AHEAD INTERVIEW USA: WHERE IS PLASTICS TECHNOLOGY HEADED? ADAPTIVE PROCESS CONTROL SYSTEM BEST COMPONENT QUALITY WITH RECYCLED MATERIALS

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1 AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue INTERVIEW USA: WHERE IS PLASTICS TECHNOLOGY HEADED? ADAPTIVE PROCESS CONTROL SYSTEM BEST COMPONENT QUALITY WITH RECYCLED MATERIALS

2 EDITORIAL CONTENTS COVER STORY 4 Interview: USA: Where is plastics technology headed? PROCESSES & PRODUCTS Dear customers, dear reader, Plastics processing is a colorful world indeed. Take, for example, the production of large, colored trash containers on the largest of our injection molding machines, the KraussMaffei MX series. Or the injection molding of closures for plastic bottles, tubes or sachets of all kinds on our smallest machine, the CX series. Sometimes it's even more vibrant, thanks to large-format, visible vehicle parts with a thermoformed film as the outer skin, which is made rigid with fiber-reinforced polyurethane. The colorful examples in this issue of AHEAD provide an amazing sample of the variety of systems as well as the continuous new developments and frequent customization in technology solutions that KraussMaffei offers. It is not only the specific applications of our customers that put our innovation machine in full swing. We place equally high priority on ongoing development of automation systems to push the limits on the length of closed process chains. A major building block of our success is the Adaptive Process Control system (APC), which made a great splash on the market in fall This decreases the amount of manual intervention, which is always prone to errors. To put it the other way around: For your benefit, we ensure the long-term increase in the quality of the products made on KraussMaffei systems. And we make the systems easier to operate. This is necessary because the increasingly complex manufacturing cells place additional demands on the operator. To make your work easier, we have also responded to these needs by further optimizing the user interfaces of our systems. The new MC6 Multitouch control system is the latest step in this direction. This continued development of the relatively recent MC6 carries over the familiar gesture control from smartphones and tablets to the machine control system, using a 24-inch display with outstanding special properties. For more details, just keep reading! Do you want to experience these and other technical innovations in live demonstrations? As usual, we'll be at many of the world's plastics trade shows this year. Whether at NPE in Orlando, Florida, or Chinaplas in Guangzhou, China innovations made by KraussMaffei are guaranteed to please! Take a look at our trade show calendar. Wherever the opportunity, we look forward to meeting you in person. 8 The new sprue picker speed, precision and economy 10 MC6 Multitouch intuitive and individualized 12 Tapping and swiping using your tablet to find the right spare part quickly 13 The new CX this little one is attracting a lot of attention 14 Adaptive Process Control system best component quality with recycled materials PARTNERS & PROJECTS 16 MX 5500 and MX 4500 made for the big leagues 18 Gealan puts MuCell technology to work 20 AllinPlast pinpoint-accurate street lighting 22 C and CX series at Menshen Packaging in the United States 24 LFI technology film instead of paint 26 Put in the best light the new HELLA plant in Mexico 28 Alligator Plastics high-tech for the beer barrel 30 Touring ski binding Kingpin FiberForm on the slopes BRAND & MARKETS 32 Open House at Poliuretano 33 Cooperation as partners interior trim systems from a single source 33 Surface RTM Award-winning lightweight construction KRAUSSMAFFEI GROUP Dr. Hans Ulrich Golz Managing Director President of the Injection Molding Machinery segment 34 Strong together and unique all over the world 35 Netstal: Maximum speed for PET preforms 35 Trade show calendar 35 Imprint

3 KraussMaffei Contents 3 4 USA plastics market Interview highlighting the trends and challenges for KraussMaffei. 16 Large machines KraussMaffei commissions the largest injection molding machine to date, the MX 5500 with 5500 tons of clamping force, at Weber GmbH & Co. KG. 14 APC Adaptive Process Control prevents fluctuations in the injection molding manufacturing process.

4 4 Cover story AHEAD Issue THE US MARKET IS BOOMING USA: WHERE IS PLASTICS TECHNOLOGY HEADED? For KraussMaffei and the plastics industry as a whole, the automotive industry is one of the most important customer groups. It is true that the manufacturers of plastics and plastics technology are confident that the US automotive industry is picking up pace. In plastics processing, customized systems are in greatest demand. AHEAD discussed this and other trends with Paul Caprio, President of KraussMaffei Corporation and with J.P. Mead, Vice President of Reaction Molding Machinery. INTERVIEW: JOACHIM WEBER CONTRIBUTING WRITER: MANUEL VON VARCHMIN PHOTOS: KRAUSSMAFFEI, ISTOCKPHOTO

5 KraussMaffei Cover story 5 In 2013, imports of plastic and rubber processing machines increased by almost 13percent to 5.9 billion dollars. PAUL CAPRIO, PRESIDENT OF KRAUSSMAFFEI CORPORATION AHEAD: Let's first look at the overall plastics processing market in the United States. What are the most important current developments? Caprio: First, the headline news: The US market is currently booming. The increased exploration of shale oil and gas has sent both energy and raw material prices on a downward trend, which is making domestic production more appealing again. This is having even more of an impact, as many states, such as Georgia, are subsidizing the establishment of new operations. Thus, numerous American processors are bringing their production back to the United States from abroad. There is also a strong rise in domestic demand, primarily in the re-strengthened automotive industry and construction industry. According to statistics from the United States International Trade Commission, imports of plastics and rubber processing machines increased almost 13 percent to 5.9 billion dollars in 2013; the share of these machines from Germany alone increased 22 percent to 1.5 billion dollars. AHEAD: What is the structure of the industry like? Is plastics processing in the United States shaped more by small companies or a few large companies? What role do the integrated processors play, for example in the food, packaging and beverage industry? Mead: There's a clear trend to be seen here. The company groups, particularly the internationally positioned groups, are becoming larger and larger. However, there are still the typical small plastics processors. But they are clearly in the minority. The largest area in manufacturing plastic parts is still the automotive industry and it continues to grow. But we are also seeing steady growth in the packaging industry. This industry has already made strong investments. However, we already anticipate significant growth in AHEAD: Are there large, generally applicable trends that pertain to the entire industry? In which way is the market moving? Caprio: There is a very clear trend toward automation. We are not only noticing this based on the growing interest that is reflected in a significant increase of demand in this area by our American customers. It can also be seen very concretely in business the sales of automation solutions has increased a full 200 percent in the last twelve months. AHEAD: What caused this change of opinion? Previously, the interest of American plastics processors in automated processes was not as pronounced. Caprio: One reason for this is technical development. Automation cells are becoming more and more complex and linking increasingly more process chain elements to an automatically controlled process. Today, this can range from the preparation of plastic compounds to the completely packaged part. These types of continuously automated systems are now also attracting American processors. Another reason to open up for this topic is the absolutely consistent quality of the products, which can only be achieved with high automation. This makes this field of work our strongest growth driver, regardless of the procedure.

6 6 Cover story AHEAD Issue AHEAD: Which user groups are particularly interesting for KraussMaffei? Caprio: In injection molding, we see great potential in the packaging area. To be able to provide our customers here with real complete solutions, such as customized turnkey systems, we are currently looking to cooperate with moldmakers in the United States. Because for applications of multicomponent injection molding in swivel plate technology, known under the process label SpinForm we need high-precision molds. The goal, so to speak, is a perfect packaging machine. Our GX series is the most suitable basis for this. Mead: There are important areas of application in the automotive industry for reaction process machinery. The American automakers are increasingly striving to replace heavy metal parts with more lightweight plastic parts. They are also beginning to appreciate the advantages of plastic and plastic laminate parts in design. Compared to metal parts, larger degrees of freedom in shaping and integrated functions are very convincing arguments. AHEAD: Which special demands do American plastics processors make for their equipment? Mead: A very important point is the ease of operation. If nothing else, this is why Automatic Process Control (APC) is so attractive for the customers; a large portion of the required expertise is relocated from the operator to the control system. American processors also place great importance on extensive production data acquisition and the ability to read out as much data as possible from the machine. Networking capability is also very significant. Thus interfaces, too, are a crucial topic. Of course, all of the process engineering is of fundamental importance, and must ensure high repeatability even at high speeds. This requires long-term precise control of the critical parameters. APC also accomplishes this in an excellent way. At a completely different level, but no less important, are the special requirements of the American market, for example adapting to the local standards for water connections and fittings and all of the electrical equipment. AHEAD: How about the subject of sustainability, which plays such an important role in Europe? Are American plastics processors and their customers striving for material and energy savings or have these goals returned to the background in the wake of the sinking oil prices? Caprio: American companies have different approaches to this topic. In this process, sustainability is gaining its own significance, but not in the same way in all companies. The basic goal to produce in an environmentally friendly manner is gaining more and more followers. However, its implementation depends greatly on local conditions, for example the amount of energy costs. Overall, it can be seen that the topics of organics and ecology are being discussed more and more intensively in the USA. AHEAD: How does it look specifically, for example, in the demand for all-electric injection molding machines, which, compared to hydraulic machines, are considered the non plus ultra in terms of energy efficiency? Caprio: All-electric machines are in demand primarily in the medical technology industry, mostly due to their hygienic properties and suitability for clean room technology. BluePower is especially a fundamental issue where cost savings are involved. AHEAD: Do American customers prefer buying ready-made or tailor-made products? Caprio: The answer is very clear. Our customers prefer solutions that are tailored very precisely to their specific needs. This even applies to software. Our ability to offer special interfaces and special programs often dictates whether the customer chooses us. Our sophisticated modular system's individualized hardware configuration capability is

