Improved Color Change Times. Learn more at NPE: West Hall Level 2 W 1983

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1 Improved Color Change Times Learn more at NPE: West Hall Level 2 W Learn more at NPE: West Hall Level 2 W 1983 Your Polymer Solution HIGHLIGHTS OF EUROPEAN TECHNOLOGY MADE FOR THE US-PLASTICS INDUSTRY

2 Why wouldn t you take advantage of the data you already have? West Hall Booth W3303 Data is just data until you make something out of it. With ENGEL s inject 4.0 solutions, you can easily capture the power of the information that already exists within your company. No other machine supplier offers such an extensive and effective array of smart products to choose from. Simplify your life with: self-adjusting machines and robots, a MES system specifically designed for what is important to you, smart service which gives you certainty with system components lifespan and increases overall availability.

3 EDITORIAL 3 Best of high tech from Europe What great solutions did European manufacturers of plastics and rubber machines bring to NPE for US plastics processors? This question is at the heart of Europe@NPE, a unique publication first published at NPE 2018 and produced by the K-ZEITUNG team. K-ZEI- TUNG is Europe s leading newspaper for plastics processing and official media partner of NPE. Here you will learn everything that s important about European innovations and their advantages, about new approaches and the current development priorities of the various companies as well as about the high status that the USA enjoys as a customer. After all, the USA is by far the most important trading partner of European manufacturers. In 2017, some 950 million dollars worth of plastics and rubber machinery was delivered to the United States from Germany alone, and manufacturers are optimistic that the 1 billion dollar mark will be exceeded for the first time in High-tech solutions from Europe ensure that the high demand for plastic products in the USA can be satisfied with high productivity, flexibility and efficiency. Here are some examples: Among other things, Engel will present a fully automated Decoject process for injection molding machines at NPE 2018, with which high-quality vehicle interior parts with low unit costs can also be produced in smaller batch sizes. 8 In an exclusive interview with Engel CEO Dr. Stefan Engleder you can find out High-tech solutions from Europe for high productivity, flexibility and efficiency what is unique about Engel s Inject 4.0 solutions and how the concept stands out from the Internet of Things and Industry 4.0 and above all how US plastics processors benefit from Inject Krauss Maffei has also come to Orlando with several premieres, including the GX 900 injection molding machine, which can produce large packaging efficiently and economically with the new Speed option, and the weight-saving Fiberform process, which combines thermoforming of organic sheet and injection molding in one process and which will be shown at NPE for the first time in conjunction with swivel-platen technology for multi-component injection molding. 14 Arburg, on the other hand, will impressively demonstrate at NPE 2018 that the company does indeed listen to the wishes of its US customers. The largest injection molding machine Arburg has ever produced will be on display at the largest stand in the company s history: however, the Allrounder 1120 H not only fulfills the many requests of US customers for larger machines, it is also extremely easy to operate thanks to innovative Gestica control in the look and feel of smart, mobile end devices. 18 In addition to the leading European injection molding machine manufacturers, many smaller companies have also come to Orlando with major innovations Hekuma, for example. With its latest system, the automation specialist will impressively demonstrate at NPE how extremely short cycle times and virtually maintenance-free operation can be combined to achieve maximum productivity and efficiency. 26 Contura will show visitors at NPE why conformal cooling of injection molds is so important, just as 3D printing opens up new dimensions in injection molding, and why vacuum brazing and diffusion welding are extremely interesting alternatives to 3D printing with metal. 41 There is not enough space here to list all the new products, but I can assure you that due to the wide range of topics and the many innovations we have included in this issue, the vast majority of readers will also get ideas that will drive them forward in their companies and give them a competitive advantage. We wish you a lot of interesting, creative input for your success Günter Kögel, Editor-in-chief EUROPE@NPE

4 4 CONTENTS Krauss Maffei Photos: Arburg US-MARKET 06 Germany remains number 1 US partner INJECTION MOLDING 08 High-qualitiy engineering parts at low unit costs 12 Engel-CEO Dr. Stefan Engleder: A country with incredible potential 14 More speed for packaging and logistics applications 18 Large machines, innovative methods 22 Friedrich Kanz, CEO of Arburg, Inc: We keep listening to our customers 24 Very fast and extremely thin EUROPE@NPE This magazine is specially made for NPE 2018 and fokussed on the highlights of European companies shown in Orlando. EUROPE@NPE is produced by K-ZEITUNG, official media partner of NPE. K-ZEITUNG is the leading plastics newspaper in Europe and reports biweekly about news and trends in the global plastics industry in German language. AUTOMATION 26 Efficient medication cup production QUALITY ASSURANCE 28 Web Guiding for Process Control MATERIAL SUPPLY 30 Ach solution knows how to use LSR in optical applications 31 Precision mixing in large dimensions EXTRUSION 32 Higher performance, more flexibility 34 Highly-efficient extrusion 38 Extrusion for the smart factory TEMPERING TECHNOLOGY 41 Close to the contour 44 Fewer rejects and greater energy efficiency Photo: Engel RECYCLING 46 Maximum process stability with ideal project tracking 47 Quality in plastics recycling in greater demand than ever BLOW MOLDING 48 New coating substantially accelerates color change 49 Kiefel is ready today for the products of tomorrow MATERIALS 50 Wide range of polymer solutions COMPANIES IN THIS ISSUE 51 The companies at a glance The biggest driver for our growth Engel CEO Dr. Stefan Engleder: We are convinced that at NPE we can once again provide new impetus and convince our customers that our solutions give them a competitive edge. 12

5 INTUITIVE AND SMART FAST AND PRECISE ERGONOMIC AND FUNCTIONAL LARGE AND EFFICIENT APPEALING AND EMOTIVE VISIONARY AND BOLD POWERFUL AND DYNAMIC May 7-11, Booth W1325, West Hall Orlando, FL Large and efficient: It s possible with us! Our ALLROUNDER 1120 H combines electric speed and precision with hydraulic power and dynamics. And with our innovative GESTICA control system, operation is even more intuitive and smarter this is high-end technology that s fun to work with!

6 6 US MARKET Source: National Statistical Institutions The most important suppliers of plastics and rubber machinery in the USA (Imports 2016) Germany remains number 1 US partner Germany Japan France Canada China Others Germany is and will remain the USA s most important trading partner for plastics and rubber machinery. The German companies delivered more than 950 million US dollars worth of machinery to the USA in The demand for high-quality plastics and rubber machinery in the USA is high and well above the production of the US manufacturers. For example, the US market for plastics and rubber machinery represented a volume of just over 4.5 billion dollars in In the same period, however, corresponding machines were produced in the USA to the value of only 3.0 billion dollars, of which 1.4 billion dollars was exported to other countries, underlining the importance of free trade for the USA and its partners. The high demand in the USA could only be met by correspondingly high imports, which reached a value of 3.0 billion dollars in Since then, the Trump government s tax reform has created additional incentives for companies to invest in capital 28 PERCENT of the US imports of plastics and rubber machinery comes from Germany. Canada ranks second with 16.2 percent. Japan holds third place with a share of 12.9 percent. goods with new opportunities for immediate write-offs, which should give additional impetus to demand. Bill Carteaux, President and CEO of the US Plastics Industry Association - PLASTICS, expects 2018 to be an outstanding year in the history of the NPE. Demand for plastics and rubber machinery is also driven by high consumption, which accounts for around 70 percent of GDP in the USA. High consumption is expected to lead to a further increase in plastics consumption in the USA, which will have a positive effect on the industry. Experts estimate that Americans will consume a total of around 32.3 million tons of plastics in 2018.This is 2 percent more than last year, which should additionally fuel demand for plastics and rubber machinery. After Germany, which is the most important supplier of plastics and rubber machinery to the USA with a 28 percent share of US imports in 2016, Canada ranks second with 16.2 percent. Japan holds third place with a share of 12.9 percent. Although China was able to increase exports to the USA by an impressive 25 percent in 2016 compared to 2015, it was only fourth in the ranking of the USA s most important trading partners for plastics and rubber machinery. China s share of US imports was 8.7 percent in For Chinese manufacturers, the United States is thus only the second most important market after Vietnam, and just ahead of India. By far the most important sales market The situation is different in Germany, where the USA is by far the most important sales market for plastics and rubber machinery. Incidentally, the situation in the North American market in 2017 was better than originally expected for German manufacturers of plastics and rubber machinery. As the German industry association VDMA emphasizes, manufacturers are also highly optimistic about the first half of Looking at all global sales markets, the opportunities in North America are currently rated best. Technically speaking, the trend in North America towards energy-efficient injection molding machines operating with the highest precision continues unabated. Not least because of this, the proportion of electrically driven injection molding machines in the USA is already around 50 percent. GÜNTER KÖGEL W Web-Link kug.vdma.org

7 You may already know that we lead the plastics industry in pioneering technologies and high-performance machines that bring shape to the products used in every industry and in our daily lives. But it is our people dedicated to your success that give you the extra advantage. From our service technicians to our engineering groups, our management team to our customer service, sales and support staff we re all here for one purpose: your success. We re proud of both the technology and the service we provide. NPE, West Hall Level 2, Hall A, Booth W403 Our machines shape the world. Our people help shape your success. KraussMaffei KraussMaffei Berstorff Netstal

8 8 INJECTION MOLDING High-quality engineering parts The highlights of Engel s presentation at NPE include fully automated production cells for the Decoject method and the manufacturing of plastic/metal composite components for the teletronics sector. SUSANNE ZINCKGRAF Process integration and automation continue to gain importance in North America, while the topics of digitalization and networking are coming to the fore with processors. What these trends have in common is that they lead to more quality, efficiency and economic viability, but also to a higher complexity of production processes. As a systems solutions provider, we ensure that even complex processes can be easily and securely controlled, says Mark Sankovitch, Managing Director of Engel in the United States, in the run-up to NPE Three years ago, the Austrian injection molding machine builder appointed dedicated business unit managers for North America and has since continuously reinforced its local industry expertise and application-technical capacities. The feedback of our customers is excellent, says Sankovitch. The most recent successes confirm that we are on exactly the right track. We can respond to the requirements and requests of our customers in the various industries even faster and provide them with more tar- A Duo 5160/1000 injection molding machine will be used for the production of ready-to-install door trim at NPE. In the production cell, an Easix articulated robot will move over the component contour along the laser and then places the finished door trim on the conveyor belt. Photo: Engel

9 INJECTION MOLDING 9 Even large interior components can be economically manufactured using Decoject. The desired surface characteristics such as color, structure, robustness and haptics are provided through the foil. Photo: Engel at low unit costs geted support in solving their very individual challenges. As a systems provider, we are increasingly accompanying our customers throughout the entire life cycle of the ma chines and systems this is the trend that we are addressing with the new structure. Fully automated Decoject process more economical for small lot sizes For the automobile industry, the Austrian machine builder will present a fully automated, integrated manufacturing cell for the Decoject process at its NPE booth for the first time in North America. This technology combines injection molding and in-mold graining (IMG), opening up new horizons for the production of premium interior automotive components. In contrast with conventional in-mold decorating (IMD), the coating is not simply transferred from the foil to the component, but rather the foil is punched out and remains on the component. In addition to Even for smaller production runs, Decoject provides us with an extremely cost-effective possibility of optically upgrading injection molded components and coordinating surfaces in the vehicle interior. Larry Alvey, Head of the Automotive Business Unit of Engel in North America color and pattern, surface structure and haptics also come into play in this manner. At the same time, the scratch-resistance of the surfaces is increased considerably. Even for smaller production runs, Decoject provides us with an extremely cost-effective possibility of optically upgrading injection molded components and coordinating surfaces in the vehicle interior, says Larry Alvey, Head of the Automotive Business Unit of Engel in North America. During NPE, a Duo 5160/1000 injection molding machine will produce interior upper door trim with a variety of surface structures for automotive applications, from a refined leather grain, including the seam, to a modern carbon look. The Decoject thin foils were developed by Benecke-Kaliko. To start the process, the foil is drawn from the roll into the open mold, heated by an IR-radiator mounted to the robot grip and preformed directly in the injection mold by means of a vacuum. Immediately afterwards, the foil is back-injected with polypropylene and punched out before the robot removes the component and transfers it to the integrated laser station for precision cutting. One ready-to-install part leaves the production cell every 60 seconds. Since a design change requires only a few minutes for the exchange of the foil rolls, the lot size no longer affects the cost per unit. To save additional raw material, the Mucell foam injection molding process of Trexel is used. Other partner companies involved in the project include Georg Kaufmann Formenbau, Galvanoform Gesellschaft für Galvanoplastik, HRS Flow, ICO System International Coating and Borealis. The automation of Engel makes an essential contribution to the efficiency and flexibility of the process: the heating of the

