DESMA MOULDS, COLD RUNNER SYSTEMS & TURNKEY PROJECTS Producing rubber and silicone moulded parts profitably and precisely

Transcription

1 DESMA ccc 1 Soul & Solutions for Global Success DESMA MOULDS, COLD RUNNER SYSTEMS & TURNKEY PROJECTS Producing rubber and silicone moulded parts profitably and precisely

2 DESMA Editorial 3 EDITORIAL»Even under dynamic conditions DESMA moulds and cold runner systems safeguard your competitive advantage.«desma injection moulding machines produce sophisticated products made of rubber and silicone for a very wide range of industries. In order to secure all competitive advantages for elastomer processing companies even in view of rising costs for energy, raw material and disposal, and also while they are fulfilling their environmental responsibility, DESMA not only offers leading machine technology, but innovative moulds, cold runner systems and turnkey projects as well. Ahead with DESMA moulds. The DESMA mould shop produces injection moulds and cold runner systems for all clamping forces and machine makes. Along with DESMA machines, comprehensive injection moulding systems result which excel with efficiency and environmental protection. The various industry requirements are factored into the DESMA developments and ensure with intelligent technology maximum performance, productivity and profitability in elastomer processing. Capitalizing on margins successfully. The moulds of DESMA safely satisfy all quality requirements in injection moulding. Costs for material, heating and power are thus considerably lowered and at the same time higher capacities and even more efficiency and flexibility are achieved in production. Do you also want to profitably produce your rubber and silicone moulded parts with lasting effect? Here you learn about how to shape your success with DESMA moulds. 04 DESMA TURNKEY PROJECTS, ADVANTAGES & BENEFITS Technology and maximum efficiency from one source 06 DESMA COLD RUNNER SYSTEMS & ITM PROCEDURE Taking full advantage of cost-saving potentials 08 DESMA MOULD MANUFACTURING CENTERS & CONTACTS First address for individual injection moulds and cold runner systems 10 DESMA & YOU WAYS OF COOPERATION What are your requirements? So you can reach the perfect solution. Martin Schürmann, DESMA Managing Director Dr. Harald Zebedin, DESMA Managing Director

3 4 DESMA TURNKEY PROJECTS, ADVANTAGES & BENEFITS DESMA TURNKEY PROJECTS, ADVANTAGES & BENEFITS 5 DESMA Turnkey Projects, ADVANTAGES & BENEFITS Technology AND MAXIMUM EFFICIENCY FROM ONE SOURCE Turnkey systems from the injection moulding expert. DESMA designs and builds individual moulds, cold runner blocks and systems for process automation which suit the use in DESMA injection moulding systems perfectly. Tailor-made and process-oriented solutions for all clamping forces, volumes of production and needs, which guarantee profitable production in other machine makes as well. - Production costs + Production accuracy + Flexibility Profitable all down the line. The proven DESMA injection moulds and innovative cold runner systems enable your company to increase volume and capacity and to considerably lower the costs for heating, material and production at the same time and thus to secure real competitive advantages. + Machine capacity Process optimization DESMA moulds are fine-tuned and ready for production. This reduces optimization times and raises machine capacity. Various compounds and methods can be tested preliminarily in the DESMA Process Engineering Center. More flexibility DESMA FlowControl cold runner systems with different actuation options by the injection moulding machine make flexible production processes possible. Zero-waste production The patented DESMA DesFlex system completed by the FlowControl technology realizes an article production with zero-runner and low flash. Set-up time reduction DESMA cold runner systems can be very easily purged and cleaned for compound changes. Active volume adjustment By using mould-integrated pressure sensors PressureSense, the FlowControl cold runner nozzles can be flexibly closed depending on the inner cavity pressure. This allows for automatic compensation of volume variations due to insert tolerances and of batch fluctuations of the compound. The complete pressure profile in the cavity is graphically displayed with the operating panel. Additionally, sensitive inserts can be protected from damage. The result is always a perfect filling degree. Reduction of material costs Separate nozzle actuation and direct injection open up significant material cost-saving potential and flexible volume balancing right at the machine control. - Material costs - Time for heating, optimizing, set-up and cleaning - Waste Increase in capacity After changing the mould, and with the same Flow- Control cold runner block, appropriate nozzle balancing is automatically activated for a fast production start. Cure time reduction The DESMA FlowControl+ cold runner block with dynamic nozzle closed-loop control permits to control the energy input and thus enables cure time reductions by up to 25 % in the production of seals. Reduction of production cost Maximum production accuracy The DESMA Vario cold runner system with adjustable nozzle positions provides tremendous potential for cost-savings especially for small series, because it can be adapted to various moulds. The distributing system in the DESMA Vario cold runner system ensures uniform injection irrespective of the adjustable nozzle position. Production without rework More reliability With the DESMA DesFlex compensating system, production of precision articles with little or completely without rework is possible. Comprehensive documentation and a spare parts list can guarantee fast and purposeful supply of spares. And what is more, the skilled experts of the DESMA service team always provide advice and support. A personal contact for machine, cold runner and moulds ensures direct communication.

