THE NEW PX THE ALL-ELECTRIC MADE- TO-MEASURE MACHINE T-RTM THE PERFECT COMBINATION. THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue 02.

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1 AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI Issue THE NEW PX THE ALL-ELECTRIC MADE- TO-MEASURE MACHINE T-RTM THE PERFECT COMBINATION

2 EDITORIAL CONTENTS COVER STORY 4 The new PX the all-electric made-tomeasure machine 9 Interview: Three questions for Dr. Daniel Ammer, Director of Development BRAND & MARKETS 10 Leading experts for leading solutions 12 T-RTM: The perfect combination 14 A CX on tour across Europe Dear customers and readers, KraussMaffei will once again more than live up to its reputation as a technological leader and driver of innovation with its trade show appearance at K We will present you with products of the highest quality as well as premium-quality process solutions for global market trends. These trends include the growing demand for plastic products in the medical and logistics sectors as well as for lightweight construction projects in the automotive industry. As one of the main highlights, KraussMaffei is presenting the first all-electric injection molding machine that can be configured completely freely: the new PX series. It combines the advantages of an all-electric injection molding machine with maximum modularity. Processors benefit from high precision, productivity and flexibility in all production phases. Visit our booth to learn all about our small CX series with expanded clamping force sizes and to experience our FiberForm and ColorForm technology in live demonstrations. In addition, you can catch a glimpse of the quickly installed, flexible and space-saving automation solutions from KraussMaffei automation technology, including the new TwinZ LRX linear robot for complex stack mold applications. Lightweight construction is increasingly tapping ever-growing potential, not just in the automotive sector but also in other business areas such as the wind power, aviation and logistics industries. It is in these business areas that KraussMaffei is assuming its position as a world leader. We owe this to our in-depth process expertise in injection molding technology and reaction process machinery, and in particular to the unique combination of the two technologies. As the Managing Director of the Reaction Process Machinery segment at KraussMaffei, I am especially excited to present KraussMaffeiʼs T-RTM technology to you. It combines the benefits of reaction process machinery, thermoplastic materials and shaping in the resin transfer molding process (RTM), making it the perfect combination for modern lightweight construction. On behalf of KraussMaffei, I invite you to visit us at K 2016 (Hall 15 at Booth B27/ C24/ C27/D24). Become inspired by our technological expertise and our innovative ability! If you do not get a chance to visit, you can always reach our injection molding and reaction process machinery experts for consultation. PROCESSES & PRODUCTS 15 CX: Now on a larger scale 17 Custom-made networking with Plastics ColorForm in series 23 Small helper with a big impact 24 Lightweight construction with a robot ballet 26 A new dimension in versatility and flexibility 29 Versatility as a recipe for success 32 Fast cycle for sealing edges PARTNERS & PROJECTS 34 As a twin pack 36 Itʼs a lighter drive with composites 38 New look for the new Thermomix KRAUSSMAFFEI GROUP 41 KraussMaffei Group anniversaries 42 Renzo Davatz is new CEO of Netstal 43 Netstal: From a vision to reality 43 KraussMaffei Berstorff: A balance of three objectives and more 43 Trade show calendar 43 Imprint Have a good read! Nicolas Beyl Managing Director President of the Reaction Process Machinery Segment

3 KraussMaffei Contents 3 4 The PX The advantages of an all-electric injection molding machine are combined with maximum modularity Plastics 4.0 Intelligent machines, integrated production and interactive services. Turnkey systems For the production of the rugged high-gloss covers.

4 4 Cover Story AHEAD Issue NEW ALL-ELECTRIC INJECTION MOLDING MACHINE SERIES FEATURES FLEXIBILITY THROUGHOUT ITS SERVICE LIFE The new PX series from KraussMaffei combines the advantages of an all- electric injection molding machine with maximum modularity in an entirely new way processors benefit from high precision, productivity and flexibility in all phases of production. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI E lectric injection molding machines are known for precision and efficiency and for admittedly limited equipment options. Until now, customers have most often been forced to decide between low-budget and high-end designs. KraussMaffei is now presenting the first all-electric machine on the market, which the customer may tailor to its specific manufacturing needs. The customer pays for exactly what it needs and nothing more. For example, enlarged platens, faster injection speeds or even the option for operation using food-grade NSF H1 lubricant. The all-electric toggle machine is premiering at the K trade show with clamping forces of 500 to 2,000 kn, and its core concept is flexibility. This is because extensive market research during the three-year development phase showed that flexibility is the primary concern for customers. Product Manager Hans Malinowski explains, The other major trend, functional integration, is extremely

