

speed clamping movements. This reduces

the standard cycle time for a center console

with a shot weight of 535 g by almost five per-

cent. In addition, energy consumption could

be reduced considerably – which also brings

tangible benefits when it comes to sustain-

ability. However, for Sinan Yamuç, Process

Development Team Leader Farplas, one the

most striking aspects of the cooperation

between Farplas and KraussMaffei is the

technological advances that have resulted

in greater visual quality for complex visible

parts. He associates this with the GX plas-

ticizing unit and its HPS AT screw, “Itʼs one

of the greatest strengths of KraussMaffei

machines. Weʼre very impressed with the

consistent shot weight and uniform melt. Itʼs

easy to see the quality consistently delivered

by the KraussMaffei machine.”

Because Farplas provides around 2,000 in-

jection-molded parts – 600 of which are ro-

tating through series production – the flex-

ibility offered by the GX also pays for itself

through easy accessibility and resourceful

mold change systems, as well as the result-

ing quick setup. Overall, it is a rugged, de-

pendable partner for high process reliability

and reproducible product quality.

The premiere of MuCell in TurkeyIt is no wonder that the amount of

KraussMaffei machines is on the rise in Far-

plas manufacturing facilities. The company

was founded in 1968 and has been actively

engaged in the introduction of new produc-

tion technologies. It is the sole provider of

many of these technologies in Turkey, such

as MuCell. For physical foaming process-

es, a blowing agent like nitrogen or CO2 is

added to the plastic melt to create a foam

structure inside of the finished component.

This can reduce the weight by up to 20 per-

cent, depending on the part geometry. The

cycle time is also shorter. Injection is 15 to

30 percent faster than for parts made entire-

ly of plastic and the holding pressure time is

no longer required because it is replaced by

foaming in the cavity. Machines with smaller

clamping forces can often be used and less

strain is placed on the mold. During the in-

troduction of MuCell technology, Farplas

took advantage of KraussMaffeiʼs expertise

as a complete system provider. Yamuç em-

phasizes the outstanding collaborative ef-

fort, “Our development surged forward and

we appreciate having direct communication

with KraussMaffei, which afforded us an ad-

vancement in knowledge. The provision of

this kind of in-depth exchange is the founda-

tion of a successful cooperation.”

Another important step for Farplas is the in-

troduction of FiberForm technology, a pro-

cess developed by KraussMaffei that offers

automakers substantial potential savings in

terms of component weight. FiberForm is

a fully automated process in which organic

sheet inserts are thermoformed in the mold

and then encapsulated with a glass fiber-

reinforced polyamide. The finished parts

(such as those for impact protection) feature

a high level of stiffness, despite potential

weight reductions of up to 20 percent and

competitive costs.

This does not nec-

essarily entail a new

investment either.

Existing injection

molding machines

from KraussMaffei

can also be upgrad-

ed using this tech-

nology, such as at

Farplas. “We were

very impressed by

the speedy, straight-

forward installation

of FiberForm components on our existing

CX 650 machine. The technical support and

assistance in carrying out on-site tests was

also outstanding,” says Yamuç.

Since Farplas is part of an entire corporate

group, the technical insights from the auto-

motive sector easily transfer over to other

divisions, such as commercial vehicles or

household appliances. This is the case for

MuCell, where the first system has since

reached its peak installed capacity. This will

certainly also apply to the IMD film technolo-

gies on deck for implementation in the com-

pany. A turnkey system from KraussMaffei

has already been ordered and is expected to

go into operation at the end of the year.