7 KraussMaffei Cover story 7 also extremely important. Whether an injection unit, clamping unit, drive or peripherals our construction sets allow us to meet the requirements our customers have without compromises. Our American customers also place importance on the flexibility of their systems. The modular system also provides an ideal basis for this. AHEAD: What role does the automation of the processing systems play? Do sophisticated systems such as the MC6 control system for controlling all process chains have a chance in the United States? Caprio: As already mentioned, automatic process control is a subject that is currently being pushed more and more into the foreground. The automatic control system throughout the entire process chain is one of the problem areas that is a central focus at NPE, the plastics trade show. We are counting on our new MC6 Multitouch control system to give us very good opportunities there, because its graphical user interface and its easy operation correspond exactly to what our customers in the United States want. Also, in the showrooms of the Advance Development Center of our customer, Proper Group International, in Warren, Michigan, the KraussMaffei APC systems are available to test on all machines. AHEAD: Now, let's talk about a customer group that traditionally carries special weight for KraussMaffei: the automotive industry. Do the large US manufacturers such as GM, Chrysler or Ford have similar development goals as their European competition? Do issues of sustainability, such as lowering fuel consumption through more lightweight design, carry similar weight as in Europe? Or does the recent decrease in oil prices relegate these goals to the background? Mead: In the United States, it remains an important long-term goal of the automotive industry to lower the energy consumption of vehicles. Because even if the oil prices are currently low, everyone knows that they will go back up some day. One way to lower fuel consumption is to use suitable software in the vehicle. Smaller vehicles are not an option with high priority for automakers in this country. Thus, the industry is following the demand. Recent trends indicate that buyers are once again purchasing large models, despite the fact that gas prices have only recently started to drop. Therefore, the vehicles PAUL CAPRIO President of KraussMaffei Corporation. J. P. MEAD Vice President Reaction Molding Machinery. are to keep their size but weigh less in the future. Along with this, interest in lightweight components is also growing in the USA. AHEAD: What does this mean for KraussMaffei? Mead: This trend is perfectly in line with our product line; we've put a lot of development work into this in recent years. This is because KraussMaffei is not just a machinery and systems expert, but also possesses expertise in the entire value-adding chain for automated manufacturing of lightweight fiber composite components, regardless of the process. We are the only company in the world to offer the best manufacturing technology for the part specifications and target quantities of our customers. Proof that this also puts us on the right path in the United States is the fact that General Motors has recently purchased three 4,000 ton production cells for its fascia production. AHEAD: Which technologies from KraussMaffei is the American automotive industry most receptive to? Is it more the lightweight materials such as FiberForm or high pressure RTM, or the wide variety of surface-finishing variants? Mead: Both. Lightweight construction is currently gaining ground strongly, as mentioned previously. And our procedure for surface finishing is met with great approval in the automotive industry. ColorForm and SkinForm perfectly combine the advantages of injection molding technology and reaction process machinery. This can be used to manufacture complex thermoplastic components with individualized, attractive polyurethane or polyurea surfaces with defined properties. Whether leather-like appearance, great surface aesthetics such as high gloss and special decoration effects, or high scratch resistance everything develops in a single process step in a reproducible and cost-effective manner. AHEAD: Where do you currently see the greatest challenges in the US market? Caprio: The market is booming so much that we brush up against the limits of our performance capability from time to time. Because even in the boom, systems off the shelf do not work KraussMaffei has to react flexibly to the desires and requirements of its customers. AHEAD: And what are your goals in the next three to five years? Caprio: We want to react even more quickly to the needs of our customers. To configure optimal solutions for the specific need, we have to work intensively with each customer to define its requirements realistically. Because a jack of all trades is not always the optimal solution. In designing truly practical and cost-effective systems, we can draw from a huge wealth of experience. It is one of our primary goals to use this experience even more strongly than before to support the customers.

8 8 Processes & products AHEAD Issue Processes & products THE NEW SPX 10 SPRUE PICKER IT S ALL BUILT IN: SPEED, PRECISION AND ECONOMY The automation system of the CX series, the small KraussMaffei injection molding machines, still had a minor gap: the sprue picker. The new servomotor-controlled SPX 10 picker is fully integrated into the MC6 control system's automation and delivers short cycle times with low operating costs and minimum space requirements. TEXT: JOACHIM WEBER CONTRIBUTING WRITER: MICHAEL FLURL PHOTOS: KRAUSSMAFFEI T he engineers in the KraussMaffei automation division did not make it easy on themselves. Many aspects had to be taken into account. The drive was to provide speed while consuming minimal energy. It was to require the least amount of space possible in terms of both its footprint and height. Lastly, the picker was to be easy and reliable to operate and maintain. The developers were successful in delivering this all in the same package. The result was the completely new SPX 10 sprue picker. Thomas Marufke, Managing Director of KraussMaffei Automation GmbH, says, From the beginning, we looked at the task as a comprehensive whole. The result is a perfectly matched system from which our customers will profit in many respects. Decision for servomotor-controlled drive The decision in favor of the servomotorcontrolled drive was clear. True, the initial investment is somewhat higher than a pneumatic drive. However, with twice the service life and proven KraussMaffei quality, the servomotor-controlled sprue picker turns this minus into a plus. Additional advantages are provided by the significantly lower operating costs and regular maintenance costs, which are slashed by the design. First, let's talk about energy costs. The servomotor-controlled sprue picker needs only one percent of the costly compressed air compared to its pneumatic counterpart. Even if we take into account the high amount of electrical energy it needs, in the end the total energy costs are reduced by 85 percent. Short cycle times Regardless of this, the SPX 10 attains shorter overall cycle times thanks to the servomotor-controlled axes, enabling a demolding time of just one second. The key feature here is the programmable servomotor-controlled demolding stroke, which enables an optimum waiting position above the tool; pneumatic pickers can travel only the maximum stroke and approach a fixed end position at any one time. The lower changeover times, and thus the costs, also add up. The rotary axis enables the SPX 10 to move into a parked position in which it has maximum space for the mold change. The complete integration into the MC6 control system enables the operator to switch programs without extra effort. The servo axes also enable positioning that is accurate to the millimeter. This makes it vastly easier to configure the demolding point manually. The high reproducibility of the servo axes means no more need for subsequent corrections to individual program positions. All of these building blocks have a tangible impact on reducing change times and costs. Most space-saving solution on the market The advantages of the compact and stable construction of the new picker are not to be underestimated. The SPX 10 is currently one of the most space-saving solutions on the market. It combines with the machine to form one unit. The detached sprue is stored within the machine's housing. This means that a side expansion in the form of a protective fence is not necessary. This way four machines can be installed in the same installation area instead of three. Even low shop heights are not an obstacle the telescoping stroke reduces the required overall height by 500 millimeters compared to a pneumatic picker. Marufke concludes by saying, The new sprue picker is exactly the productivity and efficiency driver our Automation division needed to complete the portfolio.

9 KraussMaffei Processes & products 9 SPACE-SAVING WONDER The sprue picker features an outstandingly compact and stable design.

10 10 Processes & products AHEAD Issue THE NEW MC6 MULTITOUCH CONTROL SYSTEM INTUITIVE AND INDIVIDUALIZED PEAK PERFORMANCE IN 24 INCHES Smartphones and tablets have made people accustomed to new ways of interacting with devices. It is only logical that the user interfaces of machine control systems adapt to these trends. The new MC6 Multitouch control system is an enormous step forward for KraussMaffei. AHEAD talked to Günther Grimm (Head of Software and Control Technology) to find out the details. INTERVIEW: JOACHIM WEBER CONTRIBUTING WRITER: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI AHEAD: Tell us briefly, what exactly is the MC6 Multitouch? What's new about it? Grimm: Previously, we used resistive touchscreens exclusively. This means that triggering an action required a certain amount of pressure on the display, which had a glass or film surface. The limitation was that only one button could be pressed at a time, and thus only one action could be triggered. The new MC6 Multitouch does not require any physical pressure. The onscreen images can be controlled by gestures, such as swiping or spreading your fingers to zoom. This lets the operator trigger multiple actions simultaneously, such as using the configuration screens and pressing a machine button at the same time. AHEAD: Why was the decision made to develop this product? Grimm: We're always observing the market and talking to our customers. Generally, the user-friendliness of control systems and an intuitive operating philosophy are always important considerations. This trend is most evident in smartphones, where gesture control has become firmly established. Now it's time for this technology to also take hold in industry. When the current MC6 was released, some customers already expected to be able to operate it like a capacitive smartphone screen. For these reasons, KraussMaffei was a pioneer in featuring a gesture-controlled MC6 control system at the K 2013 trade show. This innovation was met with unanimous approval among the prospective customers. The implementation was carried out then consistently and we were the first manufacturer ever to implement a 24-inch screen with capacitive touch technology. is. Of course, if a robot is integrated, its axes can also be moved via the slider. I had the idea for this back in Summer 2013, but it took a while for us to find a suitable partner who could implement this idea for a 24-inch multitouch screen. AHEAD: What are the other specific advantages of the MC6 Multitouch? What additional benefit does the customer get out of it? Grimm: The previous models of the MC6 were already very intuitive to operate and the screen is now getting gesture control. In addition, we increased the screen diagonal from 19 to 24 inches while keeping the same width, and thus gaining an additional 150 millimeters of screen space. In this space, the operator has complete freedom to place his or her favorite screen pages. Options include pages from the IMM or robot, or the display of the coolant flow or the live image of a camera. Anything is possible! This lets us deliver another important feature: customization. Each operator can configure his or her screen display individually. For example, when the operator logs into the machine with his or her RFID badge (a transponder that contains user-specific data), the system automatically shows his or her screen. This enables the operator to have personalized control of the system quickly. We should also mention that the multitouch screen simply looks great. This should not be underestimated; the higher-end appearance makes for a big part of the operator's enjoyment on the job. This helps the operator feel at ease immediately. I always say that the control panel is the machine's face. AHEAD: Were there any stumbling blocks in the development? How did you overcome them? Grimm: The greatest obstacle was that the technology for a 24-inch screen diagonal did not exist when we started with development. Thanks to outstanding cooperation with development partners and many years of experience in control technology from KraussMaffei, we were able to quickly overcome this hurdle. One particular challenge was the requirement expressed by many customers to be able to run machine movements without looking at the screen. This cannot be ensured by a conventional touchscreen display. Together with our partner, we succeeded in a singular innovation: the guideway or guide track with a software element underneath it, the slider ( SlideX). This enables the setters to control all axes of the machine without looking at the screen. The track guides the operator's command finger so it cannot slip off. The principle is simple. The further the finger is dragged to the left or right, the faster the movement EFFICIENT HANDLING The MC6 enables the operator to trigger multiple actions simultaneously.

