in partnership with industry kraussmaffei is a premium ... · our injection moulding machinery...
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Our service fOr cOst-cOmpetitive alternatives
Complete refurbishing for injection moulding machines
in partnersHip WitH inDustrY
KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide
Whatever you aim to achieve in plastics or rubber
processing, KraussMaffei is your partner. We are
the only company with intensive expertise across
the three main engineering fields. And we have a
strong track record in integrating this expertise to
develop new processes and systems.
ready for any challenge
Our Injection Moulding Machinery Division
supplies machinery and systems from 35 to 4,000
tonnes for standard applications and for all
processing variants, together with fully automated
solutions. We have a strong customer base in all the
relevant industries worldwide.
Our Reaction Process Machinery Division supplies
machines and complete systems for processing
polyurethanes and other reactive materials.
Completing our product portfolio, Automotive
Component Systems supplies foam moulds, cutters
and routers. Our customer base is wide, with a
focus on the automotive, construction and white
appliances industries.
Our Extrusion Technology Division supplies
machinery and systems for compounding, for pipe,
profile and sheet extrusion, physical foaming, and
the production of technical rubbers and inter-
mediates for tire production. Machinery from the
company’s range – from single extruders to
complete extrusion lines – is used in many
industries, including chemicals, pharmaceuticals,
automotive, construction, furniture and packaging.
people for plastics
We are the “people for plastics”. We are your
partners from the first exploratory discussion,
through development to commissioning, servicing
and operating your system, and final disposal. At all
times, you are assured of outstanding competence
in planning and engineering, as well as reliable and
fast spare parts, service and support.
adding value for customers
We put our expertise to work for your success.
With machine ranges engineered for modular-
ity, we can deliver application-specific solutions
based on our wide range of standard modules and
specially engineered solutions. This strategy offers
customers technical and cost advantages.
close to customers around the world
As an international company, KraussMaffei has a
presence in all the major markets for the plastics
and rubber processing industries and employs over
3,000 people worldwide. Our sales and service
network keeps us close to all our customers around
the world.
Life ScienceConstructionWhite goodsAutomotive Electrical / electronics
Electrical / electronics Packaging
Reduce your costs, but not your expectations – with KraussMaffei Service
KraussMaffei Service is there with fast, professional help wherever you are in the world. KraussMaffei Service is your expert and reliable partner at all times, but especially for retrofitting, refurbishing and improving the performance of injection moulding machines and for implementing energy-saving measures.
If you are buying or selling a used injection moulding machine, we can offer cost-competitive solutions for a wide range of retrofit and upgrade options. We will modernize your machine to your requirements and to conform with current safety standards. We give a 12-month factory guarantee on all completely overhauled injection moulding machines. And we’re always available for consulting and application engineering.
Page 4 Completely overhauled injection moulding machines
You get a good deal when you buy a second-hand
KraussMaffei machine that has been completely
overhauled by our experts. You get KraussMaffei
quality and service at an excellent price.
always a good investment
KraussMaffei Service (KHS) specializes in
overhauling, upgrading and remarketing previously-
owned KraussMaffei injection moulding machines.
Our engineering expertise, experience and attention
to detail are your guarantee for highest quality.
We give a twelve-month factory guarantee on every
fully-overhauled injection moulding machine we
sell. Your investment is safe and you can expect it
to pay dividends, because you can be sure of
maximum operational availability and a machine
that is an excellent match to your requirements.
customized solutions
You may be buying a second-hand injection moulding
machine, but you are getting first-class know-how.
KraussMaffei is one of the world’s leading suppliers
of advanced plastics processing machinery. When
it comes to used machines, we bring our expertise
to bear on adapting and upgrading machines and
their control systems so that you get a customized,
application specific machine. For maximum efficiency
and minimum costs, we’ve developed modular
retrofit packages. The choice is yours; you can opt
for anything from a limited, step-by-step retrofit to a
complete modernization. We naturally offer the same
retrofit options for older KraussMaffei machines you
have already installed. If you are considering a move
into new markets and new production challenges, you
can call on our teams for expert advice and for any
machine adaptations that may be necessary to realize
your new project.
