German quality at Chinese speed. The magazine from ENGEL for the plastics industry

Transcription

1 The magazine from ENGEL for the plastics industry March 2017 ENGEL raises its game in Southeast Asia New organisational unit combines local activities Page 8 In-situ polymerisation on the road to series production Peter Egger and Lorenz Reith from ENGEL s Technology Center for Lightweight Composite Technologies about the opportunities presented by the new developments Page 10 Fewer rejects and greater energy efficiency Integrated Temperature Control Solution automatically regulates pump capacity Page 12 German quality at Chinese speed BMPT in Beijing uses duo machines to produce bumpers for Daimler Page 18

2 Making lightweight design affordable Innovative lightweight design technologies are the key to sustainable mobility. But not everything that is technically feasible and beneficial in terms of sustainability actually finds its way into an application. However, innovations must always be affordable. Cost efficiency is a major driver in the automobile industry, but in many cases tends to obstruct new technologies. This is specifically what we keep in mind as we work with customers and partners on new, highly cost-effective processes for the manufacture of high-volume composite parts at our Center for Lightweight Composite Technologies in St. Valentin. Dr. Stefan Engleder CEO ENGEL Holding Where (cost) efficiency is concerned, the process integration that forms such a large part of our injection moulding operations also points the way for composite lightweight design. Through in-situ polymerisation technology based on ε-caprolactam, for example, we make it possible to functionalise the resultant FRC carrier structures inline in the injection mould (p. 10). The production cell presented at K 2016 produced ready-to-use parts in a single work step. Another advantage is the thermoplastic matrix that enables subsequent recycling. Ultimately, it is the entire value chain rather than component production that determines efficiency and market opportunities. For this reason, we see a particularly strong potential for in-situ polymerisation. Although Europe leads the field in automotive lightweight design, the subject has had an international dimension for quite some time. We have already completed projects in the USA, Mexico, China and Korea. We are also preparing our Center for Lightweight Composite Technologies for even more targeted global implementation of lightweight design projects. Producing locally is part of this philosophy. In our large-scale machine plant in Shanghai, for example, we have just celebrated delivery of the 1000th duo machine manufactured in China (p. 4). As the markets in Asia are continuing to develop dynamically, this spring we will be inaugurating a new, additional production hall at this site. We are currently seeing particularly fast growth in Southeast Asia. To meet the demand, we are investing in a regional centre in Bangkok (p. 8). In Austria namely Schwertberg and St. Valentin we have made good progress over the winter in the expansion of our plants. We are also planning growth for The Center for Lightweight Composite Technologies, by expanding its capacity for development projects and customer trials. Please do not hesitate to challenge us! Together we can succeed in combining quality with sustainability and profitability. IMPRINT Publisher: ENGEL AUSTRIA GmbH Ludwig- ENGEL-Straße 1, A-4311 Schwertberg, www. engelglobal.com Editorial team: Susanne Zinckgraf, ENGEL / Martin Streicher, ENGEL (responsible editor) Layout: NEUDESIGN office for visual communication Injection is the ENGEL customer magazine. It is published regularly in German, English, Turkish and Polish. Articles may be reprinted with the editor s consent and reference to source. All company names, trade names, trademarks or other references to third party or ENGEL products, may in fact be registered, and thus legally protected, even if no trademark symbols are used or visible in the text or copy.

3 N News Retrospectives N Current Events 4 ENGEL worldwide. around the corner. Fairs, events, projects 8 ENGEL raises its game in Southeast Asia New organisational unit combines local activities 9 Ideal working conditions from day one ENGEL put new training workshop into operation 10 In-situ polymerisation on the road to series production Peter Egger and Lorenz Reith from ENGEL s Technology Center for Lightweight Composite Technologies about the opportunities presented by the new developments 12 Fewer rejects and greater energy efficiency Integrated Temperature Control Solution automatically regulates pump capacity 14 High quality interior components at low unit cost DecoJect combines in-mould graining with injection moulding 16 Achieving much more with less Miele to modernise production in China with ENGEL injection moulding machines 18 German quality at Chinese speed BMPT in Beijing uses duo machines to produce bumpers for Daimler

4 ENGEL worldwide. around the corner. Harnessing new developments, faster inject the injection moulding forum inject, the injection moulding forum organised by ENGEL, took place for the second time early in March in Schwertberg. The aim of the event is to enable injection moulders to harness the latest research and development findings faster, and to promote the mutual exchange of experiences. Those who attended were struck by the many new ideas and tips they were able to take back to their businesses with a view to resolving specific challenges, concludes Robert Brandstetter, head of ENGEL s training department, referring to the highly moulding machine to produce large components for vehicle interiors. Supplying our thousandth machine was a major milestone for the whole workforce, emphasises Gero Willmeroth, Sales and Service President at ENGEL Machinery Shanghai. Reaching this figure Gero Willmeroth (left) and Peter Garimort, the two Managing Directors of ENGEL Machinery Shanghai, cut the celebratory cake. The inject injection moulding forum took place in ENGEL s main auditorium and technology centre in Schwertberg. positive feedback generated by the first inject event in the spring of In 2017, we bridged the gap once again between basic development and practical, dayto-day challenges. It is precisely this aspect that sets inject apart from other forums in the sector. is confirmation of ENGEL s continuing success in Asia. Having a production operation here is the only way we can guarantee customers in the region fast delivery times and flexibly adapt our machines and system solutions to specific local requirements, says Willmeroth. Strong local presence is also a decisive factor in choosing to work with ENGEL for the customer that procured the thousandth duo machine from Shanghai. The automotive supplier deploys injection moulding machines and automated system solutions from ENGEL around the world. For injection moulders, access to that knowledge is a key factor in securing competitiveness. Georg Steinbichler Senior Vice President of Technologies Research and Development Handover of the 1,000th ENGEL duo injection moulding machine from Shanghai was celebrated by staff at the plant. ENGEL in Shanghai supplies 1,000th duo machine Milestone for the workforce In November, ENGEL Machinery Shanghai supplied its 1,000th large-scale, dual platen ENGEL duo machine produced in China and held a celebration for its employees. In future, a major automotive supplier in the northeast of the People s Republic will use this injection From university to the working world JKU students visit ENGEL at K 2016 Putting students in touch with potential employers is par for the course at trade fairs. The plastics engineering faculty of Johannes Kepler University (JKU) in Linz sent a particularly large delegation to Düsseldorf for K 2016 and one highlight of their tour was a visit 4_ENGEL injection-2017