10 10 INJECTION MOLDING The highly integrated process makes the manufacturing of thermal switch housings particularly economical. A strip uncoiler, press module and processing module for thread tapping can be found upstream of the injection process, while quality control functions, laser marking and another press module are located downstream. Photo: MMS Photo: Engel The production of thermal switch housings in - cludes multiple work steps, which Engel integrates into an overall, clearly structured process. foil and the removal of the component from the mold is handled by a viper linear robot. In addition, an Engel Easix articulated robot is integrated into an Easicell placed directly next to the clamping unit of the injection molding machine with the laser station for the precision cutting of the foils. Thanks to its standardized and modular construction, the automation cell enables the extremely space-saving integration of robots and process units located upstream and downstream of the injection molding process. It also significantly reduces the complexity of the application. The entire process can be operated using the CC300 control unit of the injection molding machine. The uniform control logic throughout all components of the production cell makes it especially easy for the machine oper ator to confidently handle the integrated process without any special training. Process integration guarantees high competitive ability in teletronics In the teletronics industry, the topic of process integration often revolves around plastic/metal composite components. With the production of thermal switch housings at NPE, Engel will also demonstrate a solution for this challenge: from the punching of the contacts to the inspection and labeling of ready-to-use electronic components, all work steps are fully automatic. The raw material for the brass carrier plates is fed directly from a reel and prepunched inline, including an extruded hole. The thread is servo-electrically tapped before the carrier plates still on the line are reinjected with glass-filled polyamide on an Engel insert 60V/35 vertical injection molding machine. Quality control happens inline. In addition to a camera inspection function, high-voltage testing is integrated into the progressive composite mold, there - by already guaranteeing a comprehensive short-circuit inspection during production. In order to ensure seamless traceability, the OK parts are labeled by laser before the sprue and carrier tabs are removed and the components are separated from the belt. Eight ready-to-install parts leave the production cell every 20 seconds. This production solution, developed by Engel in cooperation with its partner MMS

11 INJECTION MOLDING 11 Portal paves the way for the smart factory The new version of the e-connect customer portal is even more understandable and easy to use. Modular Molding Systems, guarantees the lowest possible unit cost while achieving a high degree of flexibility at the same time. Thanks to the modular design of the MMS systems, additional processing units can be integrated, for example, for resistance testing or laser welding, riveting, assembly or cleaning of the parts. Regardless of the number of modules, the entire process can be monitored and regulated by the CC300 control system of the insert machine, says Stefan Aberl, Head of Automation at Engel North America. This substantially reduces complexity and significantly simplifies the operation of the entire process. Thermal switches, such as those used for monitoring electric motors in automobiles or in the domestic appliance industry, are traditionally produced in a complex, multi-stage process. In general, the metal components are even punched and reinjected at different locations. This requires not only considerable logistics expense and effort, but also a large amount of material since two independent processes need to be started. This is a considerable cost factor, especially when non-ferrous metals are used. Web-Link Photo: Engel SERVICES The new e connect customer portal of Engel will be launched in North America in time for NPE e connect simplifies and speeds up communication between processors and the machine builder while provid ing an overview of the machinery, the processing status of service and support orders and the price and availability of spare parts anytime, anywhere. From the first order, all machines and system solutions supplied by Engel are stored in the system with a display of the current status. For the best possible overview, users can reproduce the structure of their individual machinery in the system and even assign production lines to different halls or departments online. Making support and service inquiries online is not only convenient for users, but also accelerates order processing significantly. The portal makes all details relating to the service call transparent for the user and saves the service report. In particular, e connect facilitates the procurement of spare parts. Since the price and availability are saved in the system, customers can directly request and download a quotation from the platform. Customers can also track the spare part online up to its arrival at their plant. Continuously Constant Unique technologies, innovative solutions, comprehensive technical support, high expertise in all kinds of plastics applications. In others words: typical Gneuss. NPE 2018 Stand W6473 Pressure and process constant Melt filtration gneuss.com

12 12 INJECTION MOLDING The biggest driver for our growth Interview with Engel CEO Dr. Stefan Engleder on the importance of the US market, Engel s highlights at NPE 2018 and their unique advantages for US plastics processors. GÜNTER KÖGEL What are the highlights of Engel at NPE and what is important to see? And how is Inject 4.0 differ ent from Industry 4.0 and the Internet of Things? We asked Engel CEO Dr. Stefan Engleder. Dr. Engleder, how important is the US market for Engel? Very much so. We have been very successful over the past years and North America is the biggest driver for growth at Engel. Thus, Engel North America is our largest subsidiary overseas. Yet, there is still significant growth potential for Engel, for example in the packaging market. At the NPE show we address our packaging customers by showing our all electric highperformance closure machine e-cap. Our core message at NPE is that Engel provides tailor-made solutions to the individual customer s needs, enhances them with inject 4.0-technology and still keeps the operators life simple with our simplicity approach. In addition to technology, service is crucial to make the operators life simple. What has Engel improved in this regard? Over the last three years we have doubled our US service team and increased the spare parts availability significantly by enlarging our warehouse in the US headquarter in York, PA. Today, we are capable of locally supplying our customers in North America and Mexico within one day. Engel is represented at NPE with numerous innovations. What should a plastics processor from the USA definitely look at? Our most important innovations for the US plastics market come from our Inject 4.0 solutions. With these products we distinguish ourselves from other manufacturers substantially on the American market. Our Inject 4.0 concept offers smart machine solutions with assistance systems from our iq series, including iq flow control, which will be presented in America for the first time. How is Inject 4.0 different from Industry 4.0 and the Internet of Things? The difference between Inject 4.0 and Industry 4.0 or the Internet of Things is that our concept includes smart machine, smart production and smart service tailored solely to injection molding solutions with each of these three pillars standing on its own. In my opinion Engel has a leading edge Dr. Stefan Engleder, CEO of Engel Holding: Our core message at NPE is that Engel provides tailor-made solutions to the individual customer s needs, enhances them with Inject 4.0-technology and still keeps the operators life simple with our simplicity approach in smart machine solutions as we have been intensively involved in the intricacies of injection molding machines and processes for many years and have built up a quite an amount of know-how. The most important smart machine solutions, our iq products, are intelligent assistance systems that improve and simplify the machine s process capability, for example iq weight control or iq clamp control that can also be seen in our Expert Corners at the NPE show.

13 13 machine. This is why our focus is on our iq assistance systems. Let me compare this to self-driving cars: the best control system with artificial intelligence cannot prevent an accident if the assistance systems, such as distance control, do not function reliably. In the same way, the assistance systems in the injection molding machine, such as iq weight control, automatically compensate for environmental and process influences. Only when these assistance systems work reliably can you move up a level and introduce things like smart data to subsequently analyze the processes. Do iq systems actually make special demands on operators? Quite the opposite. As already mentioned, we pursue a consistent simplicity approach and have therefore invested a great deal of effort so that our machines can be operated by any employee. With our easyto-use solutions, we also stand out from other manufacturers. For example, the operator only needs to tick a box to use our iq weight control. Without further operator intervention, the injection molding machine does everything necessary to ensure that every part produced is exactly the same weight. The potential of an Engel machine can therefore be fully exploited without specific expertise and this will be demonstrated live at NPE. What is happening in the other two areas of smart service and smart production? Our solutions in the area of smart service, for example our e-connect.monitor, bring service to the next level. The e-connect. monitor system analyzes process-critical machine components, such as plasticizing screws. The service life of the screw is predicted without having to remove it, thus increasing the availability of the machine. In the area of MES solutions smart production we see two trends: on the one hand, functions such as simple data collection and status monitoring are widely-used. On the other hand, companies also take advantage of MES systems for optimizing production processes. Anyway, there is no doubt that machine learning methods and AI are going to play a dominant role for smart production in the near future. In the first step, however, we have to increase the process capability of the Photo: Engel What else will customers see at NPE? At NPE we will show vertical integration, for example the connection of the machine to the customer s network or to a cloud solution. When it comes to machine process capability our iq products will demonstrate the benefit of intelligent assistance systems on lean production processes. Costumers already using systems like the new solution for temperature control have confirmed that Engel is doing pioneer work here. As I already mentioned in the beginning we strive for providing solutions that do fit for each of our costumers individually. It is therefore that I am very looking forward to demonstrating our progresses and innovations live at NPE in Orlando. W Web-Link

14 14 INJECTION MOLDING Ideal for large-volume packaging: Injection molding machines of the GX series offer a lot of space for large molds and cooling water systems. Photo: Krauss Maffei More speed for packaging and logistics applications Krauss Maffei is traveling to NPE in Orlando with several premieres: The GX 900 injection molding machine with the new speed option is an efficient and economical solution for manufacturing large packaging. PETRA REHMET In addition to high injection speeds, thin-walled articles for packaging and logistics solutions especially require high cycle times. Krauss Maffei has therefore expanded its two-platen GX series by a new speed option, providing customers with an optional selection of different injection speeds of up to 700 mm/s depending on the injection unit. The GX model exhibited at NPE also includes faster clamping speeds, thereby shortening the dry cycle time by up to 0.45 seconds according to Euromap.

15 15 The speed option really demon strates its advantages at opening widths from 350 to 400 mm. The kinematics therefore correspond with those of comparable, toggle machines, that also do not reach their maximum acceleration until large opening strokes are achieved. Expanded parallel movements on the plasticizing side with the electrically driven plasticizing unit (E-Plast) support the short cycle times. Powerpack III provides additional speed options such as a faster clamping force build-up, screw decompression or injection unit movement. At NPE, the GX will be producing large 20-liter buckets in a twincav ity mold using the in-mold labeling process (IML). Until now, labels on such large buckets have mainly been printed. Thanks to the speed option, they can now be produced economically using the IML process. Thanks to the speed design, this occurs in short cycle times of less than 14 seconds. The machine also has the proven Krauss This combination can be used to create completely new visual and haptic component features for thermoplastic composites in a single process. Paul Caprio, President of the U.S. Subsidiary Krauss-Maffei Corporation Maffei HPS high-performance barrier screw, which enables extremely fast melting and high shot weights. In total, throughput can be increased by up to 12 percent. Fiberform combined with swivel plate technology Using the Fiberform process, Krauss Maffei has successfully established lightweight thermoplastic construction in large series production. At NPE, Krauss Maffei will be presenting a Fiberform application in combination with swivel plate technology for multi-component injection molding on a GXW /1400 for the first time. This combination can be used to create completely new visual and haptic component features for thermoplastic composites in a single process, says Paul Caprio, President of the U.S. Subsidiary Krauss-Maffei Corporation in Florence, Kentucky. Thanks Visit us at NPE 2018 Information Booth: West Hall, W8190 Exhibits live at the ARBURG & ENGEL Booth HEKUMA automation & robotic High precision & high productivity HEKUMA GmbH Dornierstr Hallbergmoos - Germany Phone sales@hekuma.com