On the path to success through specializationThe competitive situation in the automotive

sector is quite fierce, and is sure to become

even more so. Versatile, innovative com-

panies like Farplas are taking the opportu-

nity to expand their market share at the ex-

pense of large, well-known suppliers and

open up new market areas alongside existing

customer brands (Renault, Toyota, Honda,

YOUR CONTACT:

Andreas Handschke

Product and Technology Manager

Multinject/ SpinForm/TwinForm/

MuCell

andreas.handschke@

kraussmaffei.com

A STRONG PARTNERSHIP FOR MAXIMUM RESULTS

(From left to right) Aykut Basol, Production Manager, Sinan

Yamuç, Process Development Team Leader, and Ali Rıza Aktay,

General Manager, all from Farplas together with KraussMaffei

representative Volkan. Yildirim.

Ford, Fiat, Hyundai, Mercedes). As a result,

Farplas is continuously investing in updating

and expanding its machinery and is focusing

primarily on large parts. In this production,

the company utilizes machines with a clamp-

ing force > 600 tonnes and continues to out-

source smaller applications. Farplas made a

conscious decision to move towards greater

specialization through its investment in new,

groundbreaking technologies like MuCell,

FiberForm and IMD. Success has proven they

made the right choice. Production capacity is

already being fully utilized, and additional in-

vestments are planned for the future. Yamuç

has plenty of praise for the outstanding col-

laboration with KraussMaffei in making this

a reality, “We appreciate the skilled support

that KraussMaffei provided as a complete

provider from the beginning to help us im-

plement the new technologies. This is also

true of current and future projects. This type

of partnership is very important to us and is,

in a sense, vital for our long-term success.”

“ The technical support and assistance in carrying out on-site tests was outstanding”SINAN YAMUÇ, PROCESS DEVELOPMENT TEAM LEADER FARPLAS

27Partners & Projects

Process stability is a concept that embodies the idea of uniform quality with minimal

scrap. The new adaptive process control (APC) machine function from KraussMaffei also

provides this stability even during continuous change. The customer KH Foliotec utilizes

APC in the production of premium-quality interior components with in-mold labeling

(IML).

CONTINUOUS CHANGE PROVIDES STABILITY

TEXT: DR. SABINE KOB, PETRA REHMET PHOTO: FOTOLIA, KRAUSSMAFFEI

PROCESS STABILITY WITH APC

t first glance, it seems like an injection

molding process should simply function

with exceptional reliability and stability

once optimal machine parameters have

been found and no changes should be re-

quired from that point on. But a multitude of factors af-

fect the quality of the parts produced. Temperatures and

movement affect molds and machines. Material can be

affected by anything from fluctuations in viscosity be-

tween individual batches from different recycled mate-

rial admixtures to the moisture content of the pellets.

AInterruptions to the production cycle have a particular-

ly serious effect. In the event of an interruption, the melt

stays in the machine longer than usual, normally de-

creasing in viscosity as a result. The configured machine

parameters are no longer correct because it is easier

to fill – and ultimately overfill – the cavity. This results

in excessive part weight and deviations in dimensional

stability.

The APC machine function from KraussMaffei evens

out these fluctuations in the injection molding process

by adapting and continuously modifying the changeover

point between pressing and holding pressure for each in-

dividual shot by utilizing online measurement of the melt

viscosity.

Optimum product quality after restartingKH Foliotec GmbH is headquartered in Sparneck, in the

German region of Upper Franconia, and manufactur-

ers high-quality surface parts for the automotive indus-

try using the in-mold labeling process and has retrofitted

all the necessary KraussMaffei machines with APC. APC

can be installed quickly and easily without impairing pro-

duction in any way. A KraussMaffei CXZ 500-2000/750 is

now used to create a two-component radio dial panel in

AHEAD Issue 02.201528 Partners & Projects

a 1+1 injection mold. First, the transparent gray PC com-

ponent for the display is injected. Then, the mold rotates

and black PC-ABS for the case body follows in the same

cavity in the second step while the other cavity is already

being filled for the next display. This all takes place on the

back of a PC film with scratch-resistant coating and dec-

orated in black that is inserted into the mold. Its glass-

like surface makes it necessary to clean the mold sever-

al times per shift in order to remove particulates. These

interruptions in the production process, and the accom-

panying need to compensate for fluctuations, provide

an ideal application space for APC for achieving perfect

product quality again immediately after restarting the

process. Compared to operation using a fixed changeover

point, standard deviations in molded part masses (over a

24 hour run time) have been reduced from 0.16 g to 0.03 g

with APC enabled. According to Daniel Müller, Division-

al Manager for the Molding Department at KH Foliotec,

it also significantly reduces the rejection rate in series

production.