5 to the ENGEL stand. After all, the stand is not just for making new contacts, but seeing the results of work in action: for many years, the university s Institute of Polymer Injection Moulding and Process Automation (IPIM) has been a major development partner to ENGEL s Center for Lightweight Composite Technologies. To support the in-situ polymerisation technology presented at the ENGEL stand using an application ready for series production for the first time, IPIM developed programs for mould-fill and mixing simulation. technology presentations and videos at its stand to illustrate how quality and efficiency potential can be fully exploited by means of integrated system solutions from a single source. "Our first goal is to provide our customers with a competitive edge," says Andreas Leitner, Sales Director Middle East at ENGEL. Key to this aim is our high level of expertise in system solutions and automation. ENGEL has built up a strong global network of partners to support its systems business. Two of these partners Otto Hofstetter and IMDvista held a joint presentation with ENGEL in Dubai. One focus of the stand was the production of beverage caps and plastic pallets which, since they can be produced in a more environmentally friendly manner than wooden pallets in the Middle East, are gaining ground. All of the main bottlers and beverage cap producers in the United Arab Emirates are now working with ENGEL technology. Andreas Leitner, Sales Director Middle East Professor Georg Steinbichler guided the students around the stand. He is also the Chairman of the Institute for Polymer Injection Moulding Technology and Process Automation at the JKU. Production solutions from a single source Arabplast in Dubai Maximum efficiency and extremely low unit costs for the packaging industry was the core theme of ENGEL s appearance at Arabplast in Dubai in the United Arab Emirates this January. ENGEL used example products, Technologies for high competitiveness Medical seminar in Bangkok Attracting 50 participants, the medical engineering seminar arranged by ENGEL at the Plastics Institute of Thailand in Bangkok in mid-december was a big success. Together with partner companies Fostag and Hekuma, ENGEL used numerous practical examples to offer insights into the challenges and opportunities presented by injection moulding in clean rooms while showcasing innovative machine concepts and processing technologies. Attendees represented both established businesses in the sector, some of which had an international dimension, and smaller, locally based firms seeking to break The ENGEL e-cap produces as many as 1,920 closures per minute. ENGEL can draw on a wide range of technologies and materials to make pallets ever lighter while maintaining excellent stability. ENGEL presented a broad spectrum of parts in Bangkok, from high volume consumables to geometrically complex functional components. ENGEL injection-2017_5

6 into medical engineering. Despite having varying levels of prior knowledge, all participants were able to benefit from the presentations and the exhibition of parts. High acceptance of the system solutions expertise of ENGEL in Southeast Asia was once again clear from discussions on specific project enquiries held between various attendees and ENGEL experts during the event. Success without the pressure International MuCell conference in Schwertberg In partnership with Trexel, ENGEL continued its successful series of MuCell events with a practically-focused conference at the Schwertberg headquarters at the end of November. As part of the event, automotive suppliers Dräxlmaier and Alseca Engineering presented projects undertaken in partnership with ENGEL. The Romanian company Alseca is a MuCell pioneer in in which high cost effectiveness can be combined with top quality precisely as customers require. At its stand, ENGEL showed how the new opportunities presented by digitalisation and networking can be simply applied to practical situations through inject 4.0. Whether providing single injection moulding machines or integrated and fully automated manufacturing cells, ENGEL ranks as a preferred partner to the injection moulding industry in Russia. We have managed to expand our market share in the last few years, says Olaf Kassek, Managing Director at OOO ENGEL in Moscow. Investment tends to be directed at the field of technical injection moulding, followed by the packaging industry. With 29 employees, ENGEL is continuing to play to its strengths in Russia despite changing economic conditions. It is very important to our customers that we reach their premises quickly when something needs servicing. Olaf Kassek, Managing Director at OOO ENGEL in Moscow Lower weight, enhanced properties: components made with MuCell have no distortion or sink marks. Eastern Europe, specialising in the development and production of complex hybrid components. MuCell has become significantly more important in Eastern Europe over the past two years, says Michael Fischer, Sales Manager for Technologies at ENGEL. "Now the focus is on leveraging the potential that the MuCell process offers on an even broader scale." Michael Fischer Sales Manager for Technologies In-house childcare introduced Toddlers group at Schwertberg headquarters In September, ENGEL opened a toddlers group for one- to three-year-olds at its headquarters. The seven girls and five boys currently cared for will be joined by a second group later this year. As a family-run business, it is vital that we help our employees meet the challenge of balancing work and family life, says Dr. Barbara Steger, Managing Director at Ludwig ENGELKG and a member of the entrepreneurial family. The toddlers group allows employees to return to work after parental leave at the right time for them personally, without having to worry about who will look after their toddler. Intelligent solutions for enhanced process stability Interplastica in Moscow Many different factors have an influence on unit costs, from the energy requirement and repeatability to space productivity. At Interplastica, which took place in Moscow at the end of January, ENGEL demonstrated ways By providing in-house childcare, ENGEL is making it easier for employees to balance professional and family life. 6_ENGEL injection-2017