4 6 DESMA Cold runner systems & ITM Procedure DESMA Cold runner systems & ITM Procedure 7 DESMA COLD RUNNER SYSTEMS & ITM PROCEDURE TAKING FULL ADVANTAGE OF COST-SAVING POTENTIALS Technology for success. As one of the leading suppliers, we design, develop and build moulds and cold runner systems for a very wide variety of rubber and silicone articles, industries, quality standards and production requirements. Standard cold runner block Proven closed design Ease of vulcanizing and purging thanks to polished distributing channels and deflections One or two-deck cold runner blocks as productionready overall system with documentation and spare parts list Opportunity of testing different compounds and methods in the DESMA Process Engineering Center Vario cold runner block Valuable cost-saving potential especially for small series Variably adjustable nozzle distances enable multiple usage for various moulds Sophisticated nozzle technology allows for easy purging of vulcanized distributing channels A naturally balanced distributing system ensures uniform injection Balancing at the individual nozzles can be optimized by using balancing inserts The distance of the nozzle bore holes can be continuously increased, for example, from 260 mm to 420 mm Designed for every application. We provide a broad product portfolio with intelligent technologies for an extremely diversified range of objectives of the elastomer processing industry from proven open systems to forward-looking cold runner systems with shut-off systems. FlowControl cold runner block 0 % of material loss thanks to direct injection without runners Together with individual nozzle control, it enables free nozzle arrangement Multiple usage for different article sizes Ease of cleaning and compound changing Zero-waste article production together with DesFlex Safe function in case of high injection pressures, e.g. for highly viscous elastomers Significant cost-saving potential with hydraulic nozzle control integrated in the machine control system Separate activation for all injection moulding machines optionally available Volume, time or pressure-controlled input of the nozzle switching points Saving and retrieving of correct volume balancing together with mould data Direct injection of large parts, also with flexible adjustment of merging points FlowControl PressureSense FlowControl cold runner nozzles are flexibly closed depending on inner mould pressure Insert tolerances and batch fluctuations are automatically compensated Sensitive inserts protected against damage Filling degree with repeat accuracy (see graph on the right) FlowControl+ Precise control of energy input according to article contour through dynamic control of the individual nozzles and gap Reduces cure times distinctly Temperature-controlled ITM-pot ZeroWaste Temperature-controlled distributing pot with hydraulically actuated shut-off needles Direct injection of precision articles without runner loss Production solutions including zero-waste article manufacture are feasible DesFlex Compensating system for the production of precision articles with little or without rework Top-quality results with rather simple, low-cost moulds Multi-purpose application Maintenance-free

5 8 DESMA Mould Manufacturing Centers & Contacts DESMA Mould Manufacturing Centers & Contacts 9 MOULD MANUFACTURING CENTERS & CONTACTS FIRST ADDRESS FOR INDIVIDUAL INJECTION MOULDS AND COLD RUNNER SYSTEMs Always right at our customers side worldwide. DESMA designs and builds high-class moulds and cold runner systems for sophisticated elastomer products in the mould manufacturing centers of Fridingen (Germany), Ahmedabad (India) and Hebron (USA). A knowledgeable team of experts with comprehensive know-how and innovative concepts is personally at your disposal for customized realization of trade-specific requirements in the production of a very wide range of rubber and silicone moulded parts. 500 DESMA employees are committed to our customers worldwide Turnkey Full service Everything from one source DESMA Mould Manufacturing centers Germany Fridingen Rainer Kirschnick Phone: Rainer.Kirschnick@desma.biz USA Hebron (KY) Derek Langtry Phone: Derek.Langtry@desma.biz India Ahmedabad Prasann K. Shah Phone: Prasann.Shah@desma.biz Service location Contact office Information on our comprehensive range of services can be found on the internet at or just scan the QR code. i DESMA Services

6 10 DESMA Ways of Cooperation DESMA Ways of Cooperation 11 DESMA & YOU WAYS OF COOPERATION WHAT ARE YOUR REQUIREMENTS? SO YOU CAN REACH THE PERFECT SOLUTION. From planning to getting ready for production. The start of every DESMA injection mould is marked by the comprehensive know-how of the expert teams at the DESMA mould manufacturing centers. The employees of project engineering and production develop and provide tailor-made solutions for a wide variety of customer-specific requirements. A DESMA design engineer is constantly at your side during the entire production process. Customized moulds in perfection. Whether it is projecting a new mould concept for certain articles, or carrying out defined design specifications reliably the experts of DESMA fulfill all requirements perfectly. The intensive dialogue with customers and the cooperation with the DESMA Process Engineering Center and the DESMA Customer Care Center definitely guarantee excellent products that excel in technology, efficiency and quality. If required, a test mould is produced with subsequent sample moulding in the DESMA Process Engineering Center. Intensive quality controls not only encompass relevant tests, but also inspection and documentation as per the guidelines of the German Electrical Engineering Association (VDE), for instance, leak test of the temperature-control system and test of the integrated electricity. Inquiry Test mould Production Quality control Sample moulding and optimization Consulting regarding article/ article group Elaboration of a mould concept together with the customer. Technical specifications/ Design available Design data are examined and optimized, if required. The DESMA manufacturing shop professionally carries out the constructive specifications and assembles the injection mould completely. The injection moulds are tested and optimized in the DESMA Process Engineering Center until they are ready for production. Trials and the development of new procedures can take place at the Center as well. Offer preparation Design The DESMA design engineers develop individual injection moulds. Offer preparation The DESMA application engineer fine-tunes the injection mould to the machine of the customer. System solution Acceptance As a standard, every DESMA mould is delivered with detailed documentation and spare parts list. Documentation, spares and service Courses and training The mould run-off tests take place in the presence of the customer. The DESMA Customer Care Center trains companies for the usage of a new injection mould. Courses and training are available either in the Training Center or at customer sites, and on the e-training platform. For more information see the DESMA brochure Customer Care Center, Services & Training. i

7 Just scan it and get directly to our website! Klöckner DESMA Elastomertechnik GmbH Klöckner DESMA Elastomertechnik GmbH An der Bära Fridingen, Germany Phone Fax Concept/Design: monopage strategic communications design 2. print run: 800 copies 2014 EN