individual financing plans
A fully-overhauled KraussMaffei injection
moulding machine keeps start-up costs for your
new production project as low as possible. Even
more so, because you have the possibility to
various financing plans to suit your budget, from
leasing and leasing with an option to purchase to
a balance-of-purchase-price scheme.
the right partner
If you’re planning a new project and looking for
a fair partner to buy your used machine, contact
KraussMaffei. We’ll inspect your machine and
make you a fair offer. If you want us to, we’ll also
handle disassembly and transport for you.
all tHe services YOu neeD
Previously-owned injection moulding machines – the cheaper alternative, an investment with a secure future
Page 5Complete service portfolio
Your advantages at a glance:
· Refurbish and retrofit a machine to your requirements, whether it’s a machine you already own or a secondhand machine you’re planning to buy.
· Implement energy-saving measures
· Buy and sell used injection moulding machines
· 12 months factory guarantee for fully-overhauled injection moulding machines
· Upgrade to state-of-the-art – satisfies current safety criteria, with CE marking and the latest machine control system
· Consulting and advice on the right technology for your specific applications
· Assembly and commissioning
· Training and documentation
transparent tecHnOlOGY
Meet the machine: take a tour of a fully overhauled and upgraded injection moulding machine (KM 3200-13000 A)
Aluminium enclosure· with window panels and
hydraulic operation· easier control and at the
same time highest safety
Position - controlled clamping unit with proportional valves (behind machine)· integrated electronics· individually adjustable
Guideway supported sliding-shoe· eliminates platen tilt· less wear on mould· less wear on tiebars
Ultrasonic potentiomheter· fast, precise, maintenance-free· low wear
MC control system· user-friendly· real-time display of
all operating data· extensive quality controls· links to Ethernet systems· display screen close to mould
Plasticizing with shut-off nozzle· fast and precise
closure of nozzle
Ultrasonic potentiometer· fast, precise, maintenance-free· less wear and tear
Closed loop pump control· controlled by pressure and throughput· regenerative pump drives (option)· automatic demand-driven response· energy saving
Lower noise levels · +/– 76 dbA
Injection unit· directly electronically
controlled valves
Control cabinet· good ergonomics· control reserves for later
installation of other options
Options Robot interface · Entry to automated production
Wear protection for the plasticizing unit· up to six times longer service life· long-term consistent product quality
Quick-change mould fixing system· ideal for frequent mould changes
Modular hydraulics concept· parallel machine movements· pressure accumulator for fast
injection up to 600 mm/s
Electric-motor screw drive· plasticizing in parallel with
all machine movements
Teleservice interface
Page 8 Completely overhauled injection moulding machines
The clamp units of KraussMaffei injection
moulding machines offer a number of decisive
benefits for your production and from the
beginning on its easy to use.
no-tilt mould fixing platen
Massive, projecting sliding shoes support the
moving platen as it moves across the machine bed.
Together with the four tiebars, they are capable of
countering every tilting moment, so that even very
heavy moulds will remain absolutely parallel dur-
ing opening and closing. The benefit for you: no
mould wear and no wear on the guide elements.
High-precision position control
Opening and closing movements are tightly
controlled. The end positions “Mould lock” (as
the mould closes) and “Mould open” (as the
mould opens) are repeated with absolute preci-
sion, no matter how heavy the mould and how
fast it is moving. This precision guarantees that
the mould securing process and parts removal
(optimized for time and stroke) are both smooth
and precise.
sensitive mould securing
Mould securing is the most critical phase in the
cycle. In engineering our injection moulding
machines, special attention was paid to getting the
locking phase perfect, in order to give fullest
protection to delicate mould contours. On
adjustable stroke sections, it is possible to program
and call up several different mould closing speeds
and pressure limits independently of each other.
clamp unit
Reliable, precise and flexible
Fixed platen: core pulls and mould-
master valves with proportional valve
closed-loop control
Moving platen: core pulls and ejector
valves with proportional valve
closed-loop control
Proportional valve closed-loop control
for the clamp block
Page 9Clamp unit
flexible for part removal equipment
Parts handling equipment is generally positioned
at right angles to the injection moulding machine,
with parts transport on the operator or
non-operator side. The KraussMaffei clamping
system allows handling equipment to be installed
in the machine’s longitudinal axis as well. There
is ample space for the installation of linear or
6-axis robots.
safety covers
Large window panels give a clear view of the mov-
ing mould and machine components. The front
and rear panels can be opened separately. These
doors give access to the ejector area. The housing is
designed to allow easy connection of the hoses and
cables supplying the mould.
ready for special tasks
Standard machines are not capable of meeting the
requirements of highly specialized applications.