11 KraussMaffei Processes & products 11 GESTURE CONTROL User-friendliness and an intuitive operating philosophy are important considerations for KraussMaffei. AHEAD: What's the unique feature of the control system that distinguishes it from the competition? Grimm: Only one of our competitors recently also started offering a glass touchscreen, but only in a size of 21 inches. It does not have the guideway feature that relieves the operator of the need to always keep looking at the display. We do not know of any other control system on the plastics machine market with comparable features and we can proudly say that our MC6 is the vanguard and trendsetter. AHEAD: Are there new functions as well? Grimm: Just a few years ago 2012 to be exact we launched the MC6 control system, which was a major step towards greater userfriendliness. The guiding principle was that it should take no more than two steps to get where you need to go. This innovation also enabled us to make new developments to make operation even easier. These functions are included in the glass touchscreen. Now, however, we have the additional benefit that everything has also become more intuitive and better organized due to the expanded display options that wouldn't be possible without the larger screen. AHEAD: Where do you see the trend going in control systems? Grimm: One important direction for development is customization. The more users can adapt a system to their personal needs and habits, the more they will enjoy working with that system. The MC6 Multitouch has once again brought us closer to this goal. Another trend is visualization, displaying the system and its current states in images rather than in series of numbers. This makes it easier for operators to maintain the complete overview of their system at all times. The MC6 Multitouch is already a major milestone on this path. Larger screens are the prerequisite for this and will be an ongoing trend. We should not underestimate the need for forms of operation that are even simpler and more intuitive. In today's world, an ever-smaller number of skilled workers have to be more productive all the time. Lengthy programming sequences or even The guideway or guide track ground into the glass enables the operator to control all axes of the machine without looking at the screen. GÜNTHER GRIMM, HEAD OF SOFTWARE / CONTROL ENGINEERING, KRAUSSMAFFEI time-consuming training sessions are counterproductive. The MC6 Multitouch control system meets these requirements even today. We make extensive use of technology from the PC world, particularly from Microsoft. We build on this technology. It is part of the MC6 control system. AHEAD: How has the market received the MC6 Multitouch control system? Grimm: We presented the system in its current form at the Fakuma trade show in fall Since then, we've gotten a lot of positive responses and a great number of inquiries. Concrete demand is also shaping up really well. Since the beginning of the year, we've been able to successfully implement numerous projects. Demand from the US is particularly high; companies there prefer graphical input and easy operation. The MC6 Multitouch accommodates these requests better than any other system to date.

12 12 Processes & products AHEAD Issue TAPPING AND SWIPING IN YOUR SPARE PARTS CATALOG USING YOUR TABLET TO FIND THE RIGHT SPARE PART QUICKLY Gone are the days when operating or maintenance personnel had to run back and forth between the factory hall and office to find the order number for a spare part they need for a system. With the complete information package in hand, they can now do this right at the machine. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI A fter extensive testing by its in-house service personnel, KraussMaffei Reaction Process Machinery now also offers its customers a tool that can contribute to markedly higher efficiency in the maintenance area: a spare parts catalog on a tablet computer. Its advantage compared to the existing desktop catalog is that maintenance or operating personnel can define the spare parts they need right at the machine on sight and with all information required for precise determination. This ability to use the application anywhere makes work noticeably easier, says Peter Volpert, Head of Spare Parts Service and Documentation Department for Reaction Process Machinery, who played a key role in the introduction and technical implementation of the software. The tablet's user interface is optimally coordinated to the control system via touchscreen and supports intuitive operation using your fingers. Maintenance personnel can use tapping and swiping to display linked parts lists, detailed exploded drawings, detailed information on parts list items, and (optionally) the machine documentation. This means that personnel can retrieve and read all important information right at the machine. Operation couldn't be easier The simple and clearly arranged menu display easily guides the operator from the level of the entire machine, through assemblies and on to the individual parts they are looking for. A search function provides additional help in finding parts or service documents quickly. Once the parts required are defined, they can be ordered directly from the catalog by or a request can be sent to the responsible department of the company. This fast and paperless process shortens the procurement time of spare parts and thus increases the effective service life of the machine. assurance: If a system is added on to or modified later, we can also import this data into the system without any problems. Available as part of the package or as a retrofit By offering the machine database on the tablet, KraussMaffei is primarily pitching this to operating and maintenance personnel of already installed machines. Both they and purchasers of new machines can buy the entire device, including the basic software, at the market launch price of 899 euros. Until August 2015, you can also receive it as a bonus gift for a spare parts package worth at least 30,000 euros. This package is recommended as original equipment in any event. This ability to obtain information anywhere lets skilled workers get their job done easier. " PETER VOLPERT, HEAD OF SPARE PARTS SERVICE AND DOCUMENTATION DEPARTMENT, KRAUSSMAFFEI REACTION PROCESS TECHNOLOGY The tablet shows the machine the spare parts catalog with all additions in exactly the configuration installed at the customer's facility. This also makes searching for variants and version numbers unnecessary. If a customer operates multiple reaction process machinery units, they can also be integrated incrementally and separately into the tablet computer each in its respective configuration. Volpert adds this

13 KraussMaffei Processes & products 13 A SUCCESSFUL START The new CX from KraussMaffei features high productivity and innovative detailed solutions with respect to energy efficiency, automation, space-saving design and zero-defect production. MARKET LAUNCH OF NEW CX IS WELL RECEIVED THIS LITTLE ONE IS ATTRACTING A LOT OF ATTENTION The new CX made quite a splash in its first appearance. At the Fakuma trade show in Friedrichshafen, Germany, KraussMaffei showed the wide range of applications for its new CX machine series with clamping forces up to 1,600 kn. A CX 35, a CX 80 Hybrid and a CXV 160 delivered impressive displays of cost-effective manufacturing solutions that can be implemented in minimal space thanks to the twin-platen design. TEXT: DR. SABINE KOB CONTRIBUTING WRITER: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI F or plastics processors, these compact dimensions are a major selling point, as they enable space savings of 10 to 20 percent compared to the competition. In addition, beneath the CX's cantilevered clamping unit, there is plenty of space for mold temperature controllers or demolding equipment. The space-saving concept extends into a mobile automation cell with 6-axis robot, which supported on rollers can be installed and removed on the side of the machine for maximum flexibility. This way the robot can be used anywhere and, if necessary, can be transported to the next manufacturing cell and started there. A newly developed servomotor-controlled sprue picker with telescoping stroke is also ideal for buildings with low ceilings. New CX series features many optimizations The CX not only saves space, it also saves operating costs. The intelligent storage management with disconnectable rechargeable battery saves ten percent on energy. The optional BluePower Vario drive offers even more; a variable-speed asynchronous motor reduces idling capacity and improves efficiency. This conserves up to 30 percent of energy compared to traditional hydraulic variants, particularly for applications with longer cycle times. Speed in production also results in higher part output. The CX clamps about 15 percent faster than the predecessor model. This is achieved using new valve technology that works optimally with hydraulic switching concepts. Mold changes are fast, too. A bar-pulling function, either manual or automatic, makes access to the machine easier where necessary and a bayonet lock enables mold changes without screwing or adjusting. Just click, connect the mold to the machine via the extensive interfaces and start up the machine. That's all it takes you're ready for the first shot into the good parts box! The new Adaptive Process Control (APC) machine function makes this possible. Previously, injection molding companies sought to complete the start-up process in full with its fluctuations in melt viscosity, mold temperature and many other aspects before producing parts for the customer. APC eliminates the need for this safety buffer. The machine function measures the melt viscosity continuously and adjusts the injection parameters from shot to shot. This is important when the percentage of recycled material changes or when there are frequent interruptions in the manufacturing sequence, for example by inserting films for IML parts, but also for changes in the room's climate. APC works like cruise control for injection molding processes, maintaining the set speed reliably whether driving uphill or downhill. The result is consistent component quality with extremely tight weight tolerances and little scrap. APC can be retrofitted for all existing Krauss- Maffei machines with MC5 and MC6 control system it is not limited to the new CX.