16 16 INJECTION MOLDING High precision and no leakage: The fully electric PX Silcoset series score points in the processing of complicated material liquid silicone rubber (LSR). At NPE, a PX Silcoset will produce special medical dosing caps. Photos: Krauss Maffei to the TPE component, the center armrest produced at NPE has func tional parts and visible parts with surfaces that are extremely soft and visually appealing, which increases comfort and visual aesthetics in the vehicle interior. In turn, the use of the organic sheet increases the rigidity and strength of the component. This means that the reinforcing ribs and component itself are made with thinner walls, resulting in a reduction of weight. Fiberform combines the thermoforming of organic sheets and injection molding in a single process. The result is particularly lightweight, high-strength fiber-reinforced plastic components used The design options of inductive mold heat balancing for surfaces are immense. Paul Caprio, President of the U.S. Subsidiary Krauss-Maffei Corporation mainly in vehicle construction. Intelligent automation solutions and a heating technology that has been optimized for the injection molding process support short cycle times under 60 seconds. High precision in liquid silicone rubber (LSR) processing The use of liquid silicone rubber (LSR ) is on the rise, even in the United States. Especially the medical technology and automobile industries are becoming increasingly interested in the excellent physical and chemical properties of the material. This material, however, has an extremely low viscosity and especially highly transparent silicone, therefore requiring particularly high precision during injection. The PX Silcoset, which will produce special medical dosing caps at NPE, therefore combines a Matt, glossy or with a hologram structure: Exciting surface effects are created at NPE with inductive mold heat balancing. hydraulic nozzle contact force with an electric injection unit. The result is particularly high precision, says Caprio. The connection between the machine and mold is seal-tight and production is free of leaks. Special screw seals on the shaft support this process. The spring-loaded return-flow lock of the screw also guarantees reliable closing behavior during the processing of the low-viscosity material. The PX at NPE has enlarged platens for the next level of clamping force, which in turn permits the use of a larger tool at the same clamping force of 500 kn. Large clamping units, small injection units this means that only as much space as is required for the manufacturing job is taken up during production. Inductive mold heat-balancing without post-processing At NPE, a CX with inductive mold heat-balancing will create impressive surface effects without post-processing in cooper ation with partner Roctool (HD plastics). The design options in the technology are immense, Caprio says. Whether shades of colors, hologram, glossy or matt effects, everything can be done in the one-shot process without additional postmold processing such as film decoration or painting. At NPE, the CX 200 with a 16-cavity mold will produce 16 different surfaces and therefore design variants of a plastic housing for a game console. The CX 200 from Krauss Maffei scores points in this application as an extremely economical and precise two-platen machine. This includes, for example, the drive con-

17 17 Reliably linked with Plastics 4.0 INDUSTRIE 4.0 Krauss Maffei is advancing Industry 4.0 under the umbrella term Plastics 4.0 and showcasing solutions at NPE that can help customers sustainably increase their productivity and efficiency. This fourth industrial (r)evolution will radically change the working world, says Caprio. One example is automatic optimization of intelligent machines, which ensures that processes are stable. This includes the APC plus (Adaptive Process Control) intelligent machine function, which quickly compensates disruptive fluctuations and environmental influences in the manufacturing process. An additional product from the Plastics 4.0 portfolio is Dataxplorer. This system provides a nearly microscopic view of the process, letting users respond to unclear fault patterns. Depending on the equipment of the machine, Dataxplorer displays up to 500 high-resolution signal paths, visualizing them and making them available for evaluation. Visitors to NPE can use the Fiberform and Roctool applications to experience this system for themselves. A QR code on the component or packaging gives them direct access to the specific production parameters, for example, the curves for heating the organic sheets or the injection pressure. cept according to state-of-the-art technology (IE3 types) and the energy-efficient Bluepower servo drive. An active accumulator management system completes the overall concept. As a two-platen machine, the CX series requires less installation area than longer three-platen models. Under the clamping unit, it provides space for peripheral devices and all kinds of demolding systems. An LRX 150 of the latest generation will demold any components produced at NPE. In the next step, the component and the sprue will be separated. After that, bagging and packaging will be carried out. Thanks to the space-saving design, these tasks can be completed within the protective enclosure, thereby saving the space required for feeding. Web-Link On target. New Also interested in really fast, rugged, light, accurate, customised and inexpensive infrared thermometers and cameras for noncontact measurements between 50 C to C? Visit: Thereʼs no two ways about it: our cost-effective Xi series IR cameras with their automatic spot finder function and analog/digital outputs are ideal even for OEM applications. Innovative Infrared Technology Visit us at NPE 2018 Booth S15195 Optris Infrared Sensing

18 18 INJECTION MOLDING Photo: Arburg Large machines, innovative methods U.S. premiere at NPE for the hybrid Allrounder 1120 H with 6,500 kn Highlights include Industry 4.0, innovative injection molding applications and industrial, additive production. DR. BETTINA KECK At NPE 2018, Arburg is celebrating the U.S. premiere of its hybrid Allrounder 1120 H with a clamping force of 6,500 kn in a new design and the state-of-the-art Gestica control system. In addition, the company will be presenting numerous innovative technologies and sophisticated applications for all branches of the plastic processing industry at its trade fair booth. Whether the additive production, Industry 4.0 or the processing of liquid silicone rubber (LSR), Arburg has decades of know-how in plastics processing, says Friedrich Kanz, Managing Director of Arburg USA. We see ourselves not as a machine supplier, but as a one-stop technology partner. With three sites in the United States, Arburg provides customer proximity, consultation and service. With nine exhibition pieces at its own booth, the company from Lossburg, Germany, is showing an exciting cross-section of its wide range of services. At 900 square meters, Arburg has enlarged its booth area by almost 40 percent in comparison with the last NPE in In addition, five additional Allrounder models will be available for viewing at partner booths. Friedrich Kanz, Managing Director of Arburg USA Photo: Arburg The hybrid Allrounder 1120 H can be seen outside of Europe for the first time at NPE 2018, where it will be celebrating its American premiere. It expands the clamping force range of Arburg by 30 per-

19 INJECTION MOLDING 19 The hybrid Allrounder 1120 H is celebrating its U.S. premiere at NPE The new large machine is expanding its product portfolio to clamping force ranges up to 6,500 kn. The new design and innovative Gestica control system are simply pioneering. 30 Shore A) fully automatically in a cycle time of 70 seconds, will be in the limelight. With a Multilift V 15 linear robot system and an assembly station, the wristwatches are competed ready to use including the housing and sealing cap within the injection molding cycle. cent to 6,500 kn. The new large machine stands out through its sophisticated design, which implements even more ergonomics and functionality, as well as its visionary Gestica control system, which reproduces the look and feel of smart mobile devices. At NPE, the exhibition piece will demonstrate the competence of Arburg in the turnkey sector with the familiar folding step stools: The eight individual parts made of polypropylene (PP) are handled by a Multi lift V 40 robotic system and assembled by means of a six-axis robot and assembly station within the injection molding cycle. In this way, a final product in the Arburg design is manufactured ready to use within a cycle time of only 60 seconds. Whether the additive production, Industry 4.0 or the processing of liquid silicone rubber (LSR), Arburg has decades of know-how in plastics processing. Friedrich Kanz, Managing Director of Arburg USA Turnkey processes and automation increase production efficiency To increase added value, more and increasingly extensive work steps are integrated into the injection molding process. For this purpose, Arburg offers a wide onestop-shopping range of automation services. From simple pickers to six-axis robots and complex turnkey systems, there is something for every need. All eight Allrounder models at the Arburg trade fair booth are automated. Besides the folding step stools, an additional turnkey highlight is a sophisticated LSR application. An electrical two-component Allrounder 570 A, which produces bicolor LSR wristwatches (hardnesses of 70 and Perfect micro-injection molding with LSR Together with mold partner Kipe Molds, Arburg will be showcasing a sophisticated LSR/LSR micro-injection molding application at NPE An electrical 270 A with a size 5 micro-injection unit produces silicone membranes used in valves for medical technology or the automobile industry, for example. For the manufacturing of the 0.05-gram LSR substrate (hardness of 70 Shore A), the micro-injection unit is equipped with a special 8-millimeter LSR screw. For the gram, lightweight, second LSR component (hardness of 30 Shore A), a servo-electric injection unit of Kipe Molds is used. This is installed into the 1+1-cavity mold and integrated into the Selogica control system. A Kiki robotic system removes the LSR/LSR membrane, conducts it to a camera inspection unit and then deposits it in a container. An Allrounder 570 H in a Packaging version designed especially for thin-walled products demonstrates the efficiency of the hybrid Allrounder models for highspeed packaging technology applications. Within a cycle time of a mere 1.9 seconds, the manufacturing cell produces four IML cups made of polypropylene. The decorated finished parts with a wall thickness of 0.32 millimeters weigh 3.55 grams each. The mold and automation system come from Brink. Fiber direct compounding for lightweight applications Lightweight components are of great interest to many sectors, especially the

20 20 INJECTION MOLDING A turnkey system around an electrical, two-component Allrounder 570 A produces bicolor LSR wristwatches fully automatically within the injection molding cycle. Photo: Arburg automobile industry. Fiber direct compounding (FDC) with fiberglass rovings is an affordable alternative to processing fiber-filled compounds. The FDC unit on the injection unit comprises a side feed unit with integrated cutting mechanism, adapted cylinder and special screw geometry. The fiber length, fiber proportion and material combination can be adjusted individually, thereby influencing the component properties in a targeted manner. At NPE 2018, a hydraulic Allrounder 820 S will produce two 329 gram airbag housings within a cycle time of 70 seconds. A weight monitoring function integrated into the automation process demonstrates the constancy of the shot weight. The Multilift V linear robot system then deposits the finished parts in boxes. Medical technology is also an important market with high growth rates for Arburg. At NPE, an electrical Allrounder 470 A will manufacture cups made of polypropylene designed for medical purposes using a double mold from Hofstetter. The cycle time for two cups with 1.45 grams each is about 2.9 seconds. A Hekuma automation system quickly removes and stacks the cups. We see ourselves not as a machine supplier, but as a one-stop technology partner. Friedrich Kanz, Managing Director of Arburg USA Using radius gages as an example, Arburg presents the automated reinjection of insertion parts with an Allrounder 375 V vertical rotary table machine. A Multilift Select robotic system placed directly on the machine to save space guides the metallic insertion part to a plasma pretreatment station first and then places it in the equipping station. In the tool, the parts are injected with fiberglass-reinforced PA6.6. The finished parts are removed from the single mold and then placed on a conveyor belt. Individualized, large-scale production parts Through the combination of additive manufacturing, injection molding and Industry 4.0 technologies, large-scale production parts can be refined and, if desired by the customer, integrated directly into the value chain. At NPE 2018, Arburg will demonstrate how such customer-specific individualization works using an IT-networked, fully automated production line for business card holders. In the process, a six-axis robot interlinks the injection molding process with additive production. First, the name of the visitor is entered on a tablet PC. An electrical Allrounder 370 E Golden Electric produces the injection-molded part, which is handed by a Multilift robotic system. During the subsequent laser labeling procedure, an individual bar code is applied. A six-axis robot picks up the card holder and places it in the compartment of the Freeformer. For the automatic opening and closing of the hood, the Freeformer and robotic system communicate through a Euromap interface 67. According to the information on the code, the Freeformer additively applies the desired 3D lettering using acrylonitrile butadiene styrene (ABS). Web-Link

21 INJECTION MOLDING 21 Industrial, additive production ADDITIVE MANUFACTURING At NPE 2018, Arburg will practically demonstrate that the Arburg plastic freeforming method (AKF) is suitable not only for prototyping, but also and especially for the industrial, additive production of functional components with a Freeformer and a variety of such functional components. At an interactive station, visitors can experience the components themselves by examining them by hand and convincing themselves of the functionality and quality of these parts. The open system makes the user independent: Using the AKF method, Freeformer customers can qualify their own materials and optimize the freely programmable process parameters to their specific application. An enormous advantage here is that certified original materials can be used A manufacturing cell with a hybrid Allrounder 570 H in a Packaging version will manufacture four IML cups in about 1.9 seconds at NPE Photo: Arburg The Freeformer is designed for the industrial, additive production of functional components. At the Additive Manufacturing Conference portion of NPE 2018, Arburg will hold an additional presentation on May 18, Photo: Arburg A Member of Brückner Group High Quality Film Production Lines: Efficiency, Productivity, Flexibility for medical or aerospace applications, for example. In addition to amorphous standard granulates such as acrylonitrile butadiene styrene (ABS), polyamide (PA) and polycarbonate (PC), Arburg s continually expanding range of qualified materials comprises elastic thermoplastic elastomers (TPE), medical poly-l-lactide (PLLA), PC approved for aerospace applications and semi-crystalline polypropylene (PP). People seeking more information on industrial, additive production using the Freeformer will be given the opportunity to do so within the scope of a specialist presentation held by Arburg at the Additive Manufacturing Conference on May 9, STRETCHING THE LIMITS Visit us at NPE 2018 WEST HALL BOOTH W 2727 Orlando May 2018

22 22 INJECTION MOLDING Friedrich Kanz, President & CEO of Arburg, Inc., Rocky Hill, Connecticut Photo: Arburg