5 KraussMaffei Cover Story 5 prevalent only in Europe. It is somewhat pronounced in the United States and pretty much non-existent in Asia. The desire for flexibility, however, is equally strong worldwide, because the customers of plastics processors are continually calling for smaller batch sizes. Flexible for a whole lifetime This led to the creation of a modular concept that offers the user more adaptability than they will get with any other machine on the market for an entire lifetime. From purchase, to daily production, to retrofitting. This modularity is KraussMaffei s way of consciously separating itself from other manufacturers, who usually offer no more than two product lines with different equipment: high-end or low-budget. There have been no in-between options offered to date, meaning that the customer was forced to buy from the high-end product line, even when it only needed a single equipment feature from that line. The customer would end up spending a lot of money on unnecessary features. The PX

6 POWER MEETS FLEXIBILITY The PX series allows for a high degree of freedom for mold use. Robust mechanics, high precision and dynamic drive technologies as well as intelligent energy management make the PX a reliable, productive and efficient performer in any injection molding operation. DR. HANS ULRICH GOLZ, MANAGING DIRECTOR OF KRAUSSMAFFEI AND PRESIDENT OF THE INJECTION MOLDING MACHINERY SEGMENT customer, on the other hand, can customize its machine as uniquely as a person buying a car, by specifically selecting only the options necessary for operation. The PX is like a made-to-measure suit, allowing itself to be adapted to a wide range of production conditions. Of course, this means that it can also be specially set up for operation in various industries and for various applications. An important feature of the series lies in the fact that there are versions of the machine available with platens that have been incremented up by one size, inherently increasing the clamping force to the next level as well. These intermediate models are identified using odd numbers, i.e., PX 51 to PX 161. The larger clearance corresponds to an increased maximum mold weight, approximately 750 kilograms for the PX 51 compared to 450 kilograms for the PX 50. Since the machine bed of the PX is split, clamping and injection units can also be combined as necessary. Large clamping units, small injection units in production, this means that no more space is taken up than what is absolutely necessary for the production order. There are five high-performance injection units available for each clamping unit. Each injection unit has its own performance level and can be fitted with one of three to four different screw diameters. The tried-and-tested modular concept of the hydraulic GX series was taken and applied to the all-electric PX.

7 KraussMaffei Cover Story 7 with some servo hydraulics The basic properties of all-electric machines have been set up to meet the desire for flexibility, since electric motors function independently of each other. This allows for any number of processes to run in parallel, ensuring high speeds. The three main axes of the PX for the injection unit, plasticizing unit and clamping unit are driven by air-cooled servomotors, making the PX exceptionally economical in terms of energy and water consumption. All servomotors also work in what is called recuperative mode, whereby brake energy is converted back into electricity. As a result, up to 60 percent of the brake energy can be temporarily stored and used by the machine itself or fed back into the power supply. The slave axes of the PX, meaning each axis for the injection unit and ejector movements, operate using servo hydraulics in the default version. The initial movement takes place via two parallel injection unit barrels because this enables nozzle contact forces to be built up very quickly and free of lateral forces, unlike the movements carried out with only one electric barrel. For particularly high material throughput, for example in the case of thin-wall injection molding, there is an option for increasing the injection speed for the PX to more than twice the normal speed, thereby increasing the plasticizing output significantly. The injection unit can be set up to swivel in order to make it easier to change the non -return valve or replace the screw. For the ejectors, the reason behind the servo hydraulics relates to durability. Electric drives are sensitive to the mechanical impacts that occur when plastic parts are demolded using a vibrating platen. Any customer that does not do this during production and requires even more precision has the option to equip the PX with an electric ejector drive. Even with servohydraulic slave axes, the PX is classified by Euromap and the SPE as an all-electric injection molding machine. Clamping unit: Geometry, force and speed Three things matter when it comes to the clamping unit: geometry, force and speed. In all three areas, the PX offers options for coordinating the machine to meet individual requirements. As already mentioned, the size of the platens can be increased with the odd-numbered intermediate models, meaning that the entire machine bed of the machine that is next in size is then used. This ensures that the high mold weight receives the necessary linear support. Thanks to the extremely wide support of the moving platens on linear guides, a precise parallel movement is always achieved. The tie bars are released and thus are always free of lubricant and clean. The clamping unit bed has been designed so that the entire area under the clamping unit, lengthwise and crosswise and all the way to the floor, remains free for failure and parts logistics. As a result, parts containers or conveyor belts can be rolled under the machine very easily and practically, without any crossbeams getting in the way. The maximum mold height can, if desired, be increased to 100 millimeters more than the respective standard version. For instance, it can be increased from 450 to 550 millimeters for the PX 120. EXPERIENCE PX IN PERSON At K 2016, customers can experience the new PX live, using applications from various industries and numerous equipment options. PX 50: SilcoSet Membrane in micro injection molding. PX 80: Electro Control cabinet terminal made of flameproof material. PX 120: Medicine Y-connector for hoses. PX 160: Packaging Flip-top caps. PX 200: Consumer Visible surface part with inductive dynamic mold heat-balancing.