14 14 Processes & products AHEAD Issue ADAPTIVE PROCESS CONTROL SYSTEM BEST COMPONENT QUALITY WITH RECYCLED MATERIALS The newly developed APC (Adaptive Process Control) machine function from KraussMaffei immediately compensates for fluctuations in the injection molding manufacturing process. This makes it possible to process even difficult batches and recycled materials into components that are of premium quality in every respect. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI I n 2012, the two Bavarian companies KTW Kunststofftechnik Weissenburg and KraussMaffei Technologies in Munich began a joint project aimed at reducing the rejection rate in the injection molding process. This is because, over time, component quality is influenced by external factors, even in processes with stable configurations. This is especially true when using recycled materials because this leads to frequent quality fluctuations in the raw material. But this is not the only important aspect. Room temperature and humidity can also influence the quality of finished products. To compensate for these fluctuations in the manufacturing process, KraussMaffei developed a new machine function, the Adaptive Process Control system (APC), and brought it to the production stage with the help of KTW. KTW is a highly successful, mediumsized automotive supplier with sales that have almost tripled in the last five years. The company specializes in high-quality exterior and interior components, such as finishers, paneling, covers, air ducts and wheel house shells, which are manufactured using both the standard injection molding process and through special processes involving multi-component technology, over-molding of film or fabric and variotherm technology. KTW processes approximately 5,000 tons of thermoplastic per year on a total of 21 injection molding machines. Since 1998, the company has relied solely on Krauss- Maffei injection molding technology. Since then, 14 fully automated machines in the clamping force range of 80 to 2,300 tons have been purchased in multiple installments. In 2011, as part of a larger package, KTW acquired the MX 2300, which produces wheel house shells from recycled materials for a large German automaker. In order to Our insights and wishes were successively applied to the development of the new machine function. ALBERT BURGHART, PLANT MANAGER OF KTW IN WEISSEN- BURG ZERO-DEFECT PRODUCTION On a KraussMaffei MX 2300, KTW produces wheel shells made of recycled material for a large automaker. While doing so, the APC Adaptive Process Control system ensures zero-defect production. gain experience with the new features during day-to-day production and to apply these experiences to the development process, Krauss- Maffei equipped this large machine with the Adaptive Process Control system. The polyolefin recycled material produced by KTW for wheel house shells is stored in 80-ton silos. Depending on their origin, the recycled materials vary in terms of grain size, consistency and bulk density, leading to substantial fluctuations in viscosity. KTW uses the APC system to intervene in the production process automatically, within definable limits, so that a change in material viscosity does not lead to fluctuations in component weight. Albert Burghart, Plant Manager of KTW, in Weissenburg, explains this in more detail, saying, The use of the APC function enabled us to substantially improve continuous monitoring of melt quality, significantly reduce the subsequent rejection rate and guarantee precise traceability of the components down to the individual shot. Improved process stability and component quality In injection molding production, process stability plays a critical role with respect to the quality of the manufactured components. This is why injection molding machines must operate with a very

15 KraussMaffei Processes & products 15 COMPENSATING FOR FLUCTUATIONS APC keeps processes stable even if the viscosity of the material or the flow resistance in the mold are changed by the influence of outside factors. high repeatability rate over a long production time period. In realworld applications, however, various external factors can, under certain circumstances, negatively influence a process that starts off with stable configurations. These factors range from viscosity fluctuations of the material and the influences of ambient conditions, all the way to effects caused by wear. The injection molding machine does continue to operate with typical precision, but is unable to compensate for the fluctuations from outside the process. This leads to quality defects and, ultimately, production waste. We can eliminate these problems to a large extent with our Adaptive Process Control system. The new machine function is integrated into the MC6 machine control system and analyzes the current process state in each injection process. As a result, the injection molding machine alone is capable of keeping the configured process and the end product quality stable, explains Dr. Reinhard Schiffers, Head of Machine Technology at KraussMaffei. These changes are registered by recording specific key parameters of the machine. Through clever evaluation of this process data, the machine can respond to the current process state within the specified limits. To do so, the Adaptive Process Control system adjusts the changeover point and the holding pressure profile to the current melt viscosity and current flow resistance in the mold. This makes it possible to compensate for deviations in the same shot. Spatial proximity for close collaboration and efficient processes We are very satisfied with the work we accomplished with KraussMaffei. This project involved close collaboration between our two companies that proved to be fruitful for both parties, adds Burghart. Our insights and wishes were successively applied to the development of the new machine function. Everything went off without a hitch. ALBERT BURGHART, Plant Manager at KTW in Weissenburg, is satisfied with the results. The APC Adaptive Process Control system also allows recycled material to be continuously processed into high-quality components.

16 16 Partners & projects AHEAD Issue Partners & projects MX 5500 AND MX 4500 AT WEBER MADE FOR THE BIG LEAGUES Milestones of large machines: With a clamping force of 5,500 tons, the MX 5500 is an absolute benchmark in the world of large injection molding machines. Along with another large machine, an MX 4500, it produces large-volume waste containers at Weber, the disposal specialist. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI W aste containers in all common sizes and versions are the trademark of Abfallbehälter & Container Weber GmbH & Co. KG, founded in All products are manufactured by the company at its Haan location, in the Rheinland region, Germany in accordance with the specifications of DIN EN 840. The consistently high quality of these products is ensured by continuous in-house and external tests and certifications. The company's customers include municipalities, waste disposal companies and industrial firms throughout the world. When investing in two new large machines, the company made a conscious decision in favor of KraussMaffei MX series technology. Since October 2014, the new MX 5500 and MX 4500 have been producing particularly large waste containers. The order simultaneously sets a record for KraussMaffei. With a clamping force of 5,500 tons, the MX 5500 is the largest injection molding machine in the world to date. The reasons behind Weber's investment in two new large machines were the purchase of new molds and, in doing so, expanding capacity and attaining the greater flexibility desired in manufacturing. Large waste containers with a volume of 660 to 1,100 liters are slated for production. However, the extremely large sizes of the components

17 KraussMaffei Partners & projects 17 With a clamping force of 5,500 tons the largest the MX 5500 is one of injection molding machines in the world. A large waste container should hold up to 1,100 liters. RECORD MACHINE At Weber, the KraussMaffei MX /75000, with a clamping force of 5,500 tons, produces large-volume waste containers in various colors and sizes. LRX 1000 guarantees fast cycle times and reliable handling. placed special technical requirements on the new injection molding machines. The manufacturing of large volume containers for waste disposal requires the use of large molds. The high shot weights and long flow paths require high clamping forces, says Helmut Guntermann, Managing Director at Weber, as he describes the particular task. The new injection molding machines must also produce locking forces of at least 4,500 or 5,500 tons. The new KraussMaffei machines offered us the best option for our requirements, Guntermann continued. In addition to the technical advantages of the MX series, the details behind the implementation showcase the value of the machines as well. These details include the solid design of the machine bed and the mold fixing platens, as well as the lengthened and widened sliding shoes. An added bonus was the guide for the tie bars in the movable mold plate across the entire opening width of the clamping unit. In short, these technical details provide the best conditions for operation with process reliability using heavy molds of up to 150 tons. Hydromechanical twin-platen clamping unit has appeal Large machines of the MX series are principally characterized by the hydro-mechanical twin-platen clamping unit developed by KraussMaffei. It is particularly compact in design, fast in production and low maintenance in operation. The locking system is designed for short cycles with precise positioning. Thanks to platen parallelism, the mold is protected and high part quality is ensured. Furthermore, the MX series scores points with its high melt quality and superb shot-weight consistency, adds Klaus Wimberger, Head of Design Engineering at KraussMaffei. For the design and implementation of the new large machines for Weber, the KraussMaffei Design Engineering department worked closely together with the people responsible at Weber, resulting in a successful system solution. Tailored customer solution KraussMaffei didn't just stick to standard features when designing the machines, but provided the perfect response to our specific requirements. That was a clear benefit, Guntermann continues. The many years of good experience with the large KraussMaffei machines already present among the company's machinery also factored into the customer's decision. The new MX 5500 and MX 4500 are both equipped with state-of-the-art automation solutions, specifically an LRX 1000 linear handling unit (X stroke of 3,000 millimeters). They guarantee fast cycle times and reliable handling of the large components.