Because KraussMaffei standard machines are engi-
neered to a modular design, even highly specialized
machines can based on standard modules, while
simultaneously incorporating special hardware and
software features. Here are just three examples of
many: Rotating or swivel components especially for
multicomponent moulding; special machine versions
for injection compression moulding and bolt-on
equipment, eg, for gas or water assisted injection;
easy integration of part removal robots.
A fully modernized and upgraded clamp unit
Page 10 Completely overhauled injection moulding machines
Completely modernized injection unit from an A Series machine
Refurbishing and upgrading the injection and
plasticizing unit is a good investment for more
performance, better wear protection and less
stress on the material.
plasticizing units can be matched to the
material and the process
Finely scaled performance and appropriate screw
diameters make it possible to achieve a very close
match between raw material/process/product and
plasticizing performance. For more specialized
applications, our range of machines also includes
metering and injection equipment for standard,
multicomponent and special machines.
matching the screw to the material
We supply a very wide range of standard screws.
In addition, we offer special screw concepts for
high-quality, cost-competitive processing of even
the most difficult materials. A hallmark of all our
screws is an excellent price/performance ratio.
Improving screw design is an important focus of
our R&D effort as we aim to boost screw
performance for processing of all types of plastic,
increase throughput, reduce melt temperatures and
improve mixing and homogenization.
macHine upDates
Retrofits and refurbishing cost a fraction of the price of a new machine
Our plasticizing units – your benefits
· High availability
· Competitive prices
· Refurbishing, test and inspection of old plasticizing units
· Manufactured to the highest standards
· Fast response through direct contact to KHS
Page 11Machine updates
extra wear protection where necessary
Formulations containing additives or fillers to improve
processing, or end product properties, frequently
cause problems for the processing machinery,
including abrasion and/or corrosion of the screw, the
barrel and the non-return valve. KraussMaffei offers
the option of special wear protection for these parts
that minimizes the problem.
Wear protection for constant quality and
lower manufacturing costs
Wear is not merely a maintenance problem. Worn
machine components affect process stability.
Wear on plasticizing unit components impacts on
the process, increasing the reject rate and even
bringing processing to a halt. The right wear
protection is a critical factor in achieving
consistent quality and keeping costs under
control.
configurations with two or more injection
units and bolt-on units
To make multicomponent and/or multicolour
products, standard machines are equipped with
additional plasticizing units. In a KraussMaffei
multicomponent machine, each plasticizing unit
operates completely independently to ensure optimal
plasticizing and homogenization for each material/
colour. The whole process is synchronized by the
process controller. The additional units can be
positioned above or to either side of the main unit in
”L” and ”V” positions. Other arrangements are also
possible, depending on machine size and product.
Whatever the task, KraussMaffei has the expertise
and the hardware and software to configure the right
solution.
Application-specific solutions – for example
plasticizing unit with shut-off nozzle
Second injection unit in L position on the
non-operator side of the main unit for
a second material in multicomponent
moulding
Enhanced wear protection on a high-performance
screw – the arrow marks the start of the wear
protection layer
Page 12 Completely overhauled injection moulding machines
Whether you’re looking for lower energy
consumption, faster movement times, faster
acceleration and deceleration, or constant
reproducible quality over long production runs
– the pumps for the hydraulics in KraussMaffei
injection moulding machines are designed to
deliver all these benefits.
intelligent pump drives for minimal energy
consumption (option)
The regenerative pump drive consumes up to 40%
less energy, especially when running at less than the
rated load. This is because no more than the required
oil volume and pressure is delivered at each stage of
each operation. Actual values are measured in the
pumps and adjusted instantly. This keeps energy
consumption to a minimum.
fast response time
Characteristic of the pressure- and flow-controlled
pumps is the very fast response that enables rapid
accelerations and decelerations or small pressure
variations, eg, in the holding pressure phase.
parallel machine movements cut cycle times
Options available for our standard machines include
the clamping unit open/close stroke to operate in
parallel with the ejector stroke/core-pulling. They are
also engineered to ensure completely independent
movements of the clamping unit (including ejector and
core-pull) and the injection unit (stroke and
plasticizing). KraussMaffei development engineers have
made full use of all the mechanical and control options
to reduce cycle times in a successful drive to produce
an outstandingly fast and efficient machine.