He also points out another noteworthy aspect of IML pro-

duction that the process temperature control system has

brought to light. If the company ran the mold at an oper-

ating temperature of 60 degrees and inserted a piece of

film, the film would act as an insulator, meaning the back

of the film would be colder. If the hot plastic hit that loca-

tion, it would harden faster than desired, which could in-

crease the tendency of the finished plastic part to warp.

One option for addressing this problem would be to in-

crease the mold temperature. But this is best avoided

in IML applications, because the more the film is heated

in the mold, the easier it is for the screen-printed color

coating applied on the back to run. In the injection area,

this can cause the incoming plastic to wash off a portion

of color, leading to circular spots. APC makes it possible

to control the partʼs tendency to warp without having to

increase the mold temperature.

Signifi cant reduction in scrap ratesDue to the complex value-adding chain, investing in APC

truly pays for itself in IML production. Screen print-

ing as well as forming and punching combined togeth-

er each constitute approximately 25 percent of the val-

ue-adding portion of IML parts. The typical scrap rates

for both production steps is in the low single-digit range.

The subsequent injection molding process provides the

other 50 percent of added value, but also entails the high-

est risks for the complete part. The scrap rate for black,

high-gloss visual parts can reach up to 30 percent. For

every defective IML component – some of which can be

worth more than ten euros a piece – this means the value

added from imprinting and forming in earlier steps is also

ruined. As a result, manufacturers of premium-quality

IML components have a keen interest in maintaining the

stability of their injection molding process.

APC does not replace the mold setter on a machine; in-

stead, it provides the setter with valuable support.

Sebastian Huss, Process Optimization Officer at KH

Foliotec explains: “APC helps to reduce the sources of er-

rors and to achieve better part quality as a result.”

The APC technology from KraussMaffei allows you to reduce

your manufacturing costs drastically. And the principle behind

it is simple and works like this:

– Input of the “shot weight,” “cycle time” and “price for new

material” parameters

– Choice of “reducing the scrap material portion” as well as

“increasing the portion of recycled material”

– Automatic calculation of savings in euros per year

You can find the APC calculator at the following address:

URL: www.kraussmaffei.com/en/apc-calculator.html

YOUR CONTACT:

Hans Malinowski

Product & Technology Management

[email protected]

KraussMaffei 29Partners & Projects

http://www.kraussmaffei.com/en/apc-calculator.html


POLYURETHANE WET-SIDE EQUIPMENT IN REFRIGERATORS

ALWAYS KEEP COOL

Refrigerators have to be well insulated so that cooling capacity and energy

efficiency can come together. This is particularly true for tropical climatic

conditions. In India, Whirpool India places its trust on KraussMaffeiʼs Rim-

Star mixing and metering technology for producing the critical insulating

layer made of foamed polyurethane (PUR) in the housings and doors.

TEXT: PETRA REHMET PHOTOS: ISTOCKPHOTO, KRAUSSMAFFEI

Brief Profile

RimStar 80/80:

> Precise temperature control

> Stable process control

> High product quality

> Up to 10 mixing heads

30 AHEAD Issue 02.2015Partners & Projects AHEAD Issue 02.2015

n India, Whirlpool India – a subsidiary of

US-based global conglomerate Whirl-

pool – is the market leader in manu-

facturing refrigerators and cooling

systems. The plant produces approxi-

mately 6,800 refrigerators daily in the north-

ern Indian city of Faridabad. From there, they

are sold throughout India and in neighboring

countries. Five RimStar mixing and meter-

ing systems from KraussMaffei ensure the

perfect insulation of housing and doors. The

equipment also includes Pentamix systems

from KraussMaffei.