18 18 Partners & projects AHEAD Issue KRAUSSMAFFEI CUSTOMER GEALAN SUCCESSFULLY IMPLEMENTS MUCELL TECHNOLOGY BECAUSE NITROGEN IS (ALMOST) WEIGHTLESS MuCell is a technology that benefits everyone because it consumes fewer resources both in manufacturing and later, when the plastic parts are in use. KraussMaffei customer Gealan Formteile GmbH uses it successfully to produce for the automotive industry. TEXT: DR. SABINE KOB CONTRIBUTING WRITER: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI, ISTOCKPHOTO M ucell parts are compared to conventional items particularly lightweight and developed in less time and on smaller machines with lower operating costs. Installed in cars, they also benefit the end user through low fuel consumption. This is similar to the door module of the BMW Mini, which Gealan produces on a 1,000-ton machine and which provides an eight-percent weight reduction. MuCell designates a physical foaming process. A foam structure forms in the interior of a component by using nitrogen that is incorporated in the screw. To ensure that the cells are distributed as finely as possible, the injection has to occur very quickly. For the Mini module made from fiberglass-reinforced ABS, a complete fill takes approximately one second around a third of the time of conventional components. Even at this early stage, the savings start adding up. The most important cycle time advantage comes from the elimination of the holding pressure time, which is replaced by foaming in the cavity. Additionally, a lower clamping force is required on the machine due to the decreased viscosity of the plastic-gas melt. For the door module, users were able to use an existing machine with 1,000 tons instead of a 1,500-ton machine. One-third lower clamping force is gentler on the mold and costs less for energy and other operating materials. SUCCESSFUL COLLABORATION Gealan produces various injection molded parts for the automotive industry using the MuCell process.

19 KraussMaffei Partners & projects 19 GEALAN FORMTEILE GMBH Manufacturing in a state-of-the-art building, equipped completely with KraussMaffei machines. Increased efficiency in manufacturing results in competitive advantages Gealan produces two more MuCell parts: a rear panel for air-conditioning housing and a function carrier for the center console of the Ford Lincoln, which runs on a GX 650. For the latter part, a weight saving of eight percent was also reached, which is particularly worthwhile in this case. The material, a PPA with 50 percent glass fiber content, has extremely high quality and therefore is costly. Competitive advantages are no longer obtained merely through increased efficiency in manufacturing, explains Gerhard Laubmann, the Managing Director of Gealan. Therefore, at a technological level, we are looking for ways to cut costs. The MuCell process has absolutely met our expectations. The MuCell process has absolutely met our expectations. GERHARD LAUBMANN, MANAGING DIRECTOR, GEALAN For the part geometry itself, the foam structure also provides decisive advantages. Due to its greater rigidity in comparison to solid material, walls can be designed to be thinner and ribs can be dimensioned to be narrower. Additionally, less pronounced sink marks form at locations where walls and ribs converge, because the material accumulation is lower. The more balanced pressure distribution and uniform shrinkage in the longitudinal and transverse directions also lead to less tension and warpage. This advantage becomes clearly visible in the Ford center console due to the fiberglass material's high sensitivity to warpage. The warpage was reduced by up to 70 percent. Molds in focus Here, the foam structure can only be seen if you cut apart the plastic components. This is because a closed integral skin forms where the melt contacts the mold. It requires specifically designed molds to take full advantage of the benefits of the procedure. Pay particular attention to venting and cooling because the molds are run cooler than when injection molding without MuCell. Lutz Fischer, Technical Manager at Gealan, recalls: We redesigned the Mini door module once more to exhaust all of the possibilities for the mold design. The savings potential made a compelling case to BMW and, since 2013, the parts have been in series production. Fischer also commends the collaboration with KraussMaffei: The technical interaction is always excellent, for example when implementing sophisticated projects. This type of partnership is valuable for us, because it allows us to experience new trends firsthand, such as the MuCell process. Gealan Formteile GmbH, headquartered in Oberkotzau in northern Bavaria, was founded in 1985 and, including the three subsidiaries, currently employs a staff of 507 people. The main focus of the company's activities is on technical functional parts, primarily for the automotive industry and in the fluid technology area. Some 24 KraussMaffei machines are used to manufacture parts for airconditioning systems, sound systems and motor cooling systems, among other products.

20 20 Partners & projects AHEAD Issue MAXIMUM QUALITY REQUIREMENT AllinPlast produces premium-quality LED lenses and parts for LED lamps. HIGH PRECISION WITH PREMIUM PLASTIC PINPOINT-ACCURATE STREET LIGHTING: LED LAMPS, A MARKET WITH A PROMISING FUTURE More and more municipalities are having to modernize their street lighting due to its age. Replacing inefficient mercury vapor lamps with LEDs promises energy savings of up to 80 percent. AllinPlast produces an important element of the new street lanterns : plastic lenses that guide the light exactly where it is needed. TEXT: JOACHIM WEBER CONTRIBUTING WRITER: ANNA-MARIA MEYER PHOTOS: ANNA-MARIA MEYER, ALLINPLAST T he requirements are stringent: Only a small amount of luminosity may be lost. The lenses are to enable all variants between wide scatter and sharp bundling of the light. The light must be bright without blinding drivers or passengers. Thus, this requires a level of refraction accurately adapted to the respective situation. Manufacturing plastic lenses with these types of properties requires a lot of expertise in both lighting technology and in plastics processing. AllinPlast Kunststoffenindustrie B.V. in Oud-Beijerland, Netherlands, focuses on manufacturing products for the lighting industry. The company, founded in 1968, also produces technical parts, from electronics housings to components for greenhouses and horticulture. Because it requires extreme precision, the company relies on the KraussMaffei CX series of fully hydraulic injection molding machines. They currently already make up 40 percent of the company's

21 KraussMaffei Partners & projects 21 SUCCESSFUL COLLABORATION Mark Verveer (Director of KraussMaffei Benelux) and Jack Lems (AllinPlast manager) (from left to right). machines. For the LED lenses (in processing as well), AllinPlast uses an extremely advanced material, polymethyl methacrylate (PMMA). Due to its high translucence, it is ideal when stringent demands for lighting are involved. The minor disadvantage of PMMA is that it affects bonding and, as a result, can contaminate the cavity surface. Therefore, the mold must be cleaned at least once daily. This is not a problem thanks to the good accessibility of the CX. The modular structure of the CX series fits perfectly into production. The plasticizing unit can be changed easily and quickly. The extensive range of additional machine options also provides optimum production flexibility. The range of automation solutions was also appealing. A short time ago, AllinPlast acquired a LR 150 linear robot for a C machine. Even though the company had little experience in automation at that point, the integration into the production process went quickly and without a hitch. The company now profits from lower-priced, faster and much more accurate manufacturing. The number of rejects caused by incorrect manual handling has also been reduced enormously. the AllinPlast manager. The service department also solves our problems in a way that is fast, efficient and tailored perfectly to our needs. This gives us a secure feeling. Therefore, we've decided to expand the collaboration with KraussMaffei further and purchase additional CX machines in the future. The service department also solves our problems in a way that is fast, efficient and tailored perfectly to our needs. JACK LEMS, ALLINPLAST MANAGER Efficient solutions Jack Lems particularly appreciates the collaboration with KraussMaffei. I can always reach the person I need to talk to and the collaboration is always very pleasant. It almost feels like family, says

22 22 Partners & projects AHEAD Issue C AND CX SERIES AT MENSHEN PACKAGING USA BOTTLES AND TUBES STAY SEALED Menshen Packaging has been among the major packaging specialists in the USA for over 40 years. In manufacturing various complex plastic caps and lids, the company has always trusted in KraussMaffei standard and multi-component injection molding machines. TEXT: SIMONE WERNER PHOTOS: KRAUSSMAFFEI, CORBIS VARIETY Many products from the Menshen portfolio are produced on KraussMaffei machines. W ith over five billion plastic components produced yearly, Georg Menshen GmbH & Co. KG in Finnentrop, Germany, is one of the largest companies in the global market. The company specializes in developing and producing various standard and special caps and lids for bottles, tubes and pouches, as well as sponge applicators. Their products are manufactured for the cosmetic, cleaning product, chemical and food industries at seven facilities in Germany, Spain, Russia, China, Mexico and the USA. The plant in Waldwick, New Jersey, was founded back in 1972 as the first step in the company's overseas expansion program, and has been successfully producing caps and lids for the North American market ever since while relying almost exclusively on KraussMaffei injection molding machines. Along with standard and multi-component injection molding machines, a variety of automation solutions are available for installing the complex sophisticated caps and lids. Consistently high product quality Innovative designs, optimized functionality, custom solutions and outstanding quality that can be reproduced a million times over all at an extremely low cost per piece, says Rogelio M. Ayala, Vice President of Sales and Operations at Menshen Packaging USA, explaining his customers' key requirements. These requirements are met using KraussMaffei injection molding machinery and the Group's global production network, which enables Menshen to ensure that its products are of a consistently high quality all over the world. Its plant in the US is equipped with 23 injection molding machines, 18 of which have been supplied by KraussMaffei. Numerous other systems are also housed in the overall production space of 120,000 ft 2 (approx. 11,150 m 2 ). Four complete production lines, four extrusion presses, four packaging lines and two filling machines are used to develop new products, manufacture prototypes, carry out extensive tests, and much more. Robust hydraulic machines to meet all requirements Menshen Packaging chose KraussMaffei as its partner for injection molding solutions a long time ago. KraussMaffei's US subsidiary, founded in 1966, played an important role in this process as the company's local contact partner. Today, the Waldwick plant has a total of 18 C and CX series hydraulic injection molding machines, with clamping forces of between 500 and 5,000 kn. Starting with market trends and customer requirements and working towards higher outputs with larger molds, over the following years more advanced and, more importantly, more sizable machines were acquired. Paul Caprio, President of the US subsidiary KraussMaffei Corporation in Florence, Kentucky, explains: Our CX series injection molding machines and their predecessor versions are powerful workhorses and therefore well established in the North American market. Their advanced technology and high degree of versatility have made them a popular choice with many manufacturers. Menshen Packaging, for example, also uses a two-component machine for making multicolored parts on a daily basis. With clamping forces of between 350 and 6,500 kn, CX series machines are also popular due to the fact that they are flexible and cost-efficient. Their core component is a compact dual-platen clamping unit. Thanks to the modular design, manufacturers can put together a customized machine from over