23 INJECTION MOLDING 23 We keep listening to our customers US molders have been asking Arburg over and over to continue producing larger machines. The answer can be seen at the NPE: The new Allrounder 1120 H. GÜNTER KÖGEL How important is the new Allrounder 1120 H for the US market? What about Industrie 4.0 outside Europe? What potential is there in turnkey solutions? Answers of Friedrich Kanz, President & CEO of Arburg, Inc. Mr Kanz, for the first time, Arburg will be exhibiting the new large Allrounder 1120 H at the NPE. What significance does the largest Arburg injection molding machine to date have for the North American market? With the hybrid Allrounder 1120 H, Arburg has extended its clamping force range to 730 US-tons. The new large machine in the new design and featuring the visionary Gestica control system celebrates its American premiere at the NPE 2018, where it is on view for the first time outside Germany. This expanded size of the Allrounder machine is another critical step to our success and growth in the US market. US molders have been asking Arburg over and over to continue producing larger machines, and of course we keep listening. Now, we have expanded our machine range significantly for example the clamping force range increased by 30 percent. The market is clearly ready for this new Arburg machine size, because it offers customers even more possibilities. The hybrid Allrounder 1120 H combines the speed and precision of an electric toggle-type clamping unit during mold movements with hydraulic power and dynamics during injection. The basic specifications include inch distance between tie bars and inch maximum opening stroke, providing more space for larger molds. Industry 4.0 is currently one of the most important topics for plastics processing in Europe. How can US companies profit from Industry 4.0 and what does Arburg show at NPE? With regard to Industry 4.0 and digital transformation, Arburg is a pioneer in the plastics industry with more than 30 years of experience in the automated, IT-networked production. With our know how and extensive Industrie 4.0 powered by Arburg offerings, we are extremely well positioned in this regard. The ALS is a central component for digital networking, which captures, archives and seamlessly tracks the process data as well as networking the flexibly automated process chains and transmits the collected data to a web server. Further offerings are our new six assistance packages, which actively support operation of the machine in the fields of set-up start-stop, optimizing, producing, monitoring and service. The new Arburg Remote Service ARS plays an integral part in the service package. Molders in the US are definitely moving towards more digitalization and we are in the position to support them with this. Jointly with the customers, the experts at Arburg Inc. are continuously expanding their activities towards Industry 4.0. The preconditions are automation and IT infrastructure and our ALS is an excellent place to start. For the first time at NPE 2018, we present a practical example of Industry 4.0: By combining injection molding, additive manufacturing and Industry 4.0 technologies, high-volume parts can be enhanced and customer requirements integrated directly into the value chain. We show how such customized individualization works using the example of the IT networked and fully automated production line for business card holders. A six-axis robot links injection mold ing with additive manufacturing here. First the person s name is entered on a tablet PC. An electric Allrounder 370 E Golden Electric manufactures the molded part, which is handled by a Multilift robotic system. An individual barcode is applied during the subsequent laser marking step. A six-axis robot takes the card holder and places it in the build chamber of the freeformer. For the automatic opening and closing of the cowl, the freeformer and robotic system communicate via a Euromap 67 interface. The freeformer additively applies the desired 3D lettering from ABS in accordance with the information in the code. Turnkey solutions are in great demand worldwide. How important is the subject of turnkey in the USA and what does Arburg have to offer here? We have a strong growth of the automation and turnkey sector in the US, which is opening up numerous new opportunities for our customers and ourselves. Arburg offers a wide range of automation solutions from a single source for this. From simple pickers to six-axis robots and complex turnkey systems. At the NPE all eight exhibits at our stand are automated. Arburg has been a successful system and technology partner for turnkey projects for many years and we have automation and turnkey experts at Arburg Inc. They work closely together with the Turnkey department at the headquarters in Lossburg. This means that our customers benefit from our experts decades of experience and extensive know how. In the field of turnkey solutions, we have specific partners as well as local partners. We assume responsibility for the entire project management, contribute our overarching expertise and supply a complete turnkey solution precisely adapted to the requirements at hand. W

24 24 INJECTION MOLDING Very fast and extremely thin The Elios series of Netstal premieres at NPE America. With the fully electric Elion in a cleanroom configuration, the Swiss injection molding machine manufacturer is also exhibiting a solution for mass medical consumables. Developed for the efficient manufacturing of thin-walled packaging: Injection molding machines of the Elios series combine high clamping forces with fast cycle times. Photos: Netstal MICHAEL BIRCHLER With an 8+8 cavity stack mold from Stackteck, the high-speed machine Elios manufactures 16-ounce (473 ml) delicatessen containers at a cycle time of 3.1 seconds. The system is complemented by a handling solution from CBW Automation. The series currently consists of four main versions with clamping forces of 4,500, 5,500, 6,500 and 7,500 kn. A wide range of different injection units and screw diameters enable the machines to be tailored precisely to all kinds of applications. Across the entire series, the customer can choose from 33 combinations of clamping force, injection unit and screw. Due to the consistent, modular design, practically any application is possible with this equipment kit. With Elios, our customers produce perfect, thin-walled packaging at the lowest unit costs, says Matt Membrino, Head of Sales at Netstal USA. The fast clamping With Elios, our customers produce perfect, thin-walled packaging at the lowest unit costs. Matt Membrino, Head of Sales at Netstal USA unit, the dynamic injection unit with twovalve technology and high process stability are the keys to success. The core of Elios is the new hybrid drive concept of the clamping unit with a five-point dual toggle lever. The energyefficient combination of the electrically driven travel motion and the hydromechanical build-up of the clamping force leads to a considerable acceleration of the entire movement system. In this way, Elios 7500 attains a dry cycle time of 1.9 seconds. The smaller models of the series are even faster: Elios 5500 reaches 1.7 seconds, while Elios 4500 even achieves only 1.5 seconds. High cleanroom precision The manufacturing of mass medical consumables such as petri dishes, blood vials, medical cups or pipette tips is also gaining increasing importance in the United States. These are classic Netstal applications because, in addition to high precision and cleanliness, maximum output and maximum availability are important, says Membrino. Our system solutions impress with outstanding quality and low unit costs. At NPE, a fully electric Elion in the cleanroom design will inject more than 82,000 pipette tips per hour with a 128-fold tool from Tanner in a cycle time of 5.6 seconds. The shot weight is grams. Zubler Handling provides the automation system with cavity separation. Even without the MED kit, the Elion is one of

25 INJECTION MOLDING 25 Netstal in the new Bottle Zone PET Netstal will be represented at NPE by a booth in the newly established Bottle Zone. With the current PET- Line generation of PET systems and the hybrid Elion series, Netstal offers the complete solution package for the cost-effective production of PET preforms and beverage bottle caps, says Matt Membrino, Head of Sales at Netstal USA. In addition to the standard preforms for carbonated beverages, Netstal s portfolio includes Prelactia, an efficient packaging solution with an integrated light barrier for the bottling of liquid dairy products. Bottling milk in PET containers provides numerous economic, ecological and aesthetic advantages, thereby rapidly gaining importance worldwide. The freedom in the bottle design, the long shelf life of up to six months for ultra-high temperature (UHT) milk, the low resource consumption and the reduced material costs are sustainable arguments. Prelactia has already been in use in South America and Europe with great success for several years. The interest in the technology is huge in Asia. In contrast to the co-injection process of other manufacturers, we see decisive advantages with our overmolding solution, Membrino says. We can precisely define the two layers, and thus the barrier effect. In addition, a Prelactia bottle always consists of pure PET, which considerably simplifies the recycling of the empty bottles. Prelactia is an efficient packaging solution with an integrated light barrier for liquid dairy products. the cleanest machines on the market as a result of the completely closed circulatory lubrication of the electrical clamping unit, Membrino says. With numerous options from our MED kit, they can also be flexibly equipped for the cleanroom. Up to ISO class 5 is possible, depending on the equipment package. With elements like the patented Netstal Clean Purge nozzle extractor hood, a laminar flow hood, galvanically sealed mold plates, additional cover plates and closed drag chains, the particle output is effectively reduced. The special coating for medical applications and raising of the machine simplify regular cleaning. With flexible equipping options, Elion can be individually adapted to the respective application. The Elion from Netstal offers the ideal injection molding machine for applications in the medical sector with fast cycles and correspondingly high annual output, says Membrino. W Web-Link

26 26 AUTOMATION The flexible and modular concept of the Hekuflex system guarantees, among other things, short delivery times and high productivity. Photos: Hekuma Efficient Medication cup production Hekuma will showcase its new medication cup system in the well-proven Hekuflex design at the NPE DOMINIK BECHLARZ With its new automation system Hekuma once again is convincingly demonstrating its strengths: extremely short cycle times, an almost maintenance-free automation and thus maximum productivity and efficiency. For this one brought an equally strong partner on board and realized together with the injection molding machine manufacturer Arburg the project medication cup. The 30 ml disposable plastic cups are essential tools for dispensing medications. They consist of polypropylene and can be The advantages of standardization with Hekuflex are lower equipment costs and shorter delivery times. produced in different colors. The injection mold was designed in such way that the cups are equipped with a volumetric scale, this will help with the precise dosing of medication. Due to the single use, medication cups are consumed in huge quantities. This is where the high performance automation system of Hekuma shows its strength. Equipped with a magnetic linear drive the take-out-axis is able to perform enormous acceleration and deceleration, resulting in a take-out time less than 0.2 s. The plastic cups are produced on an electric injection

27 AUTOMATION 27 the American market. There a system was shown that combined the modules for takeout, camera inspection and packaging of pipette tips. The cup system consists only of the take-out module, which is stacking the cups in two rows for storage. However, owing to the flexibility of the modular concept, the system could be extended at any time, for example, with a packaging unit. The advantages of standardization with Hekuflex are lower equipment costs and shorter delivery times. At the same time they ensure the highest possible productivity while following high quality and safety standards. These high standards play an important role in the medical sector. Smooth surfaces and a dust-free environment ensure that the requirements for the clean room are fulfilled. No moving parts in the end of arm tooling and the decision against a belt drive result in a very quiet, service reduced and lowwear machine. The robust design allows extremely long production times without disruption. In addition to the own information booth and the automation for interdental brushes shown at the Engel booth, Hekuma presents itself with this new medication cup system at the Arburg booth. W Web-Link The 30 ml disposable plastic cups consist of polypropylene and can be produced in different colors. WE ARE THE MIXING EXPERTS molding machine type Allrounder 470 A of Arburg and with a two cavities injection mold of Hofstetter. Overall, the total cycle time reaches just 2.8 s. Thus, the system produces more than parts per hour. Modular construction Hekuflex The modularity principle of the Hekuflex automation also contributes to efficiency and productivity. Hekuma s aggregation of self-contained functional stations mount ed in modules celebrated its premiere at the plastics trade show Fakuma in Friedrichshafen, Germany in 2015 and NPE 2015 for Burkhard Wulf Area Sales Manager Mixing units from MTI are the benchmark for attaining maximum specific throughput, outstanding reliability and unbeatable life time. A wide variety of options allows an individual configuration of the mixer to meet even complex process requirements. MTI the mixing company. MTI Mischtechnik International GmbH

28 28 QUALITY ASSURANCE Web Guiding for Process Control BST North America, a subsidiary of BST Eltromat International, will showcase its latest technology and products at NPE DOMINIQUE FORBES The topics of web guiding and web inspection will be in the foreground at the booth. The inspection systems, the quality assurance systems in the IPQ family, as well as the web guiding systems combine to offer an extensive portfolio of products for all needs in terms of ensuring and controlling quality in web-oriented processes. Whenever plastics or rubber processors need to monitor production quality they put their trust in the inspection solutions and web guide systems from BST North America and its subsidiary Accuweb be it extruders, calendars, systems that process plastic films, flexible packaging, multi-layer packaging materials, rubber webs or other materials. The inspection systems and web guiding systems offered cover virtually all industrial requirements. In the field of web guiding, the presentation will include reliable and configurable solutions that customers worldwide rely The Compactguide with Widearray sensors is suitable for narrow web applications. Widearray sensors feature large detection ranges to accommodate variations in web width. Photo: BST Eltromat on. Depending on the requirements, solutions are offered for narrow to wide webs. The very simple operation of the systems via the various controllers is a key reason why many customers decide in favor of the company s web guiding systems, especially in the plastics and rubber processing industry. The operators can see at a glance whether the materials are being accurately controlled, and can intervene quickly if the need arises. Real-time demonstration of Widearray edge sensors The booth will feature a real-time demonstration of Widearray edge sensors from Accuweb. Widearray sensors can be used for narrow and mid web applications, and the interface allows the sensors to be retrofitted and used with any of the company s digital controllers. Widearray sensors feature large detection ranges up to 18½ inch to accommodate variations in web width. As a