HYDraulics
Precision control, fast response, flexible for upgrades
The customer wanted to save energy, so we upgraded the machine
to use this regenerative pump drive.
The hydraulic drive in a completely overhauled
injection moulding machine.
Page 13Hydraulics
reliable proportional valves
Digital set values for operating speeds and pressures
are entered in the microprocessor controller. These
values are used to control the proportional valves.
The electrically operated valves with an additional
internal closed-loop monitoring system guarantee
high reproducibility and long-term consistent
maintenance of the set values. The result is consistent
production cycles and high product quality.
effective soundproofing cuts
noise levels (option)
The drive unit can be enclosed in soundproofed
covers, capable of reducing sound emission levels
to approx. 76 dBA. Cover panels can be detached
and lifted off individually to allow access for
service and maintenance work and easy access to
all hydraulic components.
extra, high-performance control
for injection and plasticizing
Machines can be fitted with an extra proportional
valve for the injection phase. Pressure and speed
for injection and plasticizing can then be adjusted
with ultimate precision by closed-loop control.
Normally, injection pressure is simply generated by
the machine‘s hydraulic drive pump. If required, an
additional pressure accumulator can be installed to
deliver even higher injection speeds.
Closed-loop control close to the consumer
for highest precision and dynamic control of
injection pressure, back and holding pressure.
Modular concept for ejector, core pulls and
cascades regulated via the operator display.
Clamp unit block with variable-delivery
pumps and integrated safety systems.
Page 14 Completely overhauled injection moulding machines
cOmpOnents anD prOcesses
Special solutions – a ready response to innovative technologies and new market prospects
KraussMaffei supplies proven modules and
innovative processes that let you retrofit your
machines, at a relatively low cost, ready
to enter markets where you see new business
opportunities.
Bolt-on units: low-cost entry into
multicomponent injection moulding technology
KraussMaffei makes it easy for you to move into
the growth market of multicomponent moulding.
You can add a bolt-on injection unit to an already-
installed injection moulding machine. It’s the easiest
and lowest cost approach to starting 2-component
(2C) moulding : KraussMaffei bolt-on units can also
be integrated in machines from other manufactur-
ers – we’ll handle the retrofit for you. An existing
2C machine can naturally be retrofitted with a
third injection unit for 3C moulding. And we’re the
experts in fitting a lot of machine into a little space.
To keep the footprint of your 2C machine the same,
we offer a V-version bolt-on unit. “V” stands for
vertical and this unit is mounted vertically above the
fixed platen. The L-version needs more space, it’s
mounted horizontally at 90° to the main injection
unit. Connection and disconnection is so simple, that
bolt-on units can be switched from one machine to
another if required.
Decoform: innovative one-step production
technology for premium quality decor elements
In the fast-changing automotive market, the
development time for new models shortens year by
year. Models and brands are now largely
differentiated not by technology, but by fittings,
comfort features and customer choice. This means
that the design and quality of the passenger compart-
ment play an ever more important role in purchase
decisions. In a fiercely competitive market with costs
under immense pressure, the challenge is to produce
high quality moulded parts at low unit cost. The
Standard machines can be fitted with one or more
additional injection units to create, for example,
a 3-colour machine
View from the top of an overhauled
KM 3000-13000 A
Independent bolt-on unit horizontal position
Independent bolt-on unit vertical position
Linear robot
Page 15Components and processes
results can be seen in the rapid advance in produc-
tion technologies for each new generation of cars.
The same methods can be used to gain quality and
cost advantages in aircraft and train interiors and
seats, and in the furniture industry.