23 KraussMaffei Partners & projects 23 HYDRAULIC ALL-ROUND TALENTS The CX series injection molding machines feature high flexibility, cost-effectiveness and end product quality. 100 combinations of clamping and injection units. This means they can find the right solution to meet almost any requirements. Precision plays an important role, particularly in the packaging industry precision in the closing movement and locking force, as well as precise and absolutely reproducible metering of the processed raw materials. Another important factor in guaranteeing that Menshen's final products are of exceptional quality is its in-house research and development department. Numerous items of testing equipment enable consistently thorough quality assurance checks to be made at every stage of the development and production processes. Molds are cleaned, inspected and repaired at the company's mold manufacturing facility, where prototype molds can also be made. Ease of operation and quick response times We worked closely with KraussMaffei prior to placing an order with them, so when their machines arrived here at our plant all we had to do was connect them to the energy and water supply and then start manufacturing it really was just a case of 'plug-and-play' performance, explains Ayala. We are extremely satisfied with the KraussMaffei Corporation in Florence, Kentucky not only because their detailed knowledge of machinery and processes, but also because of the excellent advice and service we have received from them. Their employees are highly competent, they respond quickly to our questions, and their maintenance and replacement-parts services are highly efficient, he adds. Having service engineers who are close at hand and can be available at short notice is essential, especially in the mass production of plastic caps and lids. Many of Menshen's customers are major multinational corporations that do Innovative designs, optimized functionality, custom solutions and outstanding quality that can be reproduced a million times over all at an extremely low cost per piece. ROGELIO M. AYALA, VICE PRESIDENT SALES AND OPERATION AT MENSHEN PACKAGING USA not accept late deliveries this means that long and especially unscheduled machine downtimes must be avoided at all costs. This is where the Waldwick plant's sophisticated logistics system also plays its part. Another factor that has a significant influence on investment decisions at Menshen is how easy machines are to operate, and how quickly and easily staff can learn to control them. KraussMaffei technology fits the bill in both respects.

24 24 Partners & projects AHEAD Issue LFI TECHNOLOGY EXCELS IN MANUFACTURING LARGE-FORMAT COMPONENTS FILM INSTEAD OF PAINT Visible components in commercial vehicles and caravans have to be stable and visually appealing at the same time. The use of thermoforming films that are made rigid using fiber-reinforced polyurethane enable cost-effective production of thin, high-strength components with high design freedom. TEXT: DR. HARALD SAMBALE, PETRA REHMET PHOTOS: KRAUSSMAFFEI COMPLEX GEOMETRY To be able to implement large-format components as well, the LFI unit of the new system is guided by a 7-axis robot. P arat GmbH + Co. KG specializes in manufacturing large-format components with high-gloss surfaces. At the Neureichenau location in the Bavarian Forest, the company operates several KraussMaffei LFI (Long Fiber Injection) systems. A short time ago, Parat invested in a fourth KraussMaffei LFI system that is suitable for the production of particularly large-format components. These types of components with a weight of up to 30 kg are used primarily for commercial vehicles and motor homes, explains Christian Kornexl, Head of Development at Parat. In the area of commercial vehicles, for example, this involves engine hoods, fenders and canopies for tractors and other agricultural machines. For motor homes, Parat manufactures complete front end and rear panels with an area of several square meters. In these applications, the numbers of pieces are often in the range between 500 and approximately 10,000 components, Kornexl says. Therefore, it has proven useful to manufacture the components as a combination of thermoforming thermoplastic film with fiber-reinforced polyurethane. The new LFI system is operated in the double-shuttle process. Two moving tables, on which the molds are located, move in alternation from both sides, first into the polyurethane feed station and then into the press. At the beginning of the processing cycle, the machine personnel place the thermoforming film into the mold. The side of the film facing the mold later makes up the visible, high-gloss surface of the component. In the feed station, the mixture of polyol, isocyanate and glass fiber is applied to the rear side of the film. For the LFI process, the polyurethane wets the glass fibers that reinforce the component while they are still in the mixing head. This has the advantage that more cost-effective rovings can be used as reinforcement material instead of preformed fiberglass mats. Discharge capacity of 1,000 grams per second The LFI process unit consists of a cutter and an LFI mixing head. The cutter draws the roving in, chops it into fibers of the preset length (of 12.5 to 100 millimeters)and shoots the chopped fibers into the mixing head. There, the polyurethane components are mixed with each other and wet the reinforcing fibers. For

25 KraussMaffei Partners & projects million euros in sales were earned by the Parat Group in 2013 with 667 employees. the new LFI system at Parat, a mixing head with a discharge capacity of 1,000 g/s is used. The rovings are drawn into the mixing head in four closed lines. This prevents the rovings from interlocking or getting entangled. To implement complex geometries in largeformat components, the LFI unit of the new system is mounted on a seven axis robot. An additional special feature from a process technology standpoint is the use of two different types of polyol. We use fast-reacting and slow-reacting polyol variants, as the feeding of the polyurethane mixture can take up to 30 seconds, explains Christian Kornexl. At the beginning, we feed the slowreacting components; over the course of the shot, the percentage of fast-reacting polyol is increased successively. This ensures that the material cures uniformly and the material density in the component is not subject to any fluctuations. High production flexibility An important aspect in designing the new LFI system was the production flexibility. The track system of the moving tables is countersunk in the hall floor to ensure an ergonomic operating height. No platforms are required for inserting the film or removing parts. This lack of barriers the mold to be changed quickly. Among other benefits, we are able to approach the system directly with a forklift, Kornexl says. We also shorten the set-up times with magnetic mold-clamping systems. Thus we are capable of responding to the requests of our customers in a particularly flexible manner. Cleanliness is also a critical factor in manufacturing components with visually sophisticated surfaces. This is because, at a foaming pressure of approximately ten bars, each glass fiber that gets lost between the mold and film leads to an unacceptable visual flaw in the surface. The polyurethane feed station is encased to keep the hall environment as lint-free as possible. The doors do not open until the material pouring is complete. The press is also shielded from the environment using lock-gates. Scratch-resistant films with uniform thickness Manufacturing the component begins with a process step that is upstream of the LFI process: thermoforming the film. We turn the traditional manufacturing process on its head, because, to a certain degree, we paint the components first and then reinforce them, says Kornexl. Instead of a layer of paint, films are used to give the components a high-gloss surface. This film can be made of ABS or PC, for example. A PMMA coating increases the scratch resistance of the surface. Before stiffening with polyurethane in the LFI system, the film has to be reshaped accordingly. Thermoforming primarily depends on generating a uniform thickness in all areas, explains Kornexl. To do so, the film must first be uniformly heated. When the corresponding temperature is reached, the film is pressed onto a mold with underpressure and then shaped. Three thermoforming machines are available at Parat for the LFI films. 5 locations in Germany, Austria, The company has over Hungary and Romania. Post-mold processing with maximum precision After the LFI process, the outlines of the part are reworked to remove the residue that develops during pressing. For this work step, Parat has 15 portal milling machines, six robot cells and a waterjet system. The component size is one aspect that determines which process is used. The smaller the component, the more simple the milling operation, explains Kornexl. For large-format components, the portal milling machines provide the highest precision. The processing program is already created in advance via CAM interfaces. In this way, the finished components correspond exactly to the design data. LARGE SIZE The new LFI system produces visible parts, several square meters in size. MORE DESIGN FREEDOM THANKS TO LFI Examples of components for commercial vehicle applications that Parat produces in the LFI process include engine hoods, fenders and roof elements for agricultural vehicles and construction machinery. The objective of these applications is to reach the largest component stiffness possible with low wall thicknesses. This also includes the high requirements for the visual quality of the component surface. The LFI components have numerous advantages compared to the painted sheet metal parts used previously. First, the production costs are considerably lower since subsequent painting is not required. Furthermore, the LFI procedure provides greater freedom in component design. Minor damages in the surface of an LFI component also do not lead to visual flaws as quickly. The reason is that the coloring film has a thickness of 1.5 mm and is, therefore, significantly thicker than a layer of paint. And even if the film is damaged enough to leave the polyurethane layer exposed, unlike paint damage to sheet metal parts, no corrosion occurs. On the other hand, slightly different requirements are placed on components that are used as rear and front end panels for motor homes. The polyurethane layer here has a thickness of up to 20 mm, because, along with the mechanical properties, the insulating effect of the polyurethane also plays an important role. Previously, these types of panel elements consisted of a wood fiber board, a relatively thick EPS layer and an outer shell made of aluminum. The excellent insulating properties of the polyurethane make the LFI components considerably thinner. Because of this and the three-dimensional contour of the components, they ensure additional space in the interior of the motor home. This space can be used as storage space or for storage compartments, for example.