29 QUALITY ASSURANCE 29 IPQ-Check is the module for 100 percent print inspection of the modular IPQ-Center by BST Eltromat, which covers a broad range of tasks in quality assurance. Photo: BST Eltromat result, web widths can be changed on the fly, eliminating the need to physically reposition edge sensors, which means time savings and reduced downtime. They also allow the operator to change web position with the touch of a button. Widearray sensors self-calibrate, so they are ideal for applications with many web width changes or applications needing frequent adjustments of the web position. Widearray sensors also eliminate the need for mechanical edge seeking devices, and they have no moving parts, which means no maintenance. They are intrinsically safe, which makes them ideal for use in Class I group C and D environments. Rugged and compact in size, a Widearray sensor is easily mounted and requires only a single cable. Visitors at NPE can also receive information about BST Eltromat s IPQ-Center. This modularly-constructed system offers extensive possibilities for quality assurance in order to target the best production results. IPQ stands for Increasing Productivity and Quality in the production process. The module for 100 percent inspection is called IPQ-Check, while IPQ-View covers digital web monitoring tasks and IPQ-Spectral is a tool for inline spectral color measurement. IPQ-Workflow inte grates these three modules into a common quality assurance process which creates the basis for the continuous optimization of print processes. The IPQ-Center reliably recognizes and records errors, so machine operators are in a position to quickly and easily intervene in the process and correct settings. There willl be a demo of the IPQ-Check module. W Web-Link Visit NPE, W2771 Photos: istock battenfeld-cincinnati USA: higher performance, lower energy costs and more flexibility conex NG (right) and solex NG (left) extruder for high-performance pipe and profile extrusion. Both extruder series are equipped the Industry 4.0 compatible STARextruder: for efficient extrusion of PET for the BCtouch UX control system. production of food-grade thermoforming sheet

30 30 MATERIAL SUPPLY Photo: Ach solution Ach solution knows how to use LSR in optical applications The market for high optical applications with LSR (liquid silicone rubber) is significantly growing over the last years. The material has numerous advantages compared to alternative polymers, yet it is not always easy to process. For optical applications production technology must be particularly precise. Optical silicones can provide greater light transmission than glass, polycarbonate, and PMMA. These durable, long-lasting silicones are more resistant to UV degradation, yellowing, scratching, impact damage, heat and environmental influences. Additionally, it makes them particularly well-suited to manage the increasingly high temperatures of LED lighting systems. However, these materials are performing differently in processing compared with standard LSR and require a new approach in tool design and processing technique. Due to the lack of re-enforcing fillers, the materials hot tear resistant is quite low. Especially difficult geometries with thin wall thickness, undercuts and long pins require distinct de-molding concepts. In addition, the materials have very low viscosities. Currently, the largest application for such materials is in automotive lighting. Continuous developments in the car industry have led to a new technology of matrix LED lighting systems for head lamps. For many years, the conventional approach to automotive LED headlamp design relied on mechanical actuators to position the beams of a single, controllable LED row. The leading companies in automotive lighting have developed a more dy - namically adaptive solution. It incorporates up to more than 90 individually controllable LED pixels arrayed in different rows. It is enabling the headlamp to dynamically distribute light in real time and adapting to different driving conditions. The primary lens structure for such a design is made with high optical LSR which comes in a molded part. The shape, surface and design of Optical LSR-types require a different approach in tool design and processing. each silicone rubber pin is re sponsible for the correct light distribution. In front of each individual LED there is a long pin structure. In order to achieve the high transmission performance, special polishing technologies and tool designs are necessary. Additionally, the processing requirements are quite challenging. At NPE 2018 Ach solution is presenting a complete, fully automatic processing cell which is demonstrating the production of a LSR light guide. It is a 2-cav mold with 100 percent camera inspection for inline quality control. The tool is equipped with Ach s latest Servoshot system including the newest Ach 4.0 standard for complete monitoring and documentation of all processing parameters. With Servoshot 4.0 all data such as mold pressure, tool temperature, water flow etc. will be monitored and recorded. After the parts passing the camera inspection they are going through a weight control station which is communicating with the Servoshot unit. In case weight deviations are detected the system is automatically balancing each cavity individually. The production cell can be seen at Engel booth. PHILIPP LUBOS W Web-Link

31 MATERIAL SUPPLY 31 Precision mixing in large dimensions At the NPE 2018 trade show MTI Mischtechnik will present its current portfolio of container-type, vertical, horizontal, cooling, and heating/cooling mixers for the plastics industry. The cooling tank of the new Flex-line heating/cooling combination for Northern Pipe comprises 8,000 liters. Photo: MTI Mischtechnik keep up with our demand. Once we resolved to install a significantly larger unit, it was only logical that we should go back to MTI for its implementation. Together, we managed a solution despite all the prevailing space constraints. MTI modified the machine s design, building it around the existing steelwork, as it were. We are now eagerly awaiting its delivery and commissioning since this will overcome a real bottleneck in our plans to expand production capacity. The M 2000/K 8000 is an MTI heating/cooling mixer combination rated for a typical batch volume of 950 kilogramms (app. 2,100 pounds). It can thus provide more than 7,500 kilogramms (app. 16,600 pounds) of mixed material per hour. Designed on a modular principle, these mixers can be put to use in virtually any application. DOMINIK BECHLARZ W Web-Link One highlight at the company s booth is a heating/ cooling mixer combination MTI Flex-line type M 2000/K 8000, providing 8,000 liters of cooling vessel capacity while measuring over 7 meters (23 feet) in length and close to 5 meters (16.5 feet) in height. Directly after the show, the machine is to be shipped to Northern Pipe Products. Burkhard Wulf, Area Sales Manager at MTI, comments: We have been witnessing a trend towards ever-increasing production volumes in the U.S. market for quite some time. With this Flex-line M 2000/K 8000 for Northern Pipe Products we address the associated demand; needless to say, the same holds true for our Flex-line M 2500/K 8000 model which provides the ultimate in mixer capacity. These systems can deliver the specified mixtures in appropriate quantities without compromising on mixing qual ity or high-precision recipe compliance. We are looking forward to delivering this large- size machine to Northern Pipe soon a company which, like our own, has been a hallmark of precision, accuracy and high-grade products for decades. In our production we have relied on an MTI heating/ cooling mixer combination with 1,500 liters of heating mixer and 4,250 liters of cooling mixer capacity for almost 30 years now, explains Derek Hanson, Vice President of Engineering at Northern Pipe. In 2014, acting in close cooperation with MTI, we replaced the original cooler with a revised model of the same type. Unfortunately, it was not possible to install a larger system at the time as we had utilized the available floor space optimally already. The entire machine has been performing with high reliability since its installation, and when we needed spare parts they were promptly made available to us, along with the associated customer service. Still, the day came where this system s output could no longer

32 32 EXTRUSION Con Ex NG 65: flexible, energy-efficient PVC processing with the new BCtouch UX control system Photos: Battenfeld-Cincinnati Higher performance, more flexibility A Con Ex NG 54 co-extruder for flexibility in co-extrusion Battenfeld-Cincinnati will show at NPE 2018 the Sol Ex NG and Con Ex NG extruder series for the first time on the US market. STEFAN LENZ PVC processors today need to offer a wide range of products and are thus faced with a variety of different meter weights and output requirements. The Con Ex NG has a highly flexible design. There is one basic machine model for both pipe and profile production. The extruder s screw core fits all screw tempering systems and the gear box design allows several different motor positions (U or Z version). Processors can also choose between different barrel tempering and dosing systems. Thus, a wide range of outputs can be covered with one

33 EXTRUSION 33 machine. Gentle plastification is ensured and the machines can work with process pressures up to 7,500 psi, which are required when producing small or thin-walled profiles, or when using regrind and recycled materials in co-extrusion. Thanks to minimized residence times and quick clean ing, color changes can also be effected much faster, which saves material. Thanks to the complete thermal insulation of the barrel that minimizes radiation losses and by using reluctance or synchronous motors, the Con Ex NG offers energy savings of up to 20 percent. Con Ex NG extruders are available in three sizes (42, 54 and 65 millimeter), with outputs from 80 to 550 pounds per hour for PVC profile and WPC/NFC, and from 100 to 1,000 pounds per hour for PVC pipe. Several different space-saver or column designs are available for co-extrusion. These can be adapted to every main extruder through improved height and tilt adjustment facilities. Better quality and lower energy consumption Processors need large production capacities to fulfill their orders. The Sol Ex NG has a completely redesigned screw feed section with a significantly lower pressure profile. This ensures high specific outputs, fast process start-ups at low screw torques and no conveying instabilities, even at high back pressures of up to 7,200 psi, which are needed, for example, for the production of corrugated pipes. Thanks to the new processing unit, a reduction of melt temperature by approximately degrees Fahrenheit is possible. Therefore, the cooling length can be shortened as cooling baths need to remove less heat. Alternatively, for nearly all products, it is possible to increase line speed with the same cooling length, resulting in up to 20 percent higher outputs. Lower melt tem peratures at a consistently high level of melt homogeneity also result in better product quality for example through reduced sagging, which is particularly important for thick-walled or large-diameter pipes. Pipe producers operate under high cost pressure, which makes energy and material savings crucial for efficient production. The Sol Ex NG series needs up to 15 percent less energy, because it operates with less drive power and lower energy losses. Thanks to the grooved barrel and corresponding lower pressure profile, energy savings can be achieved by reduced barrel cooling. The machines excellent processing characteristics, combined with special wear protection solutions for the processing unit, result in material and maintenance cost savings. The extruders from the Sol Ex NG series come in four sizes (60, 75, 90 and 120 mm, 40 L/D) and with up to 20 percent higher outputs for each machine size, from 2,000 to 5,000 pounds per hour for HDPE and from 1,650 4,000 pounds per hour for PP. W Web-Link Fast Reaction optimal temperature control With contour following temperature control a maximum productivity with highest surface quality can be reached. The newest rapid heat and cool (RHC) tempering Unit»CONTURA GEKKO«assures you full process control. Please do not hesitate to use the CONTURA -potential.

34 34 EXTRUSION H i g h l y - e ffi c i e n t Extrusion Gneuss will be showcasing a range of new extrusion technologies at NPE in Orlando with its individual divisions. MONIKA GNEUSS Gneuss Extrusion Technology will show a complete Gneuss Processing Unit (GPU) including a Multi Rotation System MRS 130 extruder, a fully automatic melt filtration system RSF Genius 150 and an online viscometer VIS, for the processing of 2000 lbs/h of undried and uncrystallized polyester (PET). The Gneuss Processing Unit (GPU) has been available for several years now and has proven itself for the reprocessing of bulky PET waste such as post-consumer bottle flake and industrial waste from fiber and film manufacture without pre-drying. A Gneuss Processing Unit consists of a Gneuss MRS extruder with its unmatched devolatilization and decontamination performance in combination with a highly-efficient Gneuss Rotary Filtration System and an online viscometer VIS for intelligent dynamic viscosity control. The line on the show floor in Orlando will be Continuous Rotary Filtration System KF 150 for frequent material changes

35 EXTRUSION 35 Sheet extrusion line with Multi Rotation Extruder MRS, Rotary Filtration System RSF Genius, Online Viscometer VIS and PET foam module One area this technology has been especially successful is in PET sheet extrusion. Monika Gneuss, Vice President delivered to a customer in the U.S. after the show to process lbs/h of R-PET into a thermoforming sheet. Although originally developed specifically for PET, the MRS is now also running in polyolefin and nylon applications, and being tested on a range of other materials and applications. Thanks to the patented combination of single screw extruder with a multiple screw section, the extruder is very sturdy and particularly well suited for recycling applications. The MRS extruder permits the processing of PET without pre-drying by using a simple water ring vacuum system to pro- cess the material directly to high quality end products. This is achieved by means of its unique and patented processing section. Based on a conventional single screw extrud er, the Multi Rotation Section is a drum containing eight satellite single screws, driven by a ring gear and pinion transmission. The barrels cut into the drum are approximately 30 percent open and provide optimum exposure of the melt. Thanks to this design, the devolatilizing performance is approximately fifty (50!) times greater than that of a conventional single screw extruder and this at a vacuum of only 25 to 40 mbar. By avoiding the need for a deep vacuum system and pre-drying, the MRS is an economically efficient alternative to conventional technologies. Further arguments in its favor besides energy savings are the simple and rugged design, small footprint, its ease of operation and low maintenance, processing flexibility and last but not least its excellent melt quality and homogeneity. Photos: Gneuss One area this technology has been especially successful is in PET sheet extrusion. Besides producing high quality rigid sheet, Gneuss now also offers the option for its PET sheet extrusion lines to quickly and flexibly switch to producing physically foamed PET sheet with the addition of Gneuss new PET foam module. Foam sheet with a weight reduction of 50 percent can be extruded (depending on the process) with a consistent foam structure and mechanical properties. And this from up to 100 percent post-consumer material. Foamed PET sheet is an ideal material for economically manufacturing thermoformed containers for the food industry such as meat trays, egg cartons, cups or plates. Strong and consistent growth in North America has allowed the company to move forward with an expansion of its US facilities in Matthews, NC. The larger facilities offer a larger laboratory as well as more space for spare parts. For wide range of different applications Gneuss Filtration Technology will exhibit several different models of their patented Rotary Filtration Systems. These systems are characterized by the filter disk on which the screen cavities are located in a ring pattern and which is completely encapsulated by the two filter blocks. Screens can be inserted into the cavities by opening a small hatch door giving access to the cavities while the production process continues to run without any interruptions or disturbances. All models have been completely re - vised since the last NPE. Modifications to the screen changer housings permit operation on a wider range of applications at higher pressures, whilst offering enlarged active filtration areas. Components and modules have been standardized in order to offer shorter delivery lead times and lower costs.