7 100th machine supplied Euronyl and ENGEL celebrate large order Over the past five years, ENGEL has supplied 100 injection moulding machines for processing both thermoplastics and elastomers to the Euronyl Group. Handover of the 100th machine in the package a large-scale ENGEL duo 2300 machine was jointly celebrated by the project partners at ENGEL s Schwertberg plant in the autumn of The duo 2300 is one of the largest machines used by the Group. At present, Euronyl operates a total of 300 injection moulding machines with clamping force ranging from 300 to 23,000 kn in 10 factories across Europe, Asia and Africa. Ready-to-fit in one step Composites Europe in Düsseldorf With a wealth of injection moulding experience and automation expertise, ENGEL develops highly costeffective production concepts for the manufacture of composite parts. At Composites Europe, which took place in late November and early December in Düsseldorf, ENGEL presented pre-series production solutions. Amongst other things, the company focused on the in-situ polymerisation of ε-caprolactam and the ENGEL organomelt process. Celebrating the 100th machine: Yves Verdonschot (Plant Manager at Euronyl), Andy Soenens (owner of Euronyl), Franz Füreder (Vice President, ENGEL automotive), Tony Beeuwsaert (owner of Euronyl), Peter Neumann (former CEO at ENGEL) and Kurt Callewaert (Managing Director at ENGEL Benelux). Left to right. In the organomelt process, the continuous fibre-reinforced, semi-finished thermoplastic material is shaped, overmoulded and given a high-quality surface decoration in a single processing step. From Switzerland to Austria New head of Technical Moulding business unit Felix Hüthmair, currently Managing Director at ENGEL (Schweiz) AG, will become head of the Technical Moulding business unit at ENGEL headquarters in Schwertberg. In past years, the Automotive and Technical Moulding Business Units were under the same leadership. The designation of a director for the Technical Moulding unit will enhance the performance of both rapidly expanding divisions. Franz Füreder remains vice president of the ENGEL Automotive Business Unit. Felix Hüthmair s successor as Managing Director at ENGEL (Schweiz) AG will be Markus Schertler, who has already been serving ENGEL for many years as a sales engineer in Switzerland. I look forward to applying my sales experience to greater strategic effect while advancing new developments more broadly. Felix Hüthmair, future head of the Technical Moulding business unit Preview of spring 2017 Koplas, Seoul, Korea, March 7th-11th Technology Symposium, Corona, USA, March 8th-9th JEC World, Paris, France, March 14th-16th Plastico Brasil, São Paulo, Brazil, March 20th-24th Kunststoffe im Automobilbau (VDI), Mannheim, Germany, March 29th-30th Plastec, Cleveland, Ohio, USA, March 29th-30th Plagkem, Celje, Slovenia, April 4th-7th Technology Symposium, York, USA, April 26th-27th Interpack, Düsseldorf, Germany, May 4th-10th Plastex, Toronto, Canada, May 16th-18th Chinaplas, Guangzhou, China, May 16th-19th Plastpol, Kielce, Poland, May 23rd-26th FIP, Lyon, France, June 13th-17th ENGEL trend.scaut, Schwertberg, Austria, June 28th-29th ENGEL injection-2017_7

8 Bild: istockphoto/lichtbildfotograf Markets in Southeast Asia are continuing to develop rapidly. ENGEL raises its game in Southeast Asia Southeast Asia is one of the most dynamic and fastest growing markets in the world. To consolidate its position in the region, ENGEL has established a regional hub for subsidiaries and representatives at its Bangkok site in Thailand. Three subsidiaries, three representatives and a new hub in Bangkok: ENGEL is ideally place to capitalise on growth in Southeast Asia. Even prior to this, ENGEL was very well placed in Southeast Asia. We are seen as a technological leader in the region, where we are already a leading player in the automotive supply industry. Furthermore, we are expanding particularly fast in the packaging area, says Chief Sales Officer Dr. Christoph Steger. That is precisely why we are pooling our responsibility for these fast-moving markets. Our aim is to derive greater benefit from resultant synergies in the future while meeting customer-specific requirements in individual countries through strong local teams. Success in Asia based on strong local presence The new organisational unit is overseen by Romain Reyre. As President Southeast Asia he is responsible for the entire region. Romain Reyre has 25 years experience in the plastics and packaging industry in a career that has taken him to Europe, the USA, Latin America and Southeast Asia. In Romain Reyre, we are delighted to have brought on board a sales expert with an excellent knowledge of both plastics engineering and our target sectors, and someone who has lived in Southeast Asia for long enough to be familiar with the local markets, says Steger. Together with our teams in the various countries, some of which have been established for many years, the new hub for Southeast Asia will help us raise our game in the region. We will be able to offer even better support to customers, and meet the challenge of rising quality and efficiency demands more effectively. Continual investment in its local sites has been one of the main reasons for ENGEL s sustained success in Asia. ENGEL is the only European injection moulding machine manufacturer with three production plants in Asia. The company can guarantee customers fast delivery times and speedy service while flexibly adapting products and system solutions to regional needs. Romain Reyre heads ENGEL s new hub for Southeast Asia in Bangkok. New subsidiary founded in Vietnam A subsidiary opened in Vietnam in the late summer of 2016, joining the Southeast Asian subsidiaries in Singapore and Thailand. Previously, ENGEL Singapore had been responsible for business in Vietnam. Thomas Lim, Managing Director at ENGEL Singapore, will continue to support staff in Ho Chi Minh City. The new contact person in Vietnam is Duc Hieu Nguyen. The Vietnamese injection moulding industry is characterised by investment on the part of big international electronics groups and OEMs. These organisations produce smartphones, tablet PCs and other products locally, and have announced their intention to manufacture other goods in Vietnam. For many years already, ENGEL has been supplying these companies with injection moulding machines and integrated system solutions. Among others, Samsung is one of the longstanding partners. The high-tech area is now one of the largest segments of Vietnam s injection moulding market, says Steger. There are also new opportunities opening up in the packaging, household goods and construction areas. 8_ENGEL injection-2017