26 26 Partners & projects SINGLE-VENDOR SOLUTIONS PUT IN THE BEST LIGHT The new HELLA plant in the west of Mexico is setting benchmarks in terms of production efficiency and cleanliness. Here, the automotive supplier produces headlamps and taillights for the North and South American markets. KraussMaffei supplied all 23 injection molding machines, including their automation systems. TEXT: SIMONE WERNER PHOTOS: HELLA, CORBIS T he conveyor belts in Irapuato, Guanajuato, approximately 350 km west of Mexico City, have been running at full speed since January The plant produces around 1.2 million headlights and 2.4 million taillights annually. Built at a cost of approximately 90 million euros, the 24,000 square meter production facility is considered to be the standard throughout the group in terms of the quality of products and processes and the technologies used. We pride ourselves on lean manufacturing, and the path to the customer is planned right to the last detail, says Dominique Boulegue, who is responsible for the strategy of HELLA in Mexico. The Mexican automotive market continues to grow at a fast pace. In 2013, almost three million vehicles were produced in the country. By 2017, this number is projected to be four million. The good connection to the markets in North and South America make the country an important hub for the automotive industry; many automakers from Asia, Europe and the United States have production locations in Mexico. Boulegue adds: HELLA has been on-site since 1964 and established itself as a leading manufacturer of headlamps in the country. Production excellence with injection molding technology from KraussMaffei In order to achieve the best-possible efficiency in the production of diffusion lenses and taillights at the new plant, HELLA chose its long-term partner KraussMaffei to be its supplier for injection molding machines and automation. Our MX large machinery series, with its speed, precision and excellent melt quality, is ideal for advanced standard and multi-component applications in automotive lighting production, explains Bengt Schmidt, Head of the Automotive Business Unit at KraussMaffei. For the production of multicolored taillights for passenger cars, HELLA relies on our tried-and-tested 2 and 3-component machines with turntable molds and automation. A total of 23 fully automated injection molding machines are available for the production of exterior lighting components, housing units and reflectors. The largest machines are the MX 1600 for 2-component applications and the MX 1450 for 3-component applications. The smallest machine is the CX 300 for bulk molding compounds (BMC). The multicolored taillights made of PMMA are CX BLUEPOWER All 23 injection molding machines in the plant are from KraussMaffei. IRAPUATO: HELLA produces headlamps and taillights at this plant.

27 23 fully automated injection molding machines are available for the production of exterior lighting components, housing units and reflectors. injected on the multi-component machines. The diffusion lenses made of polycarbonate are injected on the medium-sized standard machines. The 300-ton BMC machine handles reflector production. All machines are equipped with the KraussMaffei BluePower servo drive technology. For the energy-related optimization of hydraulic drives, this technology uses the high dynamics of servomotors to adapt the rotational speed of the hydraulic system pump, always in conformity with the actual requirements. Challenging product specifications in the areas of surface aesthetics and surface quality The injection points lie directly in the mold parting line so the multicolored taillights are produced without any visual flaws. Linear robots, which also remove the finished parts from the machine, detach the sprue. The mold technology employed is based on the integrated KraussMaffei turntables. These provide optimum sealing of components from one another through the storing of the respective injected components in the cavity. This enables the uniform connection of all material components to meet the highest visual specifications. Thanks to the parallel injection process, effective mold cooling and the electric drive of the turntable, extremely short cycle times can be achieved. Unlike taillights, diffusion lenses are usually made of polycarbonate. Here, HELLA relies on the four-zone HPS (high-performance screws) with customer-specific geometry and a three-part nonreturn valve with nonstick coating. The nonreturn valve made up of the screw tip, stop ring and pressure ring features precise closing behavior and a high shot-weight consistency, even when low screw decompression is present. Thanks to the intelligent combination of shearing and mixing zones, the material is homogenized very gently under low back pressure, with the positive effect that an unwanted increase in the melt temperature and premature wear and tear of screws and barrels are prevented during plasticization. A rheologically optimized screw geometry protects both the plastic and machine. This results in a longer service life for screws and barrels, and a high level of plasticizing and output. Wide product range appeals to customers From the beginning, we were impressed by the capacity of KraussMaffei machines in terms of end product quality and productivity. For years, it has fulfilled the high standards in place for vehicle lighting production in the global HELLA network, says Boulegue. The extremely compact and powerful MX series is specially designed for continuous operation. It combines short machine times with quick cycles and a high output. The series has a modular design and can be flexibly adapted for special production requirements. The MX series is now successfully positioned in many industries throughout the world and has set standards, especially in the automotive industry. For the production of reflectors, HELLA relies on thermoset and fully hydraulic 3,000 kn injection molding machines from the CX series, which are specially equipped for the manufacturing of plastic components from granular and non-granular molding compounds such as BMC, SMC, TMC, melamine and phenolic materials. All components on the plasticizing unit, including nozzles, barrels and screws, have a highly resistant coating. In addition, functions such as core compression molding, mold breathing and mold vacuums, which guarantee constant process conditions, are included in the thermoset equipment package. Finally, the individual components, diffusion lenses, exterior windows and reflectors are assembled and bonded into complete headlights and taillights in special assembly lines, and exit the plant just in time.

28 28 Partners & projects AHEAD Issue ALLIGATOR PLASTICS SPECIALIZES IN PLASTIC PARTS FOR DEMANDING APPLICATIONS HIGH-TECH FOR THE BEER BARREL The steel drink barrel now has competition. KeyKeg is the name of the double-walled, nonrefillable plastic container from the Netherlands. KraussMaffei customer Alligator Plastics played a crucial role in its development. The company produces seals for the double-walled container, an advanced multifunction part, for manufacturer Lightweight Containers. TEXT: JOACHIM WEBER CONTRIBUTING WRITER: ANNA-MARIA MEYER PHOTOS: KRAUSSMAFFEI, ALLIGATOR PLASTICS T he sophisticated plastic keg was introduced on the market in Initially, Alligator Plastics only produced approximately 33,000 seals per year. But its intelligent and efficient product design quickly caught on. Beverage manufacturers from around the world (more than 180 countries, to be precise) were impressed by the low weight with high load-carrying ability and stacking capability, the improved service life of the fill product, the omission of return transport for empties, the separate carbon dioxide bottles and the user convenience. By 2014, a few million barrels had been produced and more than 200 breweries were using the innovative transport and storage container. These barrels are being filled with wine, hard cider and soft drinks with increasing frequency. The KeyKeg consists of four basic components: a plastic carrier known as a base cup, an exterior and interior barrel for storing and preserving the beverages and a gripping ring on the top for lifting and stacking the barrel. Great reproducibility impresses Alligator Plastics, in the Dutch town of Son, produces the seals for the double-walled plastic sleeves. It is a beer seal, dust seal, beer lid and retaining ring all in one. It also has a specially designed handle. The technical requirements for the part are also anything but trivial. The containers are tested at a pressure of up to six bars; in realworld use, they are under a pressure of three bars for up to one year. Pressure losses are not allowed, because they would immediately lead to a loss in quality of the beverages. Thus, maximum precision is absolutely necessary. The hygiene rules of the food industry additionally intensify the performance profile. DOUBLE-WALL TECHNOLOGY Alligator Plastics BV manufactures seals for beer barrels made of plastic. Thanks to the new two-chamber system, the beer never comes into contact with propellant and is optimally protected against oxidation. The injection molding company also participates significantly in further developing the product. From the 14 parts of the seal at the beginning, just four remain. Furthermore, the closure can now be assembled very easily and installed by moving onto the barrel. The parts in the multi-component process are manufactured on a KraussMaffei CXV 110 injection molding machine with a rotary table and a V injection unit.

29 KraussMaffei Partners & projects 29 The excellent reproducibility on KraussMaffei machines allows us to manufacture the seals to very tight tolerances, explains Wietse T. Wissema, owner and Managing Director of Alligator Plastics. This is due to the precise platen parallelism as well as the accurate shot weight of the plasticizing systems. They feature a uniform melting capacity, even at high throughputs. This results in precise products and high productivity and cost-effectiveness. Customized solutions Wissema particularly appreciates the technical expertise of his contacts and the close collaboration with the service department. KraussMaffei has years of experience in all relevant technology areas and can always give us important input on customer projects, says the Managing Director. Particularly in the multi-component area, we require special peripherals and solutions due to our special developments. We get them from KraussMaffei and they are perfectly tailored to our needs. The spectrum of services on offer is at the top of the industry. The Munich-based company also supervises the most recent innovation: the KeyKeg Slimline. In close collaboration with the customer, Alligator Plastics developed a base cup that only weighs 160 grams instead of 230. The new plastic carrier is only 1.5 millimeters thick and can bear a weight of 300 kilograms. This makes it possible to stack the containers in up to ten levels. Ideally equipped for the future Alligator Plastics specializes in highly complex plastic parts for customers from the automotive, foodstuffs, medicine and lifestyle areas. The company is just as innovative as it is expansive. Since 2010, the sales volume has more than doubled to 6 million euros. In mid- September 2014, the injection molding company opened up a new plant with an area of 1,800 m 2 (19,375 ft 2 ). By doing so, it doubled its operating space. The new plastic carrier has a thickness of only millimeters and can carry a weight of kilograms. First of all, the new building will receive a state-of-the-art warehouse and inventory management system. In addition to the previous 15 injection molding machines, new production systems not least of all from KraussMaffei will be set up in the now available space of the existing building. The number of seal parts has changed 14 from to 4. FLEXIBILITY IS THE TRUMP CARD KraussMaffei machines enable molds to be changed quickly and easily.