8 8 Cover Story AHEAD Issue The mold height adjustment itself takes place automatically. Regardless of whether they use hydraulic or electric power, ejectors need plenty of force for parts that shrink onto the cores. This is why the product range provides an option to increase the ejector force by 50 percent. For projects with aggressive cycle times, there is an ejector speed of 700 millimeters per second as opposed to 350. In continuous operation, the PX features an ergonomically favorable working height of 130 centimeters, which remains the same for all clamping forces, ensuring perfect accessibility of the mold and nozzle for set-up or during production. The resource consumption of energy and water is extremely low. Precision and availability, on the other hand, are high. Using additional equipment and retrofitting options, the PX can be configured specifically for certain industries, e.g., medical technology. In that industry, belt drives are enclosed, lubrication systems are closed and operation takes place using food-grade NSF H1 oil. The machine also serves as an excellent base for working with different technologies such as MuCell, FiberForm or LSR processing anything is possible. For the first time ever, the PX allows modular, flexible use of an all-electric injection molding machine as was only possible for hydraulic machines in the past. Here, KraussMaffei is utilizing its extensive technological expertise to offer customers real added value. More information px.kraussmaffei.com YOUR CONTACT: Hans Malinowski Product Manager All-Electric Machines

9 KraussMaffei Cover Story 9 The custom combination of injection and clamping units forms a core feature of the PX. It allows the series to set new standards for production flexibility. HANS MALINOWSKI, PRODUCT MANAGER ALL-ELECTRIC MACHINES AT KRAUSSMAFFEI DEVELOPED WITH PASSION: THREE QUESTIONS FOR DR. DANIEL AMMER, DIRECTOR OF DEVELOPMENT AHEAD: How did the development of the new PX go? Ammer: You could say it was truly a case of development by the book. From the start, we sought to come up with the best possible answers by asking ourselves the right questions, i.e., What does the market need? How can we offer more than other manufacturers do? These requirements were clearly established as our goal. The teams worked in close collaboration with each other and the solidarity was phenomenal. Because we achieved all the main goals, I'm sure that the machine will be a success. AHEAD: What do you consider the main strengths of the PX? Ammer: In terms of flexibility, we are clearly setting the standard in the marketplace. We have a massive availability of clamping unit and injection unit combinations and we can create a high-performance machine by taking a simple machine and adding a number of optional features to it. It's also possible to use it as clean room equipment, which is something that our Asian competitors cannot do at present. AHEAD: What are your goals going forward? Ammer: Next, we want to address the high clamping force ranges. Our plans for the coming years are already quite concrete in this regard. Our modular concept is completely scalable and will be implemented in a market-oriented manner.

10 10 Brand & Markets AHEAD Issue Brand & Markets KRAUSSMAFFEI REACTION PROCESS MACHINERY A WORLD LEADER IN TECHNOLOGY LEADING EXPERTS FOR LEADING SOLUTIONS KraussMaffei is the leading supplier of reaction process machinery worldwide. Our expertise is based on almost half a century of experience. The result is over 20 processes the entire current technology spectrum of reaction process machinery. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI O ne significant and very advanced group using reaction process machinery is the automotive industry. KraussMaffei provides that industry and others with solutions for the various application areas. Whether the application deals with foaming parts (polyurethane), high-quality surfaces in the interior or the exterior of vehicles or even highly durable, lightweight fiber composite components, our experts have a response on hand to meet any challenge or the means to find one, often through our close collaboration with colleges and universities. Comprehensive expertise KraussMaffei is the only plastics machine manufacturer in the world that delivers all services for both hardware and software, all along the value creation chain, from a single source. The products and services on offer range from machines for all reaction technology processes to mold and trimmer technology, and on to process solutions for wet and dry-side equipment, all with the necessary automation and automotive testing. The range of processes extends from the clear coat molding surface process to the custom solution of structural reaction injection molding (S-RIM) with thermoset polyurethane. This also includes a wide variety of processing methods in between, e.g., for manufacturing composites, generating various surfaces, from leather grain to a piano lacquer finish, and providing solutions in foaming polyurethane for interior auto parts, seat cushions or refrigerator insulation.