36 36 EXTRUSION Two types of measurement sensors: The Gneuss Melt Pressure Transducers operate on the proven principle of strain gauge technology and the Gneuss range of Melt Temperature Sensors feature proven thermocouple or resistance temperature measurement systems in a high precision but robust sensor. Photo: Gneuss The SFX Magnus series operates automatically as well as process and pressure constant. It is suitable for a very wide range of applications. This series is characterized by an extra large active screen surface area, its compact design, as well as extremely easy operation. Screen changes do not have any influence on the product quality. An SFX Magnus 60 with an active filtration area of 23 square inches will be on display at NPE. Gneuss top model, the RSF Genius, operates with an integrated self cleaning system for very demanding applications and highest quality requirements. Screens can be automatically re-used up to 400 times and filtration finenesses below 10 microns/1200 mesh are available. In addition to the fully automatic melt filtration system RSF Genius 150 with an active filtration area of 70 square inches, which will be exhibited with the MRS 130 extruder as part of the GPU, there will be two more RSF Genius units in different sizes on the show floor. The RSF Genius M is especially designed for highly contaminated materials, such as in recycling processes, and it can cope with higher contamination rates. Gneuss top model, the RSF Genius, operates with an integrated self cleaning system for very demanding applications and highest quality requirements. Monika Gneuss, Vice President Last but by no means least, Gneuss will exhibit a KF 150 screen changer with an active screen area of 28 square inches. The KF range of continuous filtration systems is designed specifically for applications with frequent material type, grade or color changes as well as for high pressure applications like blown film. The KF screen changers are especially compact and offer excellent value for money while permitting simple and quick screen changes on the fly. Full line of products on display Gneuss Measurement Technology division will present its complete line of pressure transducers and transmitters, temperature sensors and accessories. As a machinery manufacturer, Gneuss has the manufacturing capabilities to realize even unusual sensor requirements. The lean manufacturing structure at Gneuss makes this possible with shortest delivery times. Gneuss sensors are available to match regional or application-specific requirements such as Atex, Hart Communication or EAC In especially difficult process conditions with short pressure overloads, frequent pressure spikes as well as unmelts in the material, sensors are highly stressed. Gneuss builds a special heavy-duty design with a special membrane technology for these applications. Also, Gneuss offers a special transducer for food applications, where regular cleaning of the machinery is necessary, so that sensors are often subject to steam or water jets. Gneuss has developed a special type of sensor for these applications, which remains waterproof even if its plug is removed. W Web-Link

37 K-ZEITUNG-App mit vielen Zusatz-Infos: Bildergalerien Videos interaktive Grafiken vertiefende Beiträge zu Schwerpunktthemen Management-Tipps zu aktuellen Steuer- und Rechtsthemen Interviews in schriftlicher und/oder audiovisueller Form * Do you speak German? Read K-ZEITUNG worldwide with our free app. Sie verstehen deutsch? Lesen Sie die K-ZEITUNG weltweit mit unserer kostenlosen App.* Unsere komplette K-Familie K-ZEITUNG K-ZEITUNG-APP K-ZEITUNG EPAPER K-ZEITUNG.DE K-ZEITUNG-NEWSLETTER K-EXTRA-APP K-FAKUMA EXPRESS K-FAKUMA EXPRESS-APP Konkrete und kompetente Informationen für die Kunststoff- und Kautschuk-Industrie! Wir sind für Sie am Puls der Branche, zuverlässig, präzise, kompetent von Praktikern für Praktiker! Ihre Ansprechpartner Redaktion Günter Kögel, Telefon +49 (0) Anzeigen Axel Gerhartz, Telefon +49 (0) info@giesel.de

38 38 EXTRUSION Extrusion for the smart factory Our people help shape your success This is the motto of the Krauss Maffei Berstorff exhibit at the 2018 NPE. STEFAN LENZ At the NPE in Orlando, Krauss Maffei Berstorff is introducing a number of future-looking machines that provide processors in the construction industry with high productivity and great competitive advantages. In this way, the company is emphasiz ing its leading position as a system provider of high-quality pipe and profile extrusion plants. The conical twinscrew extruder KMD 73 K/P, for instance, demonstrates high performance and flexibility, while the Quick Switch calibration basket up to 500 mm is exemplary of a high degree of automation. Solutions for the booming construction industry Especially in North America, we have

39 EXTRUSION 39 Conical twin-screw extruder KMD 73 K/P with a high production rate for profile extrusion Photos: Krauss Maffei Berstorff noted a very high demand for conical profile extrusion machines that can be used as both main and co-extruders, says Matthias Sieverding, President of Extrusion Technology at the Krauss Maffei Group. Since the introduction of the conical extruder series to the American market in 2013, we have sold more than 40 models. The KMD 73 K/P exhibit piece particularly stands out due to its very high production rate, robust machine quality and high pressure stability, properties that processors in window profile production especially in the case of mass-produced goods consider to be important decision-making criteria. The sophisticated processing concept makes the series extremely reliable and, at the same time, very flexible when various formulas are in use. The optional bimetal cladding of the cylinder paired with a tungsten carbide welded screw a requirement of the North American market also enables its use in pipe extrusion. Space-saving co-extrusion models de - signed according to customer specification can even be installed in extremely close spaces for efficient production. NPE Orlando May 7 11, 2018 West Hall E, booth W7263 Working for a better future MEMBER OF NEXT GENERATION GROUP Customized recycling technology for the plastics converting industry. It will not only satisfy, but also inspire. S:GRAN SHREDDER-FEEDER-EXTRUDER COMBINATION

40 40 EXTRUSION Quick Switch calibration basket technological centerpiece for automatic size change in a range from to inches (280 to 500 mm) In keeping with current trends: Automation and digitalization Before the background of increasing digitalization and customization, our unique, proven Quick Switch system has assumed a pioneering role, Sieverding says. At NPE, we are exhibiting our calibration basket, the centerpiece of the successful technology that has come to be con sidered a benchmark for efficiency on today s market. The exhibit piece impressively demonstrates the effective diameter range from to inches (280 to 500 mm). Especially in the case of large pipe dimensions, the system is of great interest as the low amount of waste occurring when switching to another size has an extremely positive effect on the material costs. All process parameters can be Especially in North America, we have noted a very high demand for conical profile extrusion machines that can be used as both main and co-extruders. Matthias Sieverding, President of Extrusion Technology at the Krauss Maffei Group set precisely, saved in a smart, all-in-one, higher- level parent control system and called up again at any time. In addition to the enormous cost and time savings, the customization of the products and demand for the smallest lot sizes and shortest delivery times possible are what make the system so interesting for the smart factory with in the scope of Industry 4.0, a topic that is increasingly preoccupying more and more American processors, Sieverding says. Perfect pipe quality The KM-VT 250/1/6 vacuum tank underscores Krauss Maffei Berstorff s competence as a system provider for complete pipe extrusion systems that guarantee high end product quality. The vacuum control and the frequency-regulated pumps with complete integration into the C6 line control system guarantee optimum activation, energy savings and consistent product quality. W Web-Link

41 TEMPERING TECHNOLOGY 41 Mold temperature control for injection molding: Contura is a specialist in contoured and variotherm temperature control. Photo: Contura The market for injection molded plastic parts is growing steadily in all sectors. At the same time, however, the complexity of plastic products is also increasing, as higher functional integrity and stricter requirements for dimensional accuracy are constant challenges for product developers. However, it is much more difficult to control the temperature of more complex plastic products and they have longer cycle times. However, there is a solution to this problem: contour-guided temperature control of injection molds. To control the temperatures on the entire cavity wall and avoid overheated areas so-called hot spots mold makers have to transform the molds into an efficient heat exchanger. Water channels should follow the contour of the part over a short vertical Close to the contour The increasing complexity of injection moldings places high demands on the temperature control of tools. The solution: Tools with contour-guided temperature control. GEESKE ANTONIA HERRMANN distance and at the same time have a very low gradient. The typical vertical distance to the cavity surface for a contour-guided temperature control channel is a quarter of an inch, and the same applies to the distance between the temperature control channels. But that s easier said than done. In general, the mold cavities are complex 3D structures and the injection molds are often additionally reinforced with narrow rib structures. Drilling solutions cannot offer a satisfactory solution here. Holes for lifters, ejector pins and sub-inserts give the core and hollow blocks the appearance of a Swiss cheese. It is impossible to create an efficient pipe network for the temperature control medium in this way. 3D printing allows almost any contours Fortunately, technologies are now available with which contour-guided temperature channels can be produced. The best known of these technologies is 3D printing. Steel powder or steel wires are welded layer by layer into a solid steel block. These QUALITY ASSURANCE FOR PLASTICS & RUBBER Visit us: Booth W7481 Web Guiding Surface Inspection 100% Inspection Color Management Register Control Web Monitoring Workflow Process Automation Color Measurement Measurement of Thickness + Basis Weight More Information:

42 TEMPERING TECHNOLOGY 42 constructions can have any design with cooling holes at any conceivable point. As the dimensions for steel components based on this technology are still very limited, 3D-printed inserts are currently usually of smaller dimensions. The most commonly used steel grade for injection molding applications in 3D printing is Maraging 300 with excellent toughness and hardness of approx. 52 Rockwell C. This grade of steel is very good for welding and therefore a good choice for use in 3D printing machines. Maraging 300, on the other hand, is not a typically shaped steel and the lack of chromium and carbon in this steel leads to a lack of carbides. These small, very hard particles give standard mold steels such as H13 better wear resistance especially important when resins with fillers are used in injection molding. This disadvantage compared to conventional mold steels, as well as the relatively high costs for the production of a core block are still obstacles for broader acceptance in mold construction. This is where Contura from Germany comes in. Contura works with other technologies that are suitable for the production of contour-tempered mold inserts. These are technologies that were used in the past to build contour-guided temperature control lines, but whose market breakthrough never took place. Interesting alternatives: Vacuum brazing and diffusion welding Vacuum brazing and diffusion welding are two excellent ways of producing contour-tempered mold inserts. The shaped steel is cut into slices on multi-axis CNC milling machines following a CAD model. Then the designed cooling channels following the contour of the molding are milled into the panes. Finally, everything is reassembled into a solid steel block using one of the methods mentioned above, so that the joined block contains a contour-guided pipe network for the temperature control medium. In addition to the characteristic of using standard and powder metallurgical steel grades, the joining techniques can more than keep up with 3D printing when comparing costs. The possible block sizes Contura is not limited to specific processes in the fabrication of the mold insert blank. The steel grades that are used and the requirements are supported by many different manufacturing methods. Photo: Contura that can be produced with joining techniques are also significantly larger than with 3D printing. The dimensions for joined inserts are about 30 inches 15 inches 5 inches, while a 3D-printed insert of 10 inches 10 inches 10 inches can be regarded as huge and is already approaching the limit in terms of insert size. Integrated copper pins improve heat conduction A very interesting feature when using connection technologies is the firm integration of copper pins into the steel skeleton of the core blocks. At Contura, these copper pins are made of copper with a very high degree of purity. The thermal conductivity of these copper pins is typically 20 times better than that of the shaped steel used. This means that the copper pins can show their strength, especially in narrow areas of the core blocks, such as small slatted areas or the small intermediate rib areas that form the support ribs of a molding. Since the copper pins are firmly integrated into the steel framework by diffusion welding, for example, they are a completely integrated part of these small slats. The average thermal conductivity in these areas is increased by 5 to 6 times the values of the shaped steel and can often even reach the values of highly conductive copper alloys. While the lever arm resistance of the slats is only slightly reduced by the use of copper pins, the mold maker can produce the final surface structure on hardened section steel as usual, unlike on a copper alloy surface. An example of Contura manufacturing: a 1.5 inch high steel blade with a width of 0.25 inch would still exhibit very good cooling performance if copper pins were firmly integrated into this blade, if the copper pins end near to or directly in a channel of the temperature control medium. With all these possibilities for 3D printing, diffusion welding and vacuum brazing, however, Contura s experience shows that it is no longer sufficient to design the cooling channels according to gut feeling. The length of the channels, which are arranged in the required narrow mesh width for contour-guided temperature control, can easily be several feet. At this point in time, detailed engineering is important, which requires sound knowledge not only of 3D printing and joining techniques, but also of