Whirlpool is not a new customer for

KraussMaffei. The collaboration started

back in 2012. The first wet-side equipment,

a RimStar 80/80, was sent to Brazil and has

been successfully producing refrigerators

in South America ever since. “The RimStar

system in Brazil has impressed us with its

reliability and production efficiency in recent

years,” says Rohit Dhiman, Projects Director

at Whirlpool Faridabad, “It was only logical

for us to choose KraussMaffei again when

making the new investment.”

Stable process control and high product qualityThe primary strengths of the RimStar sys-

tems include stable process control and high

product quality. The definitive reason for this

is the KraussMaffei mixing head technology.

Depending on the application, the five new

RimStar systems at Whirlpool are equipped

with up to ten mixing heads. For the poly-

urethane foaming of the refrigerator hous-

ings and doors, linear and transfer mix-

ing heads from KraussMaffei are used. The

main characteristic of these transfer mixing

heads is laminar and splash-free pouring of

the mixture into open and closed molds. They

are particularly designed for processing

hard-to-mix systems. In short, the custom-

er benefits from high service lives as well as

low maintenance expenses.

Another outstanding feature of the

KraussMaffei RimStar machines is the par-

ticularly precise temperature control of the

components, which guarantees a constant

temperature at all times. In this application,

pentane is employed as the blowing agent

to avoid using chlorofluorocarbons. The en-

tire equipment configuration was manufac-

tured in accordance with German TÜV speci-

fications, successfully receiving acceptance

from TÜV Süd on-site.

Optimum premixing of the pentane compo-

nent in the production line for refrigerator

housings and doors is provided by the fully

enclosed Pentamix 40 premix stations from

KraussMaffei. The pentane is safely intro-

duced into the polyol component. For this

purpose, a 40 l high-pressure pump devel-

oped in-house is used on the polyol side in

addition to a 5 l plunger metering pump. High

metering accuracy is achieved even at very

low feed rates.

Dhiman, the project manager, was partic-

ularly appreciative of the technical exper-

tise of, and the close collaboration with,

KraussMaffei, Goodies International and the

KraussMaffei representative in India: “All of

our contact partners provided profession-

al support throughout the project engineer-

ing process and commissioning phase and

handled our requests quickly and individual-

ly. Overall, collaboration with Whirlpool em-

ployees on-site was perfect.”

I

YOUR CONTACT:

John-Paul Mead

Head of Business Unit

White Appliances

[email protected]

31KraussMaffei Partners & ProjectsKraussMaffei


A WIDE VARIETY OF SUCCESSFUL POLYURETHANE INSTALLATIONS AT THE FUYAO GROUP

AUTOMOTIVE GLASS: A BRILLIANT OUTLOOK Seals made of polyurethane are not only resistant to UV light, very lightweight and reliable,

they also have practically no compression set and reduce vibration and sound. One of the

areas their advantages are showcased best is in the encapsulation of car windows. And this

is also where the Fuyao Group, the market leader in China, has been using the RimStar mix-

ing systems and WinCap mold carriers developed by KraussMaffei right from the start.

TEXT: PETRA REHMET EDITORIAL SUPPORT: THOMAS ELFROTH PHOTOS: FUYAO, COLOURBOX

n its home market of China, the Fuyao

Group is the largest Chinese man-

ufacturer of glass for the automo-

tive industry and already the market

leader. Founded in 1987, the compa-

ny is also one of the worldʼs largest suppli-

ers in this segment. Its customers include

the largest internationally operating man-

ufacturers of automobiles and buses, in-

cluding VW, General Motors and Ford. In

order to encapsulate car windows, Fuyao

has exclusively used the sophisticated poly-

urethane mixing and metering technolo-

gy from KraussMaffei from the start. The

Fuayo Group and KraussMaffei started their

cooperation in 2002. Since then, 19 RimStar

mixing and metering machines with a total

of around 50 mixing heads for polyurethane

processing have been used successfully at

six Fuyao plants. In 2014, KraussMaffei made

another delivery of five RimStar systems with

another nine mixing heads to China and an-

other system with two mixing heads as the

first of several machines to the Fuyao plant

in Lake Orion, MI, in the United States.