KraussMaffei offers DecoForm and DecoPress
machines where the proven quality of our engi-
neering and our high-performance components are
the answer to cost-competitive production of high-
quality decor parts. Modular and upgradeable,
they are also ready for the future.
in-mould decoration instead of laminating:
faster, better, cheaper
In-mould decoration – injecting a polymer backing
onto a film or fabric insert in the mould – has
proved most successful when the mould is
equipped with hot runners and needle shut-off
nozzles. These are independently controlled to
avoid damaging the insert material through high
melt temperatures and pressure, shear forces and
shifting. In-mould decoration delivers powerful
technical and economic benefits. It involves fewer
process steps. It’s more environmentally friendly,
firstly because no adhesive means no solvents are
used. Secondly, it’s possible to use regrind in the
substrate material and, thirdly, for high
recyclability the same type of polymer can be
used for the décor film and the substrate. Unit
manufacturing costs for IMD can be substantially
lower (between 15 and 30%) than for conventional
laminating processes.
tandem and stack moulding
These production processes can both be
integrated. They both offer potential for extremely
cost-competitive and economic production.
Hydraulic station with pressure accumulator
for DecoForm and DecoPress applications
Microprocessor controller
micrOprOcessOr cOntrOller
Intelligent, easy-to-use and upgradeable
Control comfort with state-of-the art technology
Perfect process control requires a microprocessor-
based control system, capable of providing
intelligent functions, easy to operate and
error-resistant.
fast and accurate display of processes,
values and graphics
KraussMaffei‘s microprocessor controller is
standard on all our injection moulding machine
ranges, including our multicomponent, thermoset
and special purpose machines. It’s easy to use and
ensures state-of-the-art process control with fast
signal processing for exact reproducibility of set
values within the tightest tolerances. The fast,
multitasking operating system displays actual
values, graphics, etc. in real time, stores set and
actual values and provides easy connectivity to a
PC environment.
simplified touch-key screen for easy,
errorfree machine operation
The number of push buttons and soft keys on the
control panel has been reduced to a minimum, so
that access to the control menus and parameters
has never been simpler or the error risk lower. Even
where functions have been expanded, the enhanced
display format makes for a more compact
presentation without loss of functionality. Motor
and heating are switched on/off using separate
buttons on the operator panel.
colour stn flat-panel display
Controller operation is fully supported by PC display
technology, such as windows, scroll bars and buttons.
Plain text information is toned down, the emphasis is
on easy to understand symbols and pictographs. The
net result is a quicker and surer grasp even of com-
plex interactions and processes. This approach makes
it easier to understand and/or change the production
status currently being displayed. More information
on a page also means less paging. The total number
of pages has been reduced significantly. Parameters
can be tagged, so that pressing the help key will
then invoke an on-line explanation, eg, of functional
operation, setting ranges, etc.
Page 16
Page 17Scope of activities - refurbishing, retrofits and upgrades
scOpe Of activities –
refurBisHinG, retrOfits anD upGraDes
What we can do for you – products and services from KraussMaffei Service
With KraussMaffei Service and the KHS team
your first point of contact, you can be sure of
outstanding support, quality workmanship and
competitive prices. Contact us for upgrades and
retrofits, complete overhauls, modifications and
performance enhancement – or if you want to buy
or sell a used machine. Here is a list of our main
products and services for your injection moulding
machines:
· Retrofits and upgrades
· Overhauling machines
· Performance enhancement
· Modifications for special applications
· Energy consulting
· Implementation of energy-saving measures
· Upgrade and refurbish hydraulic screw drives
· Automation solutions
· Planning application-specific special machines
· Purchase and sale of used machines
· Machine recalculation for design and
process engineering
· Bolt-on units for all machine sizes and brands
· Refurbishing plasticizing units
· Redesign of shut-off nozzles
· Modernizing control systems
· Loan machines for temporary
production bottlenecks
· Expert moving service for machines and
complete production plants
· Cycle-time optimization by integrating electric
screw drives and up-to-date control systems
· Preassembly of components
... and more
Your KHS customer service team
Rely on us for a fast and competent response to
all your service needs anywhere in the world.
Whatever you need – from troubleshooting or
training to spares or repairs – we’re on the job.