9 ENGEL s new two-level training workshop at the Schwertberg headquarters offers ideal working conditions from day one. Ideal working conditions from day one Expansion of the technology centre at the ENGEL s headquarters in Schwertberg has created more than 10,000 square metres of additional usable space. The main beneficiaries of the investment are ENGEL apprentices, who were the first to occupy the new building last autumn. The new training workshop, which has an open-plan design extending over two levels and admits ample daylight, has provided young people with ideal working conditions from day one. At present, 180 men and women are undergoing training in nine technical professions in the new facility. The original training workshop attracted many national awards and ranked as one of the most modern facilities of its kind in the country. The new workshop is even bigger and more modern, says Werner Wurm, who oversees global apprentice training at ENGEL. All workstations have been designed to comply with the latest ergonomic standards, and we have invested in new CNC, lathe and milling machines as well as a new electrical laboratory. New electrical laboratory preparing trainees for Industry 4.0 The apprentices are especially proud of the electrical laboratory, where they are trained to handle the demands of increasing digitalisation and networking within the industry. The professional field of mechatronics is already a major focus of training at ENGEL. In future the combination of mechanical engineering, electronics and information technology will be in even greater demand. In view of Industry 4.0, ENGEL anticipates a future need for more employees - not just in the area of assembly but also in the field of information technology. With a retention rate of 98 percent, in-house professional training is an important factor in terms of securing skilled workers. To ensure apprentices even more focused on their future activity at an early stage, ENGEL launched its careers through apprenticeships project. In their second year, apprentices may apply to a particular department of the company by means of a covering letter. We set out the options for development in the various divisions and then specifically tailor the content of third year training to the plans our young people have, says Johannes Höflinger, who is responsible for apprenticeships at the Austrian plants. New training workshop for Shanghai too The training workshop in Schwertberg is a model for ENGEL Group apprentice training around the world. ENGEL is also providing training in the technical trades at its German site in Hagen, the component plant at Kaplice, Czech Republic, and the large-scale machine plant in Shanghai, China. In Shanghai, a new training workshop is currently being built as part of plant expansion work. By setting up a dual vocational training programme, ENGEL is emerging as a pioneer in China. A new apprentice workshop in Shanghai is being built in the course of the expansion work. Open day for training workshop The new training workshop attracted more than 250 students and parents to its Open House event. The ENGEL apprentices gave guests a guided tour of the new premises, introduced the trades and professions, reported on their training courses and future prospects and offered insights into their everyday working routines in several practical demonstrations. Many of the young visitors promptly put themselves forward for a sample day, a prerequisite for those seeking apprenticeship contracts at ENGEL. In 2017, the company plans to recruit another 45 apprentices in Austria. In the long term, we will need a great many skilled professionals, emphasises Johannes Höflinger, who is particularly keen to motivate young women to take up a technical trade. Women who join us can earn much more than they would in the more traditional female occupations. The open day for the training workshop was a big success, attracting more than 250 guests. ENGEL injection-2017_9

10 In-situ polymerisation on the road to series production In the injection moulding industry it is standard practice to produce ready-to-use parts that drop out of the mould in a single work step. The production of fabric or fibre-reinforced lightweight components is still quite some way from this ideal model of efficiency, but the gap is getting smaller. In October, at K in Düsseldorf, ENGEL presented an example based on in-situ technology. Injection asked Peter Egger, Director of the ENGEL Center for Lightweight Composite Technologies, and Dr. Lorenz Reith, a developer in the reaction technology area, about the opportunities presented by the new developments. Mr. Egger, what was special about the manufacturing cell used to produce composite parts live at K? PETER EGGER: For the first time, we realised an integrated and highly automated process for the in-situ polymerisation of Caprolactam to form fibre composite carrier structures which are functionalised through injection moulding. The multi-component process uses fibre fabric, ε-caprolactam and thermoplastic granules to create lightweight, ready-to-fit parts. This is a major milestone on the road to series production. When we introduced the first prototype machine for in-situ polymerisation, we had to transfer the FRC preform to a second mould or machine for the purpose of functionalisation in injection moulding. How does the new multi-component process work, Mr. Reith? LORENZ REITH: At the trade fair, we demonstrated the new possibilities by producing lightweight shovels. To do this we used an ENGEL v-duo 700 vertical machine, with two differently temperature-controlled moulds supplied by our system partner Schöfer. One cavity is set up for the reactive process and the other handles the injection moulding process. After moulding of the continuous fibre reinforced carrier structure, the integrated viper robot transfers this to the second cavity. Here, detailed features such as edge surrounds, rib structures, screw domes and other functional structures such as a logo, are injection moulded in parallel with the manufacture of the next reactive part. Why is the Center for Lightweight Composite Technologies devoting so much energy to in-situ polymerisation? REITH: In-situ polymerisation offers major opportunities for us when it comes to producing complex composite parts as efficiently and cost-effectively as possible. Generally speaking, various procedures are available. The multi-stage approach, employing pre-consolidated semi-finished products which are trimmed, heated, shaped and overmoulded is useful where waste can be kept to a minimum and no local reinforcements are needed to improve stiffness and strength. Reactive processes, which include HP-RTM and in-situ polymerisation, offer advantages in connection with complex lay-up conditions, hollow profiles and hybrid layer structures. However, further functionalisation is relatively complex in the HP-RTM process. The components produced are made of epoxy resin or polyurethane so that joining elements and reinforcing structures typically need 10_ENGEL injection-2017