30 30 Partners & projects AHEAD Issue SKI BINDINGS REQUIRE THE GREATEST RELIABILITY WITH A LOW WEIGHT COMFORTABLE UPHILL AND DOWN FIBERFORM ON THE SLOPES In 1952, Hannes Marker applied for his first safety ski binding patent. Ever since, Marker, now Marker Völkl, has stood for innovation and safety in the sport of skiing. In December of 2014, Marker introduced its latest product to the market: the Kingpin touring ski binding. KraussMaffei participated in its development along with S&W GmbH. TEXT: JOACHIM WEBER CONTRIBUTING WRITER: STEFAN SCHIERL PHOTOS: MARKER VÖLKL, ISTOCKPHOTO NEW The Kingpin touring ski binding from Marker features a high level of comfort and is especially appealing with performance in descent that is uncommon for touring ski bindings.

31 KraussMaffei Partners & projects 31 Easy handling for maximum flexibility in descent mode. FiberForm technology makes it possible to have a high loadcarrying ability. High-performance parts with the lowest-possible weight for all extreme situations. On a small, narrow surface, the multi-function stringer contains three highly loaded function elements, all made from fiberglass-reinforced polyamide. Sitting under the back end of the binding is a spindle plate (that is no longer a plate), which adapts the binding to the boot length. During ascent, the ski brake is locked on a safety screw that sits in a hole that is extrusion-coated with plastic and is located in the middle of the part. A horizontal bushing on the front end carries a pin, around which a toggle lever rotates. The skier uses this to toggle the binding between ascent and descent modes. This is done by simply pushing the heel piece forward over the multifunction stringer (descent) or backward (ascent). T he attraction of the new touring binding is that it combines the toe piece of a conventional but visibly improved PinTech binding (for ascent) with a heel piece that has no pins and is more like an alpine binding (for descent). These pins are lateral spring pins that flexibly hold the ski boot specially equipped for this and release it in an emergency. At the same time, the pins act as a joint for rotation of the boot during an ascent. Testers affirm that the Kingpin binding is very comfortable, highly reliable and especially delivers a performance not commonly found for a touring ski in descent. And with certification in accordance with DIN ISO 13992:2007, TÜV [German Technical Inspection Association] also confirms the high reliability of this binding. High-tech product When the ski binding is mounted, you can hardly see KraussMaffei's contribution: the multifunction stringer, a functional carrier under the heel piece of the binding. As inconspicuous as the part may seem, it is high-tech in the truest sense of the word. Its basic body is a composite sheet, a pressed part with plastic composite on a carbonfiber mat base, which is extrusion-coated with a fiber-reinforced plastic and provided with multiple function elements. FiberForm is the name of the process from Krauss- Maffei that combines thermoforming with injection molding, and meets a central requirement of Marker, the customer, namely manufacturing high-performance parts with the lowest-possible weight. A view toward functional integration The development of this part was truly challenging, says Stefan Schierl, Development Engineer at KraussMaffei Technologies, because we were faced with very stringent specifications in regard to the loading precision and the mechanical and visual properties. But the appeal of this new development also consisted in creating a product that exemplifies the possibilities of functional integration. Even this relatively small part shows a large portion of the performance spectrum that is possible with FiberForm. Composite sheets provide advantages To bind up the fiber ends of the composite sheet and manufacture a precise exterior shape, the part is also extrusion-coated with glass-fiber-reinforced plastic. Additionally, a part in the front area of the composite sheet is reshaped into a bead, a groove-like depression that mechanically reinforces the stringer. This is also an example of the functional integration possible with composite sheets. In general, this component is ideally suited for demonstrating the advantages of composite sheets, namely, producing defined mechanical properties and functional integration in one injection molding machine in only two process steps, Schierl emphasizes. Low weight with high function So far FiberForm, the combination of thermoforming and injection molding, has been used primarily in the automotive industry. In serial production this is used to produce seat pans and backrests, instrument panel supports, side-impact protective elements and semi-structural components made of fiberreinforced plastics. Whether added ribs for extra stiffness, shaped openings with a reinforced edge or complex geometries the FiberForm process can be used to produce many pieces that would be difficult or impossible to manufacture as a sheet metal part. And all of this in only one process. Like injection molding, FiberForm is easy to automate and integrate into an injection molding plant. Since FiberForm can be combined with nearly all special processes available for the injection molding process, this results in countless approaches for functional integration and component design, Schierl adds in highlighting the possibilities.

32 32 Brand & Markets markets AHEAD Issue Brand & markets OPEN HOUSE AT POLIURETANO FASCINATION WITH POLYURETHANE Whether it's hard or soft, poured or foamed, the interest in and range of applications for polyurethane also remains strong in Mexico. More than 100 visitors made the Open House at Poliuretano at KraussMaffei in Mexico a successful customer event. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI LIVE OPERATION Demonstration of the EcoStar 16/16 polyurethane mixing and metering system during the Open House at Poliuretano at KraussMaffei Mexico. K raussmaffei commenced the Open House at Poliuretano with Mexican trumpets and a live demonstration of a polyurethane mixing and metering system. In October 2014, more than 100 customers accepted the invitation to Querétaro, in central Mexico, in to learn about the newest developments and technologies in polyurethane processing. The fascination and interest in polyurethane remains strong in Mexico. This also reflects the positive feedback from visitors at our open house event, explains Emilio Lopez, Head of the KraussMaffei Group subsidiary in Mexico. Numerous new developments and application options in the area of polyurethane have arisen, resulting in part from increasing demand for cost-effective, lightweight construction solutions. Our HP-RTM and LFI technologies offer the best solutions for composite processes, and our molded flex & interior trim meets the needs of automakers (OEMs) and tier 1 suppliers for short cycle times and low manufacturing costs, continues Lopez. Successful open house The visitors at the open house saw the technical benefits of the EcoStar 16/16 polyurethane mixing and metering system live and on-site. Selected specialist and guest presentations on the current topics of composites, glass encapsulation, molded flex & interior trim and major appliances enhanced the successful event.

33 KraussMaffei Brand & markets 33 COOPERATIVE PARTNERSHIP WITH 3CON INTERIOR TRIM SYSTEMS FROM A SINGLE SOURCE KraussMaffei is reinforcing its system expertise for reaction process machinery in the area of interior trim and has worked together as a partner with 3CON Anlagenbau GmbH since the beginning of the year. The ambitious automotive supplier with headquarters in Ebbs, Austria, is among the leading global providers of laminating, edge folding and thermoforming technologies. TEXT: PETRA REHMET PHOTO: KRAUSSMAFFEI GLOBAL COOPERATION Shared system expertise in the area of interior trim: Nicolas Beyl, President of the Reaction Process Machinery segment of the KraussMaffei Group, and Hannes Auer, CEO and founder of 3CON (from left to right). In the area of interior trim, KraussMaffei's reaction process machinery implements production systems for foamed or back-foamed parts for vehicle manufacturing with surfaces with especially high aesthetic quality. This includes parts such as instrument panels, door coverings, door panels and window trims. KraussMaffei provides customized system solutions from a single source, starting with the molds, including the mixing and metering systems, and spanning all the way to equipment for cutting and punching finished components. Through the partnership with 3CON, KraussMaffei is now expanding its system expertise. Nicolas Beyl, President of the Reaction Process Machinery segment of the KraussMaffei Group, explains, 3CON is a valuable partner to have at our side. Together with them, we can also offer our customers technologies for laminating, folding and thermoforming. Hannes Auer, founder and CEO of 3CON, adds, We are very glad to have KraussMaffei, a company with global standing, at our side. The two companies have cooperated closely in both domestic and international matters regarding sales and project engineering since the beginning of the year. MORE INFORMATION ABOUT 3CON Continuous growth and a high degree of innovative ability are key characteristics of 3CON, which was founded in Approximately 200 employees are currently working at the company's headquarters in Ebbs, Kufstein, Austria. All major automakers and their suppliers maintain global sales and service support locations. The company's eagerness to innovate is evident from its array of proprietary developments and worldwide patents. Outstanding examples include a new vacuum-laminating system for shorter cycle times and material savings, as well as the ESL process (Exact Shape Laminating), which was developed in-house. MORE INFORMATION AT MATERIALICA AWARD 2014 AWARD-WINNING LIGHTWEIGHT CON- STRUCTION Surface resin transfer molding (surface RTM) from KraussMaffei enables mass production of fiber-reinforced visible components in vehicle manufacturing. TEXT: PETRA REHMET The Materialica Design + Technology Award is a coveted prize. On October 21, 2014, it was once again awarded to innovative design and technology products in four categories at the Materialica trade show in Munich. The gold prize in the Surface & Technology category went to KraussMaffei Reaction Process Machinery. The roof module for the Roding Roadster R1 sports car, which was created using surface resin transfer molding, received the award. Immediately paintable At approximately 0.45 square meters and dimensions of 772 mm x 585 mm, the roof element is a true lightweight. Thanks to its carbon fiber-reinforced continuous fibers, it weighs a mere 2.57 kilograms. A high fiber volume fraction of 50 percent provides the necessary strength and stability. The jury was also impressed by the suitability of the surface RTM procedure for mass production applications. The fully automated manufacturing process enables cycle times of just five to seven minutes, which increases the number of units produced. Another selling point is that the component can be painted immediately. Additional post-mold processing such as filling and looping are omitted, which greatly reduces costs. MORE INFORMATION AT