Polyurethane performs extremely well dur-

ing encapsulation compared to other materi-

als with numerous advantages. The material

is UV light-resistant, very lightweight but still

Iresilient; it also has basically no compres-

sion set and reduces vibrations and sound.

Polyurethane systems facilitate large-scale

automation and have very short curing times.

This makes them ideally suited for applica-

tions in the automotive industry. “Although

the RIM windows encapsulation process is

the most expensive process compared with

other processes, RIM windows encapsula-

tion is now the industry standard on account

of the durability of the polyurethane seals,

the process reliability and the installation

advantages of a polyurethane seal compared

with bonded rubber seals or thermoplastic-

injected seals,” explains Thomas Elfroth,

Technology Manager for Window Encapsula-

tion at KraussMaffei, and who is responsible

for the markets in Asia.

Versatile metering and mixing technology makes the differenceEngineered as modular systems, the ma-

chines in the RimStar Series can be flex-

ibly configured to match application spec-

ifications and customer requirements.

Polyurethane materials can be perfect-

ly conditioned, metered and mixed using

RimStar machines. The wear-optimized

high-pressure pumps in the RimStar se-

ries, which were developed and produced

in-house by KraussMaffei, also permit exact

and reliable metering of different matrix

components. Magnetic couplings, volume

GEARED FOR GROWTH

In its home market of China, Fuyao is already number one in the

market for automotive glass. Founded in 1987, the company is also

one of the worldʼs largest suppliers in this segment.

32 Partners & Projects AHEAD Issue 02.2015

or mass flow measurement, temperature-

control systems and sophisticated MSR

technology also form part of the metering

system standard. KraussMaffei offers its

customers a large number of variants for

optimum availability and heat-balancing of

material components. “It does not matter

what size of component and what produc-

tion volume customers want to produce,

KraussMaffei has a customized solution for

them,” said Elfroth.

Mixing heads are the second main compo-

nent of the RimStar machines. The two nor-

mally liquid components of the polyure-

thane system are mixed in the mixing head.

In polyurethane processing one compo-

nent consists of polyols, catalysts and addi-

tives, while the second component contains

isocyanate. “The ideally matched system

YOUR CONTACT:

Thomas Elfroth

Technology Manager for

Window Encapsulation

[email protected]

components in KraussMaffei technology

provide short, rheologically optimized line

paths between the individual machine com-

ponents with the result that only low pres-

sure losses occur and

heat-balancing can be

controlled precisely.

This means that we can

always guarantee the

high process reliability

and excellent product

quality that our auto-

motive customers de-

mand,” added Junlong

Shen, Director Product

Validation at Fuyao.

WinCap mold carriers - Ergonomic and functionalThe electric mold carriers in the WinCap Se-

ries, which were completely revamped in

2013, have been successfully used for many

years to encapsulate vehicle glass panes

with polyurethane. The improved mold carri-

ers offer machine operators better ergonom-

ics and greater user-friendliness because

the swiveling mold fixing platens make it

easier to remove mold parts and insert sub-

strates. Parallel mold carrier movements

and high traveling speeds enable short cycle

times and high productivity. The other main

advantages are a reduced noise level and low

energy consumption due to the electric drive

units. Optionally available magnetic clamp-

ing plates also make it easier to perform

necessary mold changes. This ensures fast

flexible production.