43 TEMPERING TECHNOLOGY 43 mechanical engineering, including dynamics and thermodynamics. In the future, the mold maker will be required to be familiar with the influence of the temperatures of the water or temperature control medium in various areas of the mold, in particular with regard to the distortion of the moldings and the surface appearance. The rule is to equip each area of the mold with temperature channels as close to the contour as possible. The temperature control channels must then be divided into independent circuits that can be controlled independently of one another. Each individual circuit can have different temperatures, which can ultimately help to control the shrinkage behavior of the molding. Modern FEM software not only helps to see the mold surface temperatures in all mold areas, but also to display information on the dynamic behavior of the temperature control medium such as flow rates, pressure drop and Reynolds numbers and whether the flow of the temperature control medium is laminar or already turbulent. 15 percent lower unit costs are realistic Contura s experience shows that the effort is worth it: with a well-engineered, contour-guided temperature-controlled mold, there is a reduction in the average cycle time of about 30 percent compared to a conventional mold. At the same time, the stability of the process increases and the reject rate is generally reduced by up to 70 percent. In addition, the number of reworking operations on the tool insert is reduced by up to 50 percent. All these advantages should facilitate investment decisions for contour-guided temperature control. Overall, a unit cost reduction of 15 percent or more is realistic. And so it is not surprising that contour-guided temperature control is clearly on the advance. Especially in the medical and packaging industry, a very high percentage of all molds are already equipped with contour-guided temperature control. This realistic estimate is based on more than 3,000 molds per year equipped with contour-guided temperature control, with an upward trend. This is why it is very important that injection molders should now benefit from the advantages of contour-guided temperature control and not wait for the competition to win the race. Right at the start of a project, the injection mold maker should take into account the costs for contour-guided temperature control in order to give their mold makers financial possibilities to use contour-guided temperature control for part of their molds. In view of the many advantages, Contura is convinced that in just a few years the contour-guided temperature control will find the same acceptance as hot-runner systems, which have become a kind of standard technology in mold construction. W Visit us on W 1802 New measurement principle Water selective 100% chemical-free Exact, reliable, reproducible Web-Link The next generation of moisture measurement AQUATRAC Station sales@brabender-mt.de

44 44 TEMPERING TECHNOLOGY Fewer rejects and greater energy efficiency Thanks to the e-temp temperature control units, Engel has become a system solutions provider in the field of temperature control of injection molding processes. At the launch in North America Engel will be demonstrating the new opportunities of integrated temperature-control live at NPE STEFAN LENZ With iq flow control, Engel has further expanded its range of intelligent peripherals, consolidat ing its systems expertise. The integrated temperature-control solution improves the stability of injection molding processes, reduces rejects and boosts energy efficiency. Most rejects in injection molding are the result of temperature control errors, says Joachim Kragl, Director of Advanced Molding Systems and Processing at Engel Machinery Inc. in York, Pennsylvania. This explains why the processors focus is increas ingly shifting to mold temperature control. With flomo, Engel laid the groundwork for more transparency and consistency in the temperature control process as one of the pioneers in this field back at K Engel flomo, an electronic temperature control water manifold system, replaces the maintenance-intensive cooling water distributors and even the basic version can Most rejects in injection molding are the result of temperature control errors Joachim Kragl, Director of Advanced Molding Systems and Processing at Engel Machinery Inc. individually monitor and document all cooling and temperature control circuits. The next generation e-flomo is further able to actively control either the flow rates or the temperature difference (ΔT) in all individual circuits. The advantage of ΔT control is the automatic setting of the individually required flow rate for each temperature control circuit. On-demand pump control iq flow control sees Engel taking the next step. The software networks the temperature control units and the injection molding machine to create a single unit and, based on the measured values determined by e-flomo, controls the pump speed in the temperature control units on demand. While e-flomo increases the process stability which consequently reduces the risk of rejects, automatic speed adjustment ensures that temperature control requires substantially less energy. Since the pump operates on-demand rather than at maximum output all the time, stress on moving parts is reduced and temperature control units have a longer service life, which makes it possible to extend the maintenance cycles. This allows for further substantial savings. In conventional operations, regular maintenance of the temperature control units, including the downtime associated with it, is a major cost factor. As an integrated solution, the entire temperature control process can be set

45 TEMPERING TECHNOLOGY 45 The CC300 control unit on the Engel injection molding machines displays all temperature control components in a clear-cut way on a single screen, with the individual temperature control circuits of the mold in the center. At control level, iq flow control merges the injection molding machine, equipped with e-flomo, and the temperature control devices into a single unit. The pump speed automatically adapts to the current requirements. Photos: Engel up, monitored and centrally logged at the CC300 machine control display while the ideal operating point for the particular temperature control unit is determined and set automatically. This allows injection molding shops to fully leverage their injection molding machines potential without the system operators needing special training. Self-optimizing machine To integrate the temperature control units with the CC300 control unit on the injection molding machine, Engel collaborated with temperature control unit manufactur er HB-Therm (St. Gallen, Switzerland), to develop the temperature control unit series known as e-temp. The extremely compact devices are networked with the injection molding machine via OPC UA (Open Platform Communication Unified Architecture). With its service-oriented, platform-independent and freely scalable structure, this communications model offers great flexibility. A high degree of data security is guaranteed by the technical safety features that are an integral part of the architecture. OPC UA is becoming increasingly popular in the plastics industry for networking injection molding machines, peripherals, sensors and applications and is an important component of the inject 4.0 platform by Engel. Thanks to inject 4.0, Engel is helping clients pave the way to the smart factory, with continuously self-optimizing production processes. Self-regulating systems such as iq flow control play a key role in creating smart machines. W Web-Link HESTA. Four times better. 1 Energy 2 Security HESTA has the most energy effi cient equipment in its class. HESTA blowmoulding machines save energy. Power is only required during movement (1.3s). During blowing the drives are switched off. The HESTA stroke setting system is patented. Zero point setting and mould thickness setting are carried out automatically. There is no manually setting setting of the chassis, closing movement and calibration stroke. 3 Time 4 Space All components of the HESTA blow-moulding machines are built on plug-in systems. The tool quickchange system guarantees the shortest retooling times. HESTA blow-moulding machines have a space-saving design and offer the perfect footprint for easy access. HESTA machines are approx. 30% smaller than compareable machine models. HESTA BLASFORMTECHNIK GmbH & Co. KG Werrenwiesenstraße 89 D Schwäbisch Gmünd Phone / info@hesta.de NPE2018 West Hall Level 2 - Expo Hall - W2343

46 46 RECYCLING Maximum process stability with ideal project tracking Photo: NGR Next Generation Recyclingmaschinen GmbH, an Austrian manufacturer of recycling technologies, is showcasing the P: React processing system with NGR Connect for continuous monitoring of operating parameters and the associated optimization options. Liquid State Polycondensation (LSP) of scrap PET in the P:React machine cleans the melt of harmful contamination while still offering an unmatched level of process stability. The FDA and EFSA have both approved the LSP decontamination process for 100 percent food contact applications. An upstream extruder supplies devolatized and filtered melt to the LSP process. Inside the heated reactor, the melt is exposed to a strong vacuum at very high surface area to volume ratio. These conditions initiate the polycondensation process where LSP (Liquid State Polycondensation) realized on P:React IV increase and decontamination occur extremely rapidly compared to traditional solid-state processes. In many cases, the need for pre-drying can even be avoided. Maximum IV increase and decontamination are typically achieved with a 25-minute residence time, after which, the rpet will have near virgin like qualities. The polymer melt pump at the LSP reactor outlet extracts the melt at constant volume and constant pressure. In addition, an inline viscometer gives feedback to the reactor control to ensure constant IV production. This combination of constant pressure, volume and IV provides exceptional process stability, which can be direct-coupled to nearly any downstream process such as sheet, fiber or film production. One can imagine the efficiencies of taking a raw PET scrap stream directly into a product in one-step, completely eliminating the intermediate steps of material handling, crystallizing and pre-drying of pellets. In film and sheet production using rpet, the extraordinarily high process stability of the P:React has resulted in noticeably less process downtime, leading to higher production rates. Another advantage is that more consistent material thicknesses can be achieved, leading to considerable material savings. This process stability also can give users the option to modify recipes to lower virgin/higher rpet levels thus reducing production costs. Even in the hyper-sensitive fiber spinning process, production output and fiber quality has been taken to new levels due to the increased process stability and melt quality of the P:React. NGR Connect Continuous process optimization NGR Connect gives operators a live digital connection to their recycling process. This is done by recording relevant operating parameters for the NGR system and making them accessible to the user on any end device (tablet, smartphone etc.). In conjunction with the P:React, NGR Connect monitors the decontamination performance is based on sensory signals. Recipe management directly on the machine makes it possible to classify the PET input material and link to P:React production data. As a result, users have real-time process tracking and can continuously optimize the process to meet production goals. NGR s LSP technology for PET recycling was commercially introduced to the US market at NPE Show in At the upcoming NPE in May, 2018, the P:React and NGR Connect will be on display at the NGR booth. PHILIPP LUBOS W Web-Link

47 RECYCLING 47 Quality in plastics recycling in greater demand than ever Erema will be prioritizing quality at this year s NPE. Top process and quality standards guarantee the decisive edge plastics recycling. The trend towards the sustainable handling of plastics combined with the right technology will fuel the upswing of recycling in the U.S. plastics industry. The potential of plastics recycling in the USA has never been as big as it is today. The reason for this is the interplay of several factors: the significant reduction of post-consumer plastics waste imports by China, the growing circular economy movement and the ambitious targets of major brand article manufacturers and other producers to increase the amount of recyclate in their products. If I had to describe the current situation of the plastics industry in the USA in just one word, dynamic would probably be the most appropriate, says Martin Baumann, Vice President Sales of Erema North America. Above all, China s no longer being an international customer for post-consumer waste plastic is a dramatic development. But since, unlike waste plastic, high-quality recycled pellets can still be exported to China, this represents a potential opportunity for plastics recycling in the USA and Canada. This is why Erema North America has added an Intarema TVE plus with Laserfilter to its Technical Centre for customer trials especially for the recycling of post-consumer materials with a high degree of contamination. This system typically processes film waste with paper labels from commercial waste or washed film from curbside waste to make film-grade pellets. Trade fair attendees will receive information about the Erema melt filters directly from the Erema business unit Powerfil which will be represented at NPE for the first time. The proven filter systems are now also available as individual components for extrusion plants from other suppliers. Plastics recycling is more an opportunity than an alternative with regard to sustainability and against the backdrop of increasing prices for landfilling. The focus of our technical developments lies quite clearly on increasing the quality of recyclates. It is precisely for this reason that we have developed the new Re Fresher anti-odour technology which enables us to open up completely new application opportunities for plastics recycling, says Mike Horrocks, CEO Erema North America. Additional highlights More and more producers of plastic products are counting on reducing their manufacturing costs through the recycling of clean production waste, as Martin Baumann explains: Our sales in the recycling of clean production waste are constantly growing. We put this down largely to the increasing demand for high-quality film products and the associated expansion of production capacities, says Martin Baumann. An Intarema T 1108 will be in action live at the booth, processing clean LDPE production waste direct and without pre-shredding to make high-quality recyclates. Additionally, Erema will be providing details on the world s first rpet Inline Preform system at its booth. Sipa, a leading manufacturer of PET packaging solutions from Italy, joined forces with Erema to develop a flexible, direct processing solution to make food-contact-compliant preforms from rpet flakes in a continuous process. For PET processors the pioneering system has both economic and ecological benefits: energy savings, lower logistics and process costs and higher profitability. The Inline Preform system is in full line with the global trend of processing post-consumer PET flakes direct to make sheet, strapping or end products. PHILIPP LUBOS W Web-Link Clean LDPE film waste will be processed live at the Erema booth. Photo: Erema