We’re dedicated to supplying service quality on a
par with the outstanding quality of our machines
and systems. We offer far more than spare parts
and hotlines. We’ll work with you to choose the
best and most cost-effective solution for your
operation. We’ll help you test new applications
and we’ll plan customized service packages.
all-round service
Our service offering is broad. We’ll configure your
system, install and commission it, train your staff,
plan measures to minimize your downtime risk and
maximize productivity, and carry out maintenance,
repairs and upgrades. You’ll find us fast, reliable
and competent. Our hotline is manned by highly-
trained and experienced service technicians.
If necessary, we’ll get a technician to you quickly.
Remote diagnosis, interfacing directly with your
machine’s control system, can be a practical
alternative. Spares for all important wear parts are
available at short notice. We’re continuously
expanding our service network to speed up spare
parts shipment. Talk to us about the right service
solution for your business.
customer trials and prototyping in our test lab
The Injection Moulding Division operates a test
lab fitted with the latest machinery and equipment.
We can run trials, produce prototype parts and
fine-tune processes on your behalf. We can work
with you to test and evaluate processes, machines
and equipment in order to identify the best
approach for a particular project. Our highly-
qualified application engineers are there to help you.
training with high hands-on content
Courses are held in our lab and training centre,
or, optionally, on your premises. We offer
clearly-structured basic and advanced training in
operation, process control and maintenance for
KraussMaffei injection moulding machines. On
request, we’ll plan and hold special courses on
topics of your choice. All participants spend a high
proportion of their training working hands-on
with original KraussMaffei machines.
A well-structured training program produces
skilled operators and technicians, which will posi-
tively impact your up-time and productivity.
service WOrlDWiDe
Service, support and spare parts – when you need them, where you need them
contact for training:
Rupert Gruber
Phone: +49 89 8899-3613
Fax: +49 89 8899-4173
Phone or mail KHS directly Phone or mail KHS directly
Apart from email you can contact our customer service
and spare parts team from anywhere in the world using
our service hotline or by post at this address:
Our service teams:Our service teams: On call around the worldOn call around the world
Team EuropeTeam Europe
Service Team Injection Moulding
Email: [email protected]
Spare Parts Team Injection Moulding
Email: [email protected]
Team Asia/ Near EastTeam Asia/ Near East
Service Team Injection Moulding
Email: [email protected]
Spare Parts Team Injection Moulding
Email: [email protected]
Team America/SpainTeam America/Spain
Service Team Injection Moulding
Email: [email protected]
Spare Parts Team Injection Moulding
Email: [email protected]
Ralph Lindner Ralph Lindner
Phone: +49 89 8899-3246Phone: +49 89 8899-3246
[email protected]@kraussmaffei.com
servicehotlineservicehotline
Phone: +49 89 8899-3026Phone: +49 89 8899-3026Fax: +49 89 8899-2856Fax: +49 89 8899-2856europeeurope Phone:Phone: +49 89 8899-3172 +49 89 8899-3172 Fax: +49 89 8899-3399Fax: +49 89 8899-3399asia/near eastasia/near east Phone:Phone: +49 89 8899-4298 +49 89 8899-4298america/spainamerica/spain Phone:Phone: +49 89 8899-3801 +49 89 8899-3801
Kraussmaffei technologies GmbHKraussmaffei technologies GmbH
Hall 91 West/Dept. KS 13/KHSHall 91 West/Dept. KS 13/KHS
Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2
80997 Munich80997 Munich
GermanyGermany
Kraussmaffei technologies GmbH
Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2569 ··· Fax +49 89 8899-2877www.kraussmaffei.com/usedmachines
KraussMaffei is a premium partner for the plastics and rubber processing
industries worldwide. KraussMaffei machines and systems are used wherever
plastics and rubber are converted into products. As a knowledge-driven
technology company, we build on many decades of experience and a strong
commitment to research and development.
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KraussMaffei Service is your efficient and reliable partner anywhere in the world. Our areas of special expertise include retrofits and complete overhauls, modifications and performance enhancement of injection moulding machines. We also buy and sell used machines. Our solutions and services are complete and cost-effective, for example, we’ll modernize a machine so that it exactly matches your requirements and conforms with current safety legislation. We give a 12-month factory guarantee on all completely overhauled injection moulding machines. And our expertise in process engineering, energy-saving, etc. is on call at any time.