11 to be manufactured separately and attached to the structural component. On the other hand, in-situ polymerisation produces polyamide 6, onto which functional elements can be moulded directly. In-situ technology therefore enables us to improve production efficiency while following the trend towards an increased use of thermoplastic matrix materials. What challenges did you need to overcome to integrate in-situ polymerisation and the injection moulding process? EGGER: We have made significant design adjustments and developed a completely new reactive unit, in which machine parts for the preparation and injection of reactive components are separated. In this development, we have benefited greatly from our injection moulding experience. Many established injection moulding solutions such as high precision injection with the use of servo-electric drives can be utilized for in-situ polymerisation. The synchronous injection of the two reactive components is the most challenging sequence in the processing workflow. Why is the injection process so critical? REITH: For in-situ processing, a catalyst and an activating agent are added to the ε-caprolactam in separate material containers. These additives ensure the polymerisation reaction starts immediately after mixing the two components. First the two injection plungers, which are not mechanically coupled, independently draw the required shot volumes, then inject these into the cavity in an electronically synchronised parallel movement. The nozzles on the mixing chamber also need to be opened and closed in sync with the stroke movements. ENGEL ensures this precision by means of servo-electric drives Peter Egger (left) and Dr. Lorenz Reith (right) with a lightweight shovel produced at ENGEL s stand during K and high performance process control software specially developed for the purpose. Melting units were one focus of development work. EGGER: Exactly. As in the processing of thermoplastics, the aim is to prevent unnecessary thermal exposure of the raw materials. In the melting process, monomer mixtures are heated to 120 C, close to the polymerisation temperature of C. For this reason, the material mixtures in the new reactive unit are only melted in the required quantities, and only immediately prior to processing. For the first time, we now have a technological system that supports the precise and robust processing of the necessary prepared quantity of ε-caprolactam. This will open up further interesting application possibilities. The new reactive unit can also be combined with ENGEL clamping units of different design types, which means we can attain a generally high level of flexibility in made-to-measure production solutions. What will be the next development steps? REITH: As far as efficiency is concerned, we have achieved a great deal, but we are not there yet. One aspect we are currently addressing is the synchronisation of the dissimilar processes. Since polymerisation has a longer cycle time than injection moulding, as things stand, it is not carried out in the injection moulding cycle. Then again, the cavity pressures required for in-situ production are much lower than with injection moulding production. With a suitable system layout, we can take advantage of this factor. For example, multiple reactive components can be manufactured simultaneously in a multiple cavity in-situ mould for downstream functionalisation in a single-cavity injection mould. Ideally, the cycle time for the in-situ process would precisely match the time needed for consecutive injection moulding processes. The Center for Lightweight Composite Technologies is being expanded. How will customers benefit from this? EGGER: We have even greater capacity for joint development work and customer trials. Alongside the v-duo 700, we now have a second vertical machine with a clamping force of 17,000 kn. It is equipped for traditional injection moulding as well as reactive process technology, equipped with an ENGEL easix multi-axis robot, and can be combined with the IR oven developed by ENGEL. This enables us to cover a very wide spectrum of applications and technologies. Our colleagues at the technology centre for large-scale machines in St. Valentin are providing excellent support for mould trials on horizontal systems, which are available for use in their centre. ENGEL injection-2017_11

12 Integrated temperature control solution for reduced rejects and greater energy efficiency Increasingly over the last decade, injection moulders have come to focus on mould temperature control. Temperature-control units with a speed-regulated pump form an ideal complement to closed-loop controlled water manifolds. Since they are integrated into the machine control system, synergies arise that allow easy determination of the flow rates that are actually required, automatic setting of the pump speed, and, consequently, a significant reduction in the energy consumption. Manually adjustable electronic water manifolds offer the significant advantage that they enable process monitoring. In addition, automatically controlled designs are capable of maintaining constant flow rates, even if, for example, there are fluctuations in the supply pressure. In determining the correct flow rates, two goals are pursued: Turbulent flow and a uniform temperature distribution. The heat-exchange temperature of the medium at both the supply and return ends of a cooling channel can be measured to determine the temperature difference (ΔT). It is a measure of the uniformity of the temperature distribution in the mould, and therefore, unlike the flow rate, is an important quality parameter. The ENGEL builds on systems expertise with an intelligent temperature control solution. product literature discloses values for recommended maximum temperature differences. Controlled water manifold systems, such as the ENGEL e-flomo, offer the option of separately controlling the flow rate or the temperature difference for each circuit. The advantage of the ΔT control is that the individually required flow rate is adjusted automatically for each cooling circuit. The sensors must be positioned as close to the mould as possible in order to measure the temperature difference that has actually occurred in the mould not after the water has cooled down in long hoses. Consequently, the measurement of the temperature difference in the temperature control unit is only of limited significance. It is advisable to perform the measurement in a water manifold that is mounted as close as possible to the mould. Working with instead of against one another For the heat exchange medium to be distributed as needed in the individual circuits, the flow rates in the manifold must be controlled individually. At the same time, the temperature control unit s pump runs at its nominal speed, thereby working against the resistance of the water manifold. When this happens, the braking of the flow causes energy losses. It is comparable to driving a car with the gas pedal fully down, while regulating the speed with the brake pedal. A solution, and consequently a considerable energy saving, can be achieved by using temperature control units with speed-regulated pumps, with actuation of the pump by the injection moulding machine, matched to the water manifold settings. Temperature-control units with speed-regulated pumps have been available on the market for some years, however, it is difficult for the operator to set the required speed. Assistance is offered, for example, with recommended values for the flow rate or temperature difference. If a temperature difference is regulated on the temperature-control 12_ENGEL injection-2017

13 The Benefits at a Glance Integrated solution from a single source sale and servicing of the temperature control units by ENGEL High-quality components throughout ensure highest production reliability Significant energy savings due to automatic setting of the pump speed As the temperature control unit is fully integrated into the CC300 control unit of the injection moulding machine, a separate operating panel is not required Automatic determination of the necessary flow rates by ΔT control in every circuit Peripheral equipment 9 % Robot 2 % Control unit 4 % Savings 20 % mould e-flomo Drives 26 % Temperature control devices 17 % IQ flow control Hot runner 7 % Heating 15 % OPC-UA Energy consumption shares of the system components measured on an e-motion 170/80 TL. With the automatic rotary speed control, the total energy consumption of the injection moulding system can be reduced by 20%. The e-temp temperature control units are integrated into the control system of the injection moulding machine via OPCUA. unit there is, as described above, the disadvantage of long hoses the mould and the resulting increased heat losses. Therefore, the temperature differences that are measured have only limited relevance to the process. When a downstream water manifold is used, there is little point in controlling the temperature difference in the temperature control, since a mixed temperature from all the manifold circuits is being controlled here. The temperature control solution from ENGEL, consisting of the e-flomo cooling water manifold and the e-temp temperature control units from HB-Therm, has the advantage that the iq flow control software automatically optimizes the interplay of both components automatically controlling the pump speed to the minimum required value. The secret here is that the hydraulic resistance in the manifold is reduced. The valves are opened as far as possible while the speed is simultaneously reduced. The flow rates in the mould circuits, however, remain unchanged by virtue of the smart control. The reduced speed of the pump inevitably reduces the energy consumption. The temperature control units generally account for a considerable proportion of the overall energy consumption of the injection moulding unit. This usually results not from the heating consumption, but from the power consumption of the pump which, with conventional systems, constantly runs at a high speed. As an example, the energy consumption of an injection moulding production cell is measured. Sample parts with shot weights of 7.1g each were produced from ABS on an e-motion 170/80 TL all-electric injection moulding machine with two integrated e-temp H8-100 temperature control units. The cycle time was 10 s. The supply temperature was 50 C. In normal operation, with speed control switched off, the temperature control units were responsible for 37% of the total energy consumption. The activation of iq flow control reduced the energy consumption of the temperature control units by about half, without the flow rate having changed. For the overall system, this means an energy saving of 20% with no change in production conditions. Collaboration of temperature control units and water manifolds At K 2016, ENGEL presented the new temperature control solution for the first time. The etemp temperature control units with speed-regulated pump were developed jointly with HB-Therm. They are integrated, via OPC UA, in the CC300 control unit of the ENGEL injection moulding machine, which is equipped with e-flomo. Increasingly, OPC UA is becoming established in the plastics industry for communication between networked injection moulding machines, ancillaries, sensors and applications. The industrial communication model permits the platform-independent, powerful and secure communication both at shop floor level and with higher-level control systems. ENGEL injection-2017_13