48 48 BLOW MOLDING Fast color changes for a colorful result Photo: W. Müller New coating substantially accelerates color change W. Müller, technology leader in the development of customer-specific special solutions for blow molding technology, was able to further reduce the already fast color change times of its popular extrusion die heads. The lynchpin of the latest innovation from the German special machine manufacturer is the metallamorphic flow channel coatings from the experienced surface finishing expert Dreistegen GmbH, Monschau, Germany. These massively increase the mobility of masterbatch residues on the walls of the plastic-holding channels, which were previously difficult to mobilize, even compared to the already extremely fast high-performance blow molding heads from W. Müller. Every professional knows that color change times in the blow molding industry are a very critical factor, ex - plains Guido Knipp, employee of Troisdorf-based W. Müller GmbH. In extreme cases, it can take hours for standard extrusion die heads to complete this process. With large products such as large-volume canisters, tons of waste can therefore be produced in un - favorable cases simply because of the problem of changing colors, and of course this also consumes energy unnecessarily, says the technician. This is why we have always taken this critical factor hugely into account in the development of our extrusion die heads, for example through highly optimized flow channel design. That s why our heads have always been in the top group when it comes to color change speed. But time does not stand still the color master batches are also developing. Unfortunately, this can also have a negative effect on color change times, says Christian Müller, Technical Director of the German family business W. Müller, and son of the company founder. As a leading technical supplier of high-performance extrusion die heads, we recognize this as something we have a duty to deal with, of course. With our new flow channel coatings, we have actually achieved another quantum leap, says Christian Müller. Customized flow channels: Now optimized even further A detailed look at the processes in the extrusion die head shows how the innovative W. Müller approach works. The speed of the color change strongly depends on the nature of the flow channel walls. For physical reasons, the core of the extrudate always flows faster than its peripheral areas, which are subject to direct friction with the walls, explains Christian Müller. This means that it may take some time for the last traces of the old masterbatch to be rinsed out of the die head. With a special coating that we developed in close cooperation with Dreistegen GmbH in Monschau we were able to spark another booster even for W. Müller s standards: it reduces wall friction and thus accelerates color change times. The coating is a so-called metal-amorphous functional layer which is applied to the surface of the flow channels in a complex physical process after plasma nitriding of the plastic-carrying components. This causes the plastic to flow in a laminar fashion all the way to the edge areas. The more flow-friendly surface means that existing pigment or viscous masterbatch residues can now be rinsed out a good deal faster than before. Customers who need to make frequent color changes can therefore benefit greatly from this additional option. Of course, the choice of masterbatches and other conditions must also be correct. Of course, real savings for the customer can differ, as they depend heavily on the pigments used, says Christian Müller. But the results speak for themselves. And we examined a double head: with larger systems, the material savings are naturally even greater. PHILIPP LUBOS W Web-Link

49 BLOW MOLDING 49 Kiefel is ready today for the products of tomorrow Intelligent injection stretch blow-molding technology ensures high flexibility, productivity and quality. With the development of the Blowliner, the single-stage injection-stretch blow-molding machine, Kiefel s daughter company Mould & Matic has opened up a new market. Bernhard Hornhuber, sales manager for blow molding technology, developed the Blowliner and is justifiably proud of his baby: Customers really appreciate the fact that they get the extremely space-saving line completely from a single source from granulate to packaging. The Blowliner is available in three sizes. The line processes PET, PP, HDPE and, thanks to its intelligent concept, can be upgraded to multilayer applications at any time. Above all, the premium sector, which attaches importance to high quality and transparency of packaging in medium quantities, appreciates the 1-stage system. Hornhuber gets to the heart of the reasons: Our customers need the flexibility to produce different containers with volumes between ten milliliters and five liters on the same machine. The Blowliner fulfills all of these wishes and thus contributes to sustainable high plant utilization at our customers. warm, they are removed by a linear robot with a gripping mandrel and the preforms are transferred to the stretch-blow unit. The machine works with one to four-rows blow tools that accept preforms with diameters from 10 to 150 millimeters. Each series of cavities has its own pre- and main blow valve so that the pre- and main blow pressures can be set individually. The entire stretch-blow unit has servo motor drives that provide exact repeatability, precision and energy efficiency. At the end of the blowing process, the vacuum gripper of the integrated linear unloading system removes the finished products from the tool and places them precisely on a conveyor belt or directly in boxes. Many considerations flowed into the tool technology during the conception of the Blowliner. Hornhuber recalls: Our goal was to increase the number of cavities and thus productivity with additional optimized cycle time for existing plants. It should be possible to use the hot side of the tool to manufacture very different products in terms of size and thus number of cavities. The solution lies in a balanced hot channel tool with a needle lock system. This provides the capacity for different product sizes and tool configurations. The Blowliner M permits cycle times of ten seconds, the little brother Blowliner S can even manage less than eight seconds. At the NPE, visitors will have the opportunity to experience the Blowliner M live. Mould & Matic produces pill packers made of PET on a twelve-cavity mold with a volume of 250 milliliters and a weight of 30 grams. PHILIPP LUBOS W Web-Link Photo: Kiefel Focus on the process The injection molding unit, a vertical hydraulic Engel machine, is at the beginning of the linear machine. Here the preforms are created; depending on the product these range from eight to 64 cavities. Still The Blowliner Medium through put of up to 130 kilograms PET per hour

50 50 MATERIALS Wide range of polymer solutions Albis Plastic presents a comprehensive product portfolio of high-performance plastics, compound solutions and masterbatches at NPE 2018 Albis Plastic, a global distributor and compounder of technical thermoplastics and thermoplastic elastomers, will present its portfolio of high-performance plastics, compound solutions and masterbatches at NPE 2018 in Orlando, Florida, USA from May 7 to 11 in Orange County Convention Center. Cutting-edge compounds Albis Americas has its manufacturing facility in Duncan, South Carolina, where it produces a wide range of cutting-edge compound solutions and masterbatches. Major product highlights include Altech Eco (Near-to-Prime Recycled Compounds), Alcom Lighting and Alperform Lighting product lines as well as WIC PP and WIC PA (carbon fiber compounds for lightweight construction applications). Many OEM approvals and specifications are held in automotive, healthcare, household goods and E&E sectors. Stefan Fuhlendorf, President & CEO of Albis Plastics Corporation, says, We have been in the USA for more than 50 years. In 2017 we strengthened our presence by installing a plant at our Duncan site. This enables us to offer our NAFTA based customers local production using global specifications. We are really looking forward to presenting our latest products at NPE. Latest products to see This will include Altech Eco, as Albis respond to the increasing demand for recycled plastics, the need to limit the use of fossil resources and more and more environmentally conscious consumers all resulting in the wider use of recycled materials. Altech Eco compounds with a recycled content of up to 100 percent meet this demand and are used engine covers, valve covers, air-inlet housing and UV resistant light housing. They are characterized by a positive ecological balance, Near-to-Prime quality, tailormade features, cost efficiency and good workability. Alcom LDX HTC: These light-diffusing compounds made on base of a copolyester have an outstanding degree of light transmission and diffusion as well as excellent chemical and impact resistance. They are ideal as light covers in challenging environmental conditions such as animal sheds, commercial kitchens or industrial facilities. They can be used for extrusion and injection molding applications. Alperform LD and LDX-Batch are flexible and cost-effective solutions for light diffusing coloring of polycarbonate and PMMA. They enable a quick and simple adaptation of optical properties by individual dosing within the handling process to optimize transmission and Stefan Fuhlendorf, President & CEO of Albis Plastics Corporation: Albis Americas manufacturing facility in Duncan, South Carolina, enables us to offer our NAFTA based customers local production using global specifications. Photo: Albis light diffusion, to increase light efficiency and to prevent annoying hot-spots. The Alperform LB-Batch is brandnew. This masterbatch solution also enables flexible dosing but stands out for its high cost efficiency in the self-coloring of ABS and PC for highly reflective and opaque components, including lamp housings and extrusion profiles for linear LED applications. Alcom TCD PA FR and Alcom TCD PA FR WT are thermally conductive and electrically insulating polyamide 6 based compounds used for efficient heat management. They significantly improve the service life and efficiency of LED applications and are fire retardant in line with UL 94 V-0. Two silver-gray metallic colors have been developed, based on the thermally conductive Alcom TCD PA which are suitable for thermally conductive decorative elements or as cool touch housing components, for example. Compounds based on recycled carbon fiber from CFRP production remnants in the automotive and aviation industries is another new technology with great potential. The product ranges WIC PP and WIC PA could replace relatively heavy highly-concentrated glass fiber PA compounds with lighter PP CF compounds. The weight reduction is huge, up to 30 percent. At the same time the PP carbon fiber components are more cost-effective due to their lower density and taking volume prices into account. We are happy to explain the performance of our products at our booth in detail. We are looking forward to welcoming interested visitors, customers and business partners there, says Fuhlendorf. MATTHIAS GUTBROD W Web-Link

51 COMPANIES IN THIS ISSUE 51 Ach solution... 30, 52 Albis Plastic Arburg... 5, 18, 38 Battenfeld-Cincinnati... 29, 32 Benecke-Kaliko... 8 Borealis... 8 Brabender Brückner BST Eltromat... 28, 41 Buss Contura... 33, 41 Dreistegen Engel... 2, 8, 12, 44 Erema Galvanoform... 8 Georg Kaufmann Formenbau... 8 Giesel Verlag Gneuss... 11, 34 HB Therm Hekuma... 15, 18, 26 Hesta Hofstetter HRS Flow... 8 ICO System International Coating... 8 Kiefel Kipe Molds Krauss Maffei... 7, 14 Krauss Maffei Berstorff Maurer MMS Modular Molding Systems... 8 Mold & Matic MTI Mischtechnik... 27, 31 Netstal NGR... 39, 46 Northern Pipe Products Optris Pal Plast... 1 Trexel... 8 US Plastics Industry Association... 6 VDMA... 6 W. Müller... 1, 48 EUROPE@NPE HIGHLIGHTS OF EUROPEAN TECHNOLOGY MADE FOR THE US-PLASTIC INDUSTRIE Publishing house: Giesel Verlag GmbH, Hans-Böckler-Allee Hannover, Germany Phone +49 (0) Fax +49 (0) Managing director: Lutz Bandte Giesel Verlag GmbH is a subsidiary of Schlütersche Verlagsgesellschaft mbh & Co. KG Publisher: Joachim Rönisch (roe) EUROPE@NPE EDITORIAL STAFF: Gögginger Str. 105a Augsburg, Germany Phone +49 (0) k-redaktion@schluetersche.de Editor-in-chief: Günter Kögel (gk) Editors: Jürgen Lindemann (jl, Content manager) Matthias Gutbrod (mg) Stefan Lenz (sl) Philipp Lubos (pl) Dominik Bechlarz (db) Sabine Koll (sk) Advertising manager: Axel Gerhartz Phone +49 (0) gerhartz@schluetersche.de Printed in cooperation with: Gardner Business Media, Inc Valley Ave, Cincinnati, OH , USA COMPEO Join us NPE, Orlando May 7-11, 2018 West Hall Booth W1963 The new BUSS compounder generation. Incredibly different. Brand-new in Orlando! Uniquely efficient. Incredibly versatile. Amazingly flexible. COMPEO combines the performance and robustness of its predecessors in a single modular series. Designed for all application fields and temperature ranges. With a process window that is unparalleled. Want to know more about the COMPEO compounder s forward-looking features? Welcome to Orlando!

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