Long-standing employees in China guaran-tee customer proximity and successThe highly skilled KraussMaffei staff in

China, who remain in close contact with

colleagues in Munich at all times, are

the main contact for Fuyao. They ensure

smooth installation and commissioning at

the customerʼs facility and offer the reliable

service our customers have come to expect.

Polyurethane systems facili-tate large-scale automation and have very short curing times.

BEST PROSPECTS

Polyurethane is resistant to UV light,

very lightweight, extremely reliable

and reduces vibrations and sound.


It was about a year ago that KraussMaffei introduced the newly

designed SPX 10 sprue picker for the CX series of injection

molding machines. Since then, it has been very well received

on the market. AHEAD spoke with Tobias S. Müller, Fabrica-

tion Plastics Parts Manager for Rockwell Automation AG, at

the companyʼs Aarau location in Switzerland, about his experi-

ences with the fully integrated sprue picker.

TEXT: JOACHIM WEBER EDITORIAL SUPPORT: MICHAEL FLURL PHOTOS: KRAUSSMAFFEI

SEAMLESSLY INTEGRATED

In February of this year, an SPX sprue picker accompanied a pair of

new injection molding machines coming into the Rockwell Automa-

tion production hall in Aarau, Switzerland. The two newcomers in-

creased the number of KraussMaffei machines to nine and the high-

tech picker was the first of its kind at the companyʼs facility. In total,

Rockwellʼs plastics processing machinery includes 40 injection mold-

ing units from various manufacturers working in combination with

rather simple handling equipment and sprue pickers.

400 molds in use There is a reason for this extensive machinery. The primary product

focus for Switzerland-based Rockwell Automation is manufacturing

circuit breakers. And this includes a very extensive vertical range of

manufacture. For quality reasons, a large portion of the individual

parts of the breakers are even produced in their own plant. The com-

pany is a subsidiary of the US company with the same name (sales

volume 2014: 6.6 billion dollars), one of the worldʼs leading providers

of automation products.

One number impressively illustrates the wide spectrum of the Aarau

manufacturing plant: “Due to the high in-house production, we have

approximately 400 molds of various sizes in use here in our injec-

tion molding production,” explains Tobias S. Müller, Fabrication Plas-

tics Parts Manager. Because the molds are replaced twice weekly

per machine, a high level of process automation is imperative. In the

meantime, three generations of MC control systems are in use on the

nine machines from KraussMaffei: The MC4, MC5 and the MC6 with

its incredibly simple and intuitive operation.

Seamless integration into the control system“The change to KraussMaffei machines was very well received by our

operators at the time. Itʼs an easy-to-learn control concept that has

become even more intuitive over the years,” says Müller. The fact that

the MC6 made it possible to integrate the SPX sprue picker seam-

lessly into process automation also met with plenty of appreciation.

“Since users were already familiar with the MC6 control system, they

were able to familiarize themselves with the SPX operating concept in

no time. Integration gives us the advantage of being able to program

and operate the sprue remover with a control system here. Programs

are created in minutes via the additional use of the WizardX program-

ming wizard – and thatʼs incredibly important for the large variety of

molds and programs we have as a result!”

Quick and intuitiveHigh flexibility is required not just from the hardware and software,

but from the operating personnel as well. “Our molds are organized

by clamping force size. Because we use quick release platens, one

mold can often be used on multiple machines. A simple and speedy

program switchover is very important to this process. One of the most

important things is that the user can intuitively and quickly learn how

to operate and program the control system,” says Müller about the

requirements. These requirements also apply to the servomotor-con-

trolled SPX 10 sprue picker. Complete integration into the control sys-

tem leads to a noticeable reduction in changeover times and costs.

Going above and beyond with safetyThe production manager also has his eye on another aspect: work

safety. “A safe machine is our top priority,” he concludes. This is

where the SPX 10 really shines – the safety it provides comes at es-

sentially no cost. It combines with the machine to form one unit. The

detached sprue is stored within the machineʼs housing. This means

that there is no need for a side extension in the form of a protective

fence or subsequent adjustment to the machine housing. This also

saves production floor space and valuable commissioning time.