14 Whether leather grain, seams or a carbon look: DecoJect transfers a wide variety of desired structures, colours and haptical features to the component surface. High quality interior components at low unit cost Decorative foils are being used increasingly to replace painting in order to flexibly combine a high quality surface finish of the vehicle interior with small batch sizes and low unit costs. With DecoJect, ENGEL presented the next development step at K 2016, in collaboration with partner companies: the combination of injection moulding with IMG (in-mould graining) in a highly-automated roll-to-roll process. At K 2016 ENGEL produced door panels at its booth. The DecoJect surface finish materials, developed by Benecke-Kaliko (Continental Group) ensure a visual and functional enhancement of moulded parts. In contrast to conventional IMD processes, the layer of paint is not simply transferred from the foil onto the component. Instead, the foil is sucked into the cavity, punched out and remains fully on the component. This approach adds surface structures and haptical features to the colour and pattern. At the same time, the scratch resistance of the components is substantially improved. At K 2016, a fully-automated DecoJect process was presented for the first time. An ENGEL duo 5160/1000 injection moulding machine was utilised in the production of door panels with a large surface area for the use in passenger vehicles. In order to demonstrate the new process' broad spectrum of capabilities, the parts exhibited different surface finishes, including a sophisticated leather grain with a seam and a modern carbon look. A ready-to-fit decorative part left the production cell every 60 seconds. Highly integrated and fully automated process The production cycle in the DecoJect process starts with feeding the smooth, unstructured foil through the open mould. To allow this to happen, a foil winding device (manufacturer: ICO System international coating) is mounted on the moving mould mounting platen. The servomotors on the rollers ensure a constant foil tension and make it possible to precisely control the take-off speed. The foil is held in place in a clamping frame for the thermoforming process and heated by infrared heaters. The heating fields are located in the grippers of a viper 60 linear robot. The compression process starts during heating up, with the foil being drawn into the IMG mould by an air intake mechanism. To avoid exposing the very thin foil to excessive thermal load, the heater fields can be individually controlled. At the same time, the foil's surface temperature is monitored by pyrometers. Heating up directly in the mould, and immediate deep drawing, minimizes the thermal loss and ensures an optimal grain transfer. After completing the deep drawing process, the gripper retracts so that the machine can clamp the mould and punch the foil while doing so. The pre-formed surface foil is now back injected with a polypropylene optimized for the automobile interior (manufacturer: Borealis). Trexel s MuCell process is used for this purpose. Physical foaming significantly decreases both the use of raw material and weight, while at the same time reducing warpage of the part. 14_ENGEL injection-2017

15 IMG Mould for high pressures The challenges faced in developing the manufacturing process included constructing an IMG mould capable of withstanding the high pressures involved in the injection moulding process. The nickel shell, which has funnel shaped pores for the vacuum process during deep drawing of the foil, was finally mounted on a steel frame and backed with a microporous, air-permeable resin. This helped to achieve a pressure tightness of up to 300 bar. The mould manufacturers involved in the project are Georg Kaufmann Formenbau and Galvanoform Gesellschaft für Galvanoplastik. The hot runner system for injecting the polypropylene is supplied by HRSflow. To avoid damaging the DecoJect foil at the injection point, sensitive control of the individual needles in the hot runner nozzles must be guaranteed. After the injection moulding process, the viper robot removes the part and transports it to the easicell automation cell, where the handover to an easix multi-axis robot occurs for fine trimming of the foil. The multi-axis robot and the laser cutting module are combined in the processing cell in a very compact footprint. Thanks to its standardized, modular design, the automation cell facilitates the integration of robots and other process steps upstream and downstream of the injection moulding step. The laser cutting process completes the production cycle. The easix robot deposits the ready-to-fit part on the conveyor belt and immediately proceeds to pick up the next part, which was created in the injection moulding machine parallel to the laser processing step. Cost benefits of 14 percent Benecke-Kaliko analyzed the costs of manufacturing DecoJect components during the development phase and compared these with producing painted moulded parts. The analysis took into consideration the total costs including those of the production cell and moulds, and the logistics overhead for painting. If the costs of manufacturing the painted parts are equated with 100 % as a reference, then the DecoJect component achieves 86 %. The actual injection moulding process without finish optimization accounts for 44 %. This means that the DecoJect achieves cost benefits of 14 % compared with the painted molded part. The foil solution is thus a cost-efficient alternative to the conventional method for producing premium visible components. On top of this, it offers the required flexibility in the production of small batch sizes. Only the roll of foil needs to be replaced to change the colour or styling. After just a few minutes, the production cell can carry on working without producing scrap in the process. Therefore, the batch size no longer has any impact on unit costs. The foil, which has a thickness of just 0.2 to 0.5 mm, is based on TPO. A thin PU layer makes it particularly resilient to scratching and wear, and predestines it for use in the door and panel area. It is offered in many colours and with effect paint to support flexible matching with other components in the vehicle. As a result, the DecoJect foil provides a cost-efficient method of harmonizing vehicle interior components consisting of different base materials. Because the desired surface properties, such as colour, structure and haptical features are defined by the foil, the process makes it possible to precisely adjust the carrier material to the mechanical values required by the individual application. At K 2016, a fully-automated DecoJect process was presented for the first time. The infrared heaters for heating up the foil are integrated into the linear robot's grippers. In-mould graining gives the foil the desired surface structure. ENGEL injection-2017_15