11 KraussMaffei Brand & Markets 11 Lightweight construction/ composites Pioneering technologies A unique focus of our development process is the manufacturing of composites, particularly in large industrial applications. A major topic in vehicle manufacturing for road and rail is lightweight construction, for ecological as well as economical reasons. Fiber-reinforced plastics combine low weight with high stability and increasingly stand in for more traditional materials such as steel or even aluminum. KraussMaffei is a world leader when it comes to technologies such as LFI (long-fiber injection) or HP-RTM (high-pressure resin transfer molding). For all applications with reaction process machinery, we can supply complete production lines with all upstream and downstream process steps. Furthermore, KraussMaffei is a system provider in product areas involving mixing heads and dosing machines, presses, die cutters, flexible cutting systems and foaming tools, as well as machines and systems for insulation applications. Automotive interior Insulation/major appliances Surfaces Engineering passion Of course, our experts are not content with what they have achieved so far. The company hopes to continue to influence trends and developments in reaction process machinery and to promote the technologies. Today, it is already developing solutions that customers will be able to use tomorrow to strengthen their market position even further. Please visit our newly redesigned website if you want to find out more about the fascinating world and applications of KraussMaffei Reaction Process Machinery and its applications: Special solutions

12 12 Brand & Markets AHEAD Issue LIVE DEMONSTRATION AT K 2016 T-RTM: THE PERFECT COMBINATION Continuous fibers, short cycle times, weldability and recyclability: KraussMaffeiʼs T-RTM process combines the benefits of reaction process machinery, thermoplastic materials and shaping in a resin transfer molding (RTM) process, providing the perfect combination for state-of-the-art lightweight construction as a result. TEXT: PETRA REHMET PHOTOS: FORWARD ENGINEERING A t the K 2016 trade show in Düsseldorf, KraussMaffei will be showcasing the manufacturing of an automotive fiber composite structural component with metal inlays under series production conditions. Frames for the roof shell of the Roding Roadster R1 sports car will be created several times at the trade show booth. The Roadster roof frame is based on a hybrid construction of fibers in conjunction with plastic and metal. The production process on the KraussMaffei K 2016 exhibition booth will last about two minutes. The system is intended for high-volume projects and is designed for multiple-shift operations, explains Erich Fries, Head of the Composites/Surfaces Business Unit at KraussMaffei. The T-RTM process has various benefits over parallel plastic processing processes, e.g.,the familiar RTM with epoxy resin or polyurethane (PUR). The low viscosity of just five millipascal-seconds (mpa s) similar to water allows the matrix material caprolactam to penetrate the fiber layers even with low internal mold pressures. For the application demonstrated at the exhibition, a clamping force of approx kn s is sufficient, meaning lower costs for investment and energy. In addition, the high flow capacity allows the minimum wall thickness to be reduced and the fiber volume content increased by about 60 percent. Less material consumption A so-called near-net-shape approach, which is closely contoured production, allows the material input rate of plastic and expensive carbon fibers to be reduced. That, in turn, reduces material costs. In addition, the post-mold finishing steps are also kept to a minimum. While the component has to be separated from the edge area (for example, by milling) for processes that are not near the final shape, a simple stamping or cutting process can be used. Besides the near-net-shape approach, the PREMIERE AT K 2016 The frame for the roof shell of the Roding Roadster R1 sports car, manufactured using the T-RTM process.

13 KraussMaffei Brand & Markets 13 T-RTM IN BRIEF KÜRZE In the case of thermoplastic resin transfer molding (T-RTM), a preshaped semifinished product made of fiber layers is infiltrated in a press mold with caprolactam, which was fused and mixed from two components (caprolactam base plus activator/catalyst) immediately beforehand. A chemical reaction hardens this in the cavity to form the thermoplastic polyamide 6. multi- preform concept also effects a further reduction in fiber waste and allows a (sectional) load- dependent fiber architecture. Compared to the three-dimensionally networked thermosets, the chain-like structure of thermoplastics constitutes a unique attribute: they can be reheated and reshaped, making them weldable and recyclable. The roof frame material can be regranulated and used together with its fiber portion to produce parts in the injection molding process. The mechanical properties of polyamide 6 are also interesting for structural components. The thermoplastic features higher impact strength and more ductile fracture behavior than thermosets. That means that forces can be absorbed by the material deforming before a fracture occurs. High fiber content When T-RTM is compared to injection molding, the classic area of application for thermoplastics, its benefits can also be seen in its high fiber content and low viscosity, which allow the production of parts with very thin walls. For structural components, T-RTM represents a useful supplement to the familiar RTM technologies and KraussMaffei is making full use of its extensive expertise in plastics processing. KraussMaffei is the only supplier on the market to manufacture both mixing and metering technology and presses smaller than 1,000 tons in its own facilities, enabling us to drive development of the overall system, explains Fries. YOUR CONTACT: Erich Fries Head of the Business Unit Composites/Surfaces erich.fries@kraussmaffei.com