“KraussMaffei quickly got us on board with the concept of a fully inte-

grated sprue picker complete with sprue chute,” says Müller in praise

of the design.

YOUR CONTACT:

Michael Flurl

Product Management

[email protected]

DELIVERING SUCCESSFUL

SOLUTIONS: THE NEW

SPRUE PICKER SPX 10

34 Partners & Projects


Dear Customers, dear Readers,

For the past several years, we have been completely committed to our one-of-

a-kind performance promise: “Engineering Passion.” Our decades of expertise,

our innovative ability and our passionate commitment to plastics engineering have

been your competitive edge. KraussMaffei has a tradition of being at the forefront

of groundbreaking topics of the industry.

This issue features several projects that highlight our expertise in “Trendsetting,”

some of which are in the areas of medical technology plastics, conservation of

resources, lightweight construction, functional integration, energy efficiency as

well as appearance. Not only are we taking a leading position here with our high-

performance machines, but we also see ourselves as innovative leaders for new

technol ogies. Prime examples include the SilcoSet, ColorForm, FiberForm and

CellForm (MuCell) processes developed by KraussMaffei. With the new Adaptive

Process Control System (APC), KraussMaffei has set a new benchmark in terms of

cosistently achieving zero-defect production.

Productivity PLUS is our 360 degree approach for your daily challenges in terms

of efficient production. It provides you with increased flexibility in manufacturing,

offers intelligent energy-saving solutions, extensive technology and upgrade

options as well as ease of operation and perfect accessibility to the machines.

Productivity PLUS combines the advantages offered by KraussMaffei through its

skills, knowledge and experience in machine building, automation and technology.

Productivity PLUS is also our motto at this year's Fakuma. Our dedicated team is

already looking forward to greeting you there and speaking with you about trends,

production and energy-efficient systems as well as the high quality and variety of

our products. It's just too bad that we will only be able to show you a small part

of our wide range of technologies at this large plastics trade show. These exchan-

ges with you, as well as the up-to-date information on new technologies that we

receive from universities and institutions, are an important part for our success

and daily work.

I hope you enjoy reading this edition of AHEAD and would like to take this opportunity

to turn your attention to the brief introduction of the new CEO of the KraussMaffei

Group on page 5. I look forward to working closely with Dr. Stieler!

Dr. Hans Ulrich Golz

Managing Director

President of the Injection Molding Machinery segment

CONTENTS

COVER STORY

6 Productivity PLUS: The formula for

success

PROCESSES & PRODUCTS

12 Combination technology: Three

processes in one production cell

14 Trendsetter silicone

16 Untapped potential

18 Easy and solid handle on all

peripherals

19 Additional savings potential in mold

changing

BRAND & MARKETS

20 Interview: “Fiber-reinforced

lightweight construction as

an innovation driver”

PARTNERS & PROJECTS

22 Operating without looking

24 Pipe fittings in XXL format

26 Resourceful technological leader

in Turkey

28 Continuous change provides stability

30 Always keep cool

32 Automotive glass: A brilliant outlook

34 Delivering successful solutions:

The new sprue picker SPX 10

KRAUSSMAFFEI GROUP

4 Strong together and unique all over

the world

5 New CEO of the KraussMaffei Group

35 Netstal: A win-win for all

35 KraussMaffei Berstorff: Ecology in

construction – a growth market

35 Trade show calendar

35 Imprint

EDITORIAL

IMPRINT

Publisher: KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2

80997 Munich

Germany

Phone +49 89 88 99-0

Fax +49 89 88 99-2206


Responsible: Imre Szerdahelyi (responsible for content

according to German media law)

Chief Editor: Ashenafi Shawl

Editorial team: Thomas Elfron, Michael Flurl, Dr. Sabine Kob,

Anna-Maria Meyer, Petra Rehmet, Stephan

Schierl, Dr. Reinhard Schiffers, Arne Schmidt,

Sven Schröbel, Joachim Weber

Photo credits: Colourbox, Daimler AG, Fotolia,

Fuyao, iStockphoto, KraussMaffei,

KraussMaffei Berstorff, Shutterstock

Concept and design: Kirchhoff Consult AG, Hamburg

www.kirchhoff.de

Printing: omb2 Print GmbH, Munich

The customer magazine is published twice a year

in German and English. The magazine may only be

reprinted with the written permission of the publisher.