16 Achieving much more with less The Miele brand stands for tradition and quality, and not just in Europe. To meet globally increasing demand for premium household appliances, the family business headquartered in Gütersloh, Germany has production facilities in several locations. The Dongguan plant in southern China specialises in vacuum cleaners. As one of the newest enterprises in the Miele Group, Dongguan Hong Da Electric Products Co. Ltd. is now currently looking to modernise and streamline its production. Feras Rajab, Head of Plastic Shop, is relying on state-of-the-art equipment from European development and above all on his staff to achieve this. "Solid and sophisticated technology is the prerequisite to manufacturing high-quality products. But if staff at the plant do not accept the technology, we cannot achieve our goals," Feras Rajab explains to the Injection editors visiting China. This is why staff is the German manager's top priority. 450 men and women work at the Miele plant in Dongguan; 85 of them in the Plastic Shop, for which Rajab is responsible. When he permanently relocated to China four years ago he brought along his own, very special, European-style approach to employee leadership. "I explain our decisions and expect feedback. This is the opposite of what people here are used to." But Rajab remained true to his principles, and success confirms his decision. "We have made excellent progress on our journey." Integrating the Dongguan plant with the Miele universe, and using Warendorf as a benchmark this is the mission Feras Rajab has undertaken in China. Warendorf in Germany is the location of the competence centre for plastic components in the Miele Group. Plastic parts and complex assemblies are produced there, in large quantities, in state-of-the-art, automated production cells. Initially, Dongguan was miles away from this productivity benchmark. The Dongguan facility has emerged from a former joint venture which originally had 32 injection moulding machines. They originated from various Asian manufacturers, were mostly more than ten years old, needed frequent repairs, and produced a large amount of rejects. Starting three years ago, the injection moulding machines are being successively replaced by new ones, streamlining the machinery down to 19 machines. "In future we will have the same, or an even higher production volume, with far fewer injection moulding machines and at the same time substantially improve energy efficiency and reproducibility", says Rajab. Meeting requirements with maximum economic efficiency 16 of the 19 new injection moulding machines come from the ENGEL Group, including eleven ENGEL victory injection moulding machines with clamping forces between 120 and 300 tons. ENGEL is also one of the equipment suppliers at Warendorf. "Like Miele, ENGEL is a family-owned company with a long tradition. We know that we can rely on the quality and support of our partner", says Rajab. The machine range enables Miele in Dongguan to meet the requirements for the various parts with maximum economic efficiency. Thanks to their tie-bar-less clamping units, the victory injection moulding machines achieve high levels of efficiency, even when using bulky multiple-cavity moulds with many core-pulls and sliders. The largest injection moulding part currently produced in Dongguan weighs in at one kilogram; a casing bottom made of ABS. One of the smallest parts is a view window for displaying the fill-level of the dust bag, which 16_ENGEL injection-2017

17 The injection moulding factory in Dongguan produces a wide range of parts. The high level of precision and process consistency ensures compliance with tight dimensional tolerances. Prior to assembly, employees test the parts for perfect quality. is made of PMMA injected into a 4cavity mould with a total shot weight of 10 grams. "Last month we had 280 mould and colour changes", reports Rajab. "This is what makes flexibility so important for us. We need to keep the set-up processes short." It is not just the barrier-free access to the mould area of the victory machines that contributes towards this. The precision and process consistency are even more important. "Thanks to the new machines, we are producing good parts after just three to five shots." China, the extended workbench of the world this image no longer reflects the true situation. China is also supplying the dynamically developing local markets in Asia, and the product quality requirements there are rapidly becoming tougher. Wages in China are on the up and, at the same time, companies are investing in energy efficiency and environmental protection. "If we want to manufacture in China in the long-term, we need to achieve improvements in production", says Rajab. "To allow this to happen, we need reliable technologies, we need to be quicker, and we need to automate and save energy." Rajab regularly asks his employees where they see potential for improvement. "It took more than a year, but now I even receive feedback without asking and, more and more, critical topics being discussed openly", says Rajab. However, the Head of Plastic Shop is not only interested in machine technologies. Rajab also seeks to put across the values lived in far-away Warendorf. The topic of cleanliness is particularly important to him. "I explained to our maintenance employee why it is so important for our success to regularly clean and maintain the injection moulding machines", as Rajab reports. "He internalised the topic of cleanliness to the extent that he now drives the cleanest car of all of us." Strong local presence ensures fast service Miele produces a large percentage of the parts that are necessary for the final product, giving them a high range of vertical manufacturing. Depending on the vacuum cleaner model, 80 to 90 percent of all plastic parts come from local production. Miele also follows the premise of staying local in terms of its suppliers. Rajab sees the fact that the ENGEL Group is represented with no less than three plants in Asia as optimal, as this ensures shorter lead times, procurement of spare parts in less than 24 hours, and continuity in service. For the future, Rajab is looking to make greater use of the options of remote maintenance and push forward with digitising the facility across the board. Even once all new injection moulding machines have started production, modernisation of the facility will by no means be complete. "It is very important for us to consistently keep our staff on board. This is why we cannot change everything at the same time", Rajab emphasises. "We are consciously taking one step after the other but at a fast pace." The operating figures for the facility clearly show that Feras Rajab is successful with his strategy. He is particularly proud of the fact that nobody in a position of responsibility has given notice in the last three years. This is something very special for a company in China. Head of Plastic Shop Feras Rajab (right) making the Plastic Shop fit for the future. He is highly satisfied with the support provided by ENGEL, not least due to the short distances. Vincent Wong (left), Regional Sales Manager at ENGEL, works in the Shenzhen sales office. ENGEL injection-2017_17