14 14 Brand & Markets AHEAD Issue THE SMALL TWO-PLATEN MACHINE FEATURES INCREASED EFFICIENCY A CX ON TOUR ACROSS EUROPE The small CX has always been a model of success. In 2015, the injection machine series with clamping forces of 350 to 1,600 kn was completely reworked and every opportunity was taken to increase its efficiency. It is now 15 percent faster, uses 10 percent less energy and requires 20 percent less oil volume. It had the chance to show its strengths on a road show. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI, ISTOCKPHOTO Permanently installed on a platform as a plug-and-play machine, the CX went on a tour throughout Europe by truck in mid- June of Its job was to demonstrate the qualities of the innovative injection molding machines to existing and prospective customers by representing the entirety of the new small CX series. The first stops were Romania and Italy. In mid-july, the small CX visited our cooperation partner Stäubli Connectors in Bayreuth, Germany. Hungary, Slovenia and the MSV trade show in the Czech city of Brno followed afterwards. One of the most recent visits took place in May of 2016 and was to the Austrian sporting equipment manufacturer HTM Sport GmbH (in Tyrol, Austria). Excitement for the APC machine function Numerous visitors at all locations gave overwhelmingly positive feedback. The APC (Adaptive Process Control) function generated a lot of interest. This function automates compensation for disruptions in the continuous process. On the screen of the MC6 control system, the visitors got the chance to follow along in real time as the system responded to events such as changes in the proportion of recycled material in the melt and the resulting fluctuation in viscosity, all in the same cycle. This function brings the user significantly closer to zero-defect production, says Cordula Regensburger, Product and Technology Management KraussMaffei. This function lets us provide an important contribution to production efficiency. This also applies to the accelerated mold change enabled by the new series. The mold change is made possible by the new mechanical ejector coupling from KraussMaffei in conjunction with the mechanical bayonet clamping systems from Stäubli. YOUR CONTACT: Cordula Regensburger Product and Technology Management cordula.regensburger@kraussmaffei.com

15 KraussMaffei Processes & Products 15 CX RECIPE FOR SUCCESS CX: NOW ON A LARGER SCALE Processes & Products The smaller model was only the beginning. The successful CX line from KraussMaffei, which previously provided up to 1,600 kn of clamping force, has undergone an enormous increase in efficiency as a result of an extensive new design. At K 2016 in Düsseldorf, the larger machines will now follow with clamping forces ranging from 2,000 to 4,200 kn. Two additional core themes are functional integration into the machine housing for compact dimensions and maximum flexibility for technologies such as FiberForm. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI T he focus during the redesign of the hydraulics concept was placed on optimizing the energy efficiency of the entire machine. By offering the new generation of the CX series with a clamping force range of 2,000 to 4,200 kn, we are providing our customers with an outstandingly cost-effective and precise two-platen machine, says Dr. Hans Ulrich Golz, President of the Injection Molding Machinery segment of the KraussMaffei Group and Managing Director of KraussMaffei. In total, the energy efficiency was already improved by 10 percent for the basic machine. The BluePower clamping block was redesigned with regard to flow dynamics. This means a saving potential of 40 percent in the clamping movement. In addition, the travel movements are noticeably smooth and extremely precise. How consistent the optimized efficiency is can also be seen in the new state-of-the-art drive concept (IE3 types). Further energy-saving potential (10 to 40 percent) is also provided by the BluePower ServoDrive. An active accumulator management system completes the overall concept. Other advantages result from the service life of the oil being increased by at least 25 percent. This is possible thanks to a new filter concept. Less shearing means longer oil service life. This is assured by converting to a bypass oil filter/cooling system. Compact two-platen machine The CX has been known on the market for many years as a compact two-platen machine, and even occupies less space than longer three-platen models. Under the clamping unit, it provides space for peripheral devices and all kinds of demolding systems. Innovative integrated automation solutions follow this basic idea, for example the inclusion of a robot within the machine housing. This saves considerable production space and thus basic costs. Because the noise emissions have been reduced by means of additional sound insulation and gentler oil preheating, injection molding production and assembly workplaces can be especially closely coordinated with each other. Access for service and maintenance purposes has also been improved. THE SMALL CX Clamping forces up to 1,600 kn 10% less energy 15% faster 30% quieter 25% more efficient

16 16 Processes & Products AHEAD Issue CX FROM 2,000 kn Maximum flexibility Anyone manufacturing various articles needs a high degree of flexibility in the machinery pool in order to be able to react quickly to all customer requirements. With us, all customers will find the perfect machine for their specific needs, from the wage-earning injection molder to the technology corporation. Using various modules, they can configure their respective machines individually in accordance with their own requirements, says Golz. A high level of flexibility here is ensured, for example, by the integrated water battery, the automatic tie-bar retraction device and the BluePower efficiency package in the KraussMaffei options catalog. Here, the new CX is the effective basis for further technologies, for example physical foaming (MuCell), multi-component injection molding (Multinject), the processing of organic sheets (FiberForm), silicones (SilcoSet) and thermosets (PolySet and DuroSet). Clamping forces up to 4,200 kn Service life of the oil extended by at least 25% Energy savings potential of 10% YOUR CONTACT: Cordula Regensburger Product and Technology Management cordula.regensburger@kraussmaffei.com

17 KraussMaffei Processes & Products 17 INDUSTRY 4.0 CUSTOM-MADE NETWORK- ING WITH PLASTICS 4.0 Plastics 4.0 is the umbrella term under which KraussMaffei offers its customers very concrete opportunities to take advantage of Industry 4.0. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI, ISTOCKPHOTO APC PLUS A MAJOR STEP TOWARD PLASTICS 4.0 Process Control byapc + W hen KraussMaffei introduced the Adaptive Process Control (APC) automation tool at Fakuma 2014, it was a sensation. At K 2016, the company is going one better. The successor system, APC plus, regulates with greater precision and features higher sensitivity to the material and environment. This represents another major step toward Plastics 4.0, KraussMaffei s industry-specific version of Industry 4.0. APC, the adaptive process control of Krauss- Maffei, worked very well. It responded to fluctuating material qualities and flow resistances, shortened the cycle times and the energy efficiency and allowed for the use of high proportions of recycled materials, resulting in a proportionately high yield of good parts. The central purpose of the APC system was to keep the processes stable. It was already quite close to achieving this goal. The new APC plus is allowing us to advance development one large step further, says Cordula Regensburger, Product and Technology Management KraussMaffei. Among the numerous innovative and intelligent features, one feature that stands out, for example, is the ability to take into account the specific behavior of a raw material. APC plus is able to learn even better than APC. It offers even greater precision in detecting process fluctuations triggered by changing ambient conditions, such as temperature or humidity, caused by fluctuating viscosity in the materials and due to other factors. And it automatically takes measures to counter the fluctuations. Intelligent machines In addition to the scope of services of the predecessor APC, APC plus makes additional processes possible, including the manufacturing of thin-wall articles and process control in cascade injection molding. Along with the processing of thermoplastics, the APC function is now also suitable for multi-component injection molding and processing silicone. APC plus makes machine operation even more convenient than before. For example, the operator can use the control panel of the injection molding machine to select from a drop-down list of the 20 most common base materials. But the operator also has the option of entering the parameters directly for materials for which this data has not been stored. In addition to easier handling, the operator will also enjoy noticeably improved process control. By creating the new APC plus, KraussMaffei is taking another step toward its goal of a new, networked Plastics 4.0 industry world, Regensburger reiterates. The KraussMaffei Group believes that Plastics 4.0, the version of Industry 4.0 that relates specifically to plastics processing, has three dimensions: intelligent machines, networked production processes and interactive services. APC plus is an essential contribution to the development of intelligent machines. YOUR CONTACT: Dr. Reinhard Schiffers Head of Machine Technology reinhard.schiffers@kraussmaffei.com

18 18 Processes & Products AHEAD Issue PERSONALIZED CUSTOMER SERVICE TO BE MADE AVAILABLE VIA THE WEB D igitalization is finding its way into service. By introducing an interactive service platform, the KraussMaffei Group is looking to implement the third pillar of its Plastics 4.0 strategy: interactive services. AHEAD spoke with Markus Bauer, Director of Service for Injection Molding Technology at KraussMaffei, about the goals and the benefits of eservice. AHEAD: Mr. Bauer, how would you describe the interactive service? Bauer: To us, interactive services are systems and services of a globally active service organization that are based on state-of-theart communication technologies. Interactive this is a useful connection of automated, highly efficient procedures and the one-toone communication of our customers with our specialists. It will increase our ability to respond while also allowing us to give our customers better support. An eservice platform will place our customer service firmly within the industry 4.0 era. AHEAD: What specific goals are you working toward with the development of this platform, which is sure to require a substantial investment? Bauer: The plan is for the new eservice platform to be accessible at all times through all of our websites. It is meant to provide customers all over the world with professional support and will do so quicker and more responsively than before. Our hope is to increase customer satisfaction with this platform. AHEAD: What will correspondence with a customer look like in practice? Bauer: The customer will have access to a dashboard via our eservice platform, where a clear and comprehensive overview of all relevant information, e.g. machine documentation, will be provided. A ticketing system will provide for automated inquiry tracking and an optional remote maintenance system will help move things along further. If, in the future, a need for repair is identified, the required spare parts will be checked for availability within the integrated online store and then ordered. With these and other advances, service processes will be handled in more simple and efficient manner. We will be running live demonstrations at K 2016, for instance, with the help of QR codes that are generated when necessary, our customers will automatically be forwarded to the online platform and all rele vant data for quick support, as well as error messages and software updates, provided. YOUR CONTACT: Markus Bauer Head of Service for Injection Molding Machinery markus.bauer@kraussmaffei.com

19 KraussMaffei Processes & Products 19 MORE TRANSPARENCY IN THE INJECTION MOLDING PROCESS I ndustry 4.0 means digitalization and networking. Digitalization means collecting data and making it useful (through analysis) to a greater extent than was previously possible. DataXplorer is a tool offered by KraussMaffei that brings precisely this capacity into the production process and the process is mostly automated. In many processes within plastics processing, there is still room for more efficiency. The problem is simply figuring out how this can be achieved in order to make the right adjustments and allocate resources effectively. Plastics 4.0 is the category under which KraussMaffei offers its customers very concrete opportunities to take advantage of Industry 4.0. Together with our partner iba AG (Fürth), a specialist for data evaluation, KraussMaffei has developed a tool that records process data in full with detailed precision and enables evaluation and documentation in the injection molding at a higher level of quality than ever before. Insight at the highest level DataXplorer records and saves all relevant data of the ongoing process continually with detailed resolution over time. The signal paths and long-term temperature trends are available in visualized form right on the control panel of the MC6 control system. This allows you to track the events of the system and the relationships in the production process directly. When setting up and optimizing processes, the user can compare curves right at the machine and detect differences. The history of values over the last seven days is available on the machine itself. Of course, the system also allows users to view longerterm data. All data can be saved to external devices, from a USB stick to a PC to the company network. Additional systems then allow the seamless documentation of production processes in the form of curves or selfdefined key performance indicators. Software from iba AG is then available as an option for deeper analysis. These applications provide intuitive operation while still providing indepth functionality. YOUR CONTACT: Dr. Reinhard Schiffers Head of Machine Technology reinhard.schiffers@kraussmaffei.com By offering DataXplorer as an open system for data acquisition, we are reaching the core of Industry 4.0 and enabling our customers to realize their visions for the future. DR. REIHARD SCHIFFERS, HEAD OF MACHINE TECHNOLOGY

20 20 Processes & Products AHEAD Issue ONE-SHOT PROCESS FOR HIGH-GLOSS SURFACES COLORFORM IN SERIES The ColorForm process developed by KraussMaffei passed the series production tests with flying colors. Since June 2016, the Swiss company Weidplas GmbH has been producing the ready-to-install A pillar paneling for the new Peugeot 3008 SUV at its factory in Rüti, Switzerland. The high-gloss, black lacquered surfaces are produced right in the injection mold. B y developing the ColorForm process, KraussMaffei revolutionized the manufacturing of components featuring a high-gloss finish. It makes us all the more proud that our customer, Weidplas, has now incorporated the process into a series application for a large OEM, explains Dr. Hans Ulrich Golz, President of the Injection Molding Machinery segment of the KraussMaffei Group. The ColorForm technology combines injection molding and reaction process machinery and enables fully automated manufacturing in a one-step production cycle. First, a thermoplastic base body forms in a mold, which is then flow-coated directly in a second cavity using a two-component polyurea (PUA) or polyurethane (PUR) paint. The result is a finished component with the desired lacquered color assignment and a premium-quality surface, produced within one injection molding cycle. Positive first experiences with the ColorForm technology from KraussMaffei had led Weidplas to become a project partner back at K We see the added value of the ColorForm technology in the high design freedom of the components. Clear varnish, depth effects, piano black, even metallic effects anything is possible. Additional functional integrations or multi-color lacquer can also be implemented without any problems, says Steffen Reuter, Vice President of Innovation & Technology at Techniplas, which owns the Weidplas Group. Regarding the concept of the ColorForm production cells currently installed in the Rüti factory, we opted for the swivel plate technology that TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI

21 KraussMaffei Processes & Products 21 We see the added value of the Color- Form technology in the high design freedom of the components. STEFFEN REUTER, VICE PRESIDENT OF INNOVATION & TECHNOLOGY AT TECHNIPLAS has been implemented in a SpinForm GXW injection molding machine with a clamping force of 6,500 kn. The cover with the Color- Form surface and the seal carrier lying underneath are injected simultaneously. The second injection unit of the injection molding machine is used to apply a TPE sealing element to this carrier. This produces one set per cycle with left and right A pillar paneling. The reaction system technology for the Panadur Black polyurea lacquer is also from KraussMaffei. A 2-component metering machine of the Hybrid Flex 0.2-4/4 variety with a servo electric metering piston is used for the abrasive A components. A 2-component MK5/8ULPK-2KVV mixing head is also used, which is flange-mounted on the injection mold. KraussMaffei also acted as the system provider of the completely automated cell where an IR 1500 six-axis robot from Kuka takes over the complex handling of the components. This includes aspects such as component demolding, sprue cutting as well as placement on, and removal from, the cooling station and rotary table. Handling during ultrasonic welding of the upper and lower parts presents a particular challenge. After an extended cooling time, the covers are initially placed into an ultrasonic welding system made by KLN. Here, they MORE SLENDER, MORE COMPACT New complete ColorForm machine at K 2016 KraussMaffei is presenting the GW Color- Form, a new, compact machine that integrates all components for complete processing of the paint finishing system. The new standardized configuration enables faster project launches and reduces engineering effort. Especially for new users, this makes the introduction into the one-shot process easier. To find out more about the maschine, please visit: k2016.kraussmaffeigroup.com

22 22 Processes & Products AHEAD Issue The system expertise and the outstanding collaboration of the teams have consistently led to success. NICOLAS BEYL, PRESIDENT OF THE REACTION PROCESS MACHINERY SEGMENT OF THE KRAUSSMAFFEI GROUP are cut, mounted onto seal carriers and welded in the follow-up process. Thanks to the fully automated process, consistently high quality of the finished components is guaranteed. The fact that we have come so far with the ColorForm technology can certainly be attributed to KraussMaffei s ability to supply the three technologies that are critical to this process: injection molding, reaction process machinery and automation. All from a single source. The system expertise and the outstanding collaboration of the teams have consistently led to success, says Nicolas Beyl, President of the Reaction Process Machinery segment of the KraussMaffei Group. Elegant design element Today, Weidplas is the sole supplier that produces the A pillar paneling for the new Peugeot The paneling seals the windshield for the pillar of the SUV. Due to its high-gloss black appearance, the paneling also serves as an elegant design element of the vehicle series, which was designed to meet premium standards. Weather resistance, color durability and scratch resistance were tested continuously during the development project. These results were the basis for receiving the series order in the first place. The geometry of the component posed a particular challenge. The component has a length of one meter and a width of 35 millimeters. The ColorForm process has never been used to create such a long, narrow component before. We had the courage to begin implementing ColorForm technology because we were confident about it and we still are. I am positive that we are going to open up the field for the compact class as well thanks to the premium appearance that can be achieved through ColorForm. ColorForm will be a success, says Reuter. And Weidplas is on board with this investment in cutting-edge technology. Thus, a second series order for an additional OEM has already been placed. YOUR CONTACT: Philipp Lachner Product & Technology Management philipp.lachner@kraussmaffei.com

23 A NEW SEAL END PIECE FOR POLYURETHANE MOLDS SMALL HELPER WITH A BIG IMPACT The new SealStar from KraussMaffei Reaction Process Machinery ensures safe and efficient sealing in corner and connection areas for polyurethane back-foaming. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI ESPECIALLY TIGHT SEALING The new SealStar seal end and connection pieces in molds for polyurethane back-foaming. M olds for polyurethane back-foaming components such as instrument panels requires having especially tight sealing. Here, special inflatable standard sealing hoses inserted into the mold guarantee that polyurethane does not leave the intermediate space between the film and injection molded part. These sealing hoses are made from silicone rubber or latex and are available either with or without a sealing cord. However, using them becomes difficult for end and connection pieces. This is where the greatest risk of over foaming is. With the SealStar, we developed a new, all-purpose sealing system, the full length of which can be inflated to match the present component contour, ensuring an optimum seal. This reduces additional rework significantly, explains Nicolas Beyl, President of the Reaction Process Machinery segment at KraussMaffei Group and Managing Director of KraussMaffei. The SealStar can be placed in various installation situations. Specifically