Netstal and DaeSang are successfully collaborating in South Korea.

When two s trong

c om p a n i e s j o i n

forces, the result

is a win-win situa-

tion – and customers benefit from a

performance capability that neither of

the companies could have provided on

its own. In South Korea, Netstal and

DaeSang T&C are engaged in a reliable

partnership on equal terms. As a result,

the customers get the best of European

technology and Korean relationship

management.

FOCUS ON CUSTOMER NEEDS

A WIN-WIN FOR ALL

Extruded foams are the ace in thermal insulation.

Near ly 40 percent of German

energy consumption can be at-

tributed to the building sector.

About half of that is used for hea-

ting private homes. That means this area offers enormous sa-

vings potential. KraussMaffei Berstorff contributes to realizi-

ng them.

Partially spurred by lawmakers and partially by cost-conscious

home builders or buyers, the construction industry has made

energy savings one of its top priorities. Thermal insulation is

the name of the game. Buildings everywhere, new ones as well

as existing ones, are being covered with a second envelope for

thermal insulation. Less visible: The insulation of heating or hot

water pipes in order to avoid heat loss.

THERMAL INSULATION

ECOLOGY IN CONSTRUCTION –

A GROWTH MARKET

TRADE SHOW CALENDAR FROM OCTOBER 2015–MARCH 2016

Fakuma, Friedrichshafen, Germany 13.10.2015 – 17.10.2015 KraussMaffei Group

Composite Engineering Show NEC,

Birmingham, England 04.11.2015 – 05.11.2015 KraussMaffei

Expo Plásticos, Guadalajara, Mexico 04.11.2015 – 06.11.2015 KraussMaffei, Netstal

RubberTech, Shanghai, China 11.11.2015 – 13.11.2015 KraussMaffei Berstorff

Putech Eurasia, Istanbul, Turkey 12.11.2015 – 14.11.2015 KraussMaffei

Plast Eurasia, Istanbul, Turkey 03.12.2015 – 06.12.2015 KraussMaffei

Interplastica, Moscow, Russia 26.01.2016 – 29.01.2016 KraussMaffei Group

JEC World, Paris, France 08.03.2016 – 10.03.2016 KraussMaffei

ImprintKraussMaffei 35

http://www.kraussmaffei.com

http://www.kirchhoff.de

AHEAD

Engineering Passion

Fiber composite solutionsfor advanced lightweight components


RTM Technology

Structural and semi-structural

components such as underbody

structures, side frames or seat

structures

IMC Technology

Fiber-reinforced, structural

components such as front ends,

mounting supports, instrument

panel carriers

Surface RTM Technology

Fiber-reinforced, paintable surfaces

such as roof elements, door inner

panels, trunks or engine hoods

Wet molding RTM Technology

Semi-structural components

made of recycled carbon fibers,

e. g. hybrid components

FiberForm Technology

Continuous fiber-reinforced

components such as crash

elements, B- pillar

reinforcements or seat

structures

KM_Anz_Leichtbau2015_DE-EN_AHEAD_210x280+3_5c.indd 1 25.08.15 10:37

P

KraussMaffei

DRAFT


PRODUCTIVITY PLUS:THE FORMULA FOR SUCCESS

COVERFORM®

INTUITIVE TOUCHPADS FOR MULTIMEDIA SYSTEMS

THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue 02.2015

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