18 BMPT is a flagship enterprise in China. German quality at Chinese speed There is a strong demand for European-standard vehicles in China and those vehicles have been produced locally for quite some time. To ensure consistently high levels of quality, automobile groups are defining standards that local suppliers have to meet. Beijing Beiqi Mould & Plastic Technology Co. Ltd. (BMPT) in Beijing is one company facing up to the challenge. Among other things, the plastics processing business supplies bumpers and other exterior parts to Daimler s nearby passenger car factory. Four years ago, BMPT built a special manufacturing plant in Daxing, a district in the southern part of the capital, to handle orders from the Beijing site of the German car manufacturer. From the outset, the plant was geared to maximum quality and efficiency. It took just nine months from the establishments of the factory to SOP. German quality at Chinese speed was the motto that inspired this record-breaking achievement. In fact, the motto remains just as relevant to current operations. Manufacturing processes are being BMPT utilises highly automated manufacturing cells to produce bumpers for Mercedes-Benz. continuously optimized to facilitate faster production and stay competitive, even as production volumes rise. In future, BMPT also plans to produce plastic parts for the Daimler plant in India. We are aiming to further increase our productivity and efficiency, emphasises Zhongping Zhao, Deputy General Manager of BMPT, on a tour of the ultra-modern facility. By using very advanced equipment and technologies, our products meet and even exceed the high expectations set by our customers. To match German part quality, BMPT relies on injection moulding machines developed in Austria; all machines installed at the plant are supplied by ENGEL. Five of these three ENGEL duo 3200 machines with clamping force of 32,000 kn and two ENGEL duo 4000 machines with clamping force of 40,000 kn are devoted to the production of bumpers for various Mercedes-Benz passenger cars. To raise productivity in this area, cycle times, reproducibility and other factors will be further optimised. Customer proximity ensures fast service The very high process stability and precision offered by the duo machines was critical for us, says Purchasing Manager Chenfei Clark, explaining the choice of 18_ENGEL injection-2017

19 machine. Quality specifications come directly from Benz in Germany, with the focus on surfaces and dimensional stability. The same narrow tolerances that suppliers face in Europe apply here in China. In addition, Clark is particularly appreciative of the proximity of the engineering partner, which speeds up the process. We cannot afford lengthy downtimes, and when something needs servicing, we expect ENGEL to get here very quickly, admits Clark. Thanks to a tight, decentralised network of service technicians, ENGEL is able to meet this need. ENGEL also maintains a spare parts warehouse in China. To cover local requirements, the ENGEL Group produces injection moulding machines in three factories in Asia. Large-scale ENGEL duo machines are made Staff subject every component to a visual inspection. in Shanghai. Aside from large machine production, ENGEL s automation centre for Asia is also located in Shanghai. We have experts on site to develop integrated system solutions with automation, tailored to the individual needs of clients, says Daping Hu, Area Sales Manager for ENGEL Machinery (Shanghai) at the Beijing sales office. The proportion of injection moulding machines we sell with robots is rising rapidly in China, reveals Hu. High process integration with multi-axis robots The five large-scale machines used by BMPT to produce bumpers were also supplied with robots; the articulated arm robots are situated above the clamping unit. As an integral part of the process, they are responsible for removing finished parts while also supporting post-processing and quality control. The sprues are removed automatically and component edges are flame-treated. Only when these worksteps are complete does the robot place the component directly on a weighing station. The weight indicates the stability of the component, explains Jinsong Hao, injection department manager. The measurement data for individual parts is processed and stored electronically. When the system declares the bumper to be OK and approved, the two staff members operating the machine can remove it from the weighing cell and carry out a visual inspection. Every bumper is given a barcode. This allows the result of the weight check and other quality-related parameters to be traced long after the parts are installed in a car. The paint shop is next door to the injection moulding facility, where the newly injection-moulded bumpers are given their individual colour again using worldclass equipment, as Hao proudly points out. The paint shop is one of the most modern in operation anywhere in the world. It saves resources, and the paints are water-based. Servohydraulics reduce energy consumption For BMPT, environmental protection is every bit as important as it is for the company s European client. For that reason, all duo machines in the factory are fitted with ecodrive. We are aiming to cut the overall energy consumed by manufacturing by 30 percent, reveals Hao. ENGEL is really helping us achieve this ENGEL machines are the most economical in terms of consumption. Daping Hu of ENGEL frequently visits the factory to discuss new requirements, technologies and possibilities with his customer. Recently, the digitalisation of production processes has become central to the discussion; a start has been made with data tracking for every single manufacturing cell. The introduction of an MES is the next step on the road to the smart factory. The benchmark is being set not only by the customer in Germany, but also the stated aspiration of the Chinese government to deploy intelligent Industry 4.0 technologies by With its very high technological standards and strong future-oriented approach, the Daxing site of Beijing Beiqi Mould & Plastic Technology has been a flagship enterprise for the automobile industry in China from the outset. Pictures of high-ranking politicians who have paid a visit hang in the factory; German Chancellor Angela Merkel was one such visitor. We are the undisputed leader in China where the production of bumpers is concerned, says Zhongping Zhao. With innovative technologies, we will ensure this remains the case in future. Tacking new challenges in partnership: Daping Hu from ENGEL with Dongdong Zheng, Jinsong Hao, Cheng Li and Chunlei Ge of Beijing Beiqi Mould & Plastic Technology (from left to right). ENGEL injection-2017_19

20 ENGEL Injection_en/ndes/ ENGEL. Your partner for innovative composite technologies Less weight, fl exible designs, convincing characteristics: The future belongs to lightweight composite technologies. ENGEL is a driving force in the plastics industry and is your ideal partner in developing innovative products. Let our competence, experience and visionary solutions in fibre composite systems lead to your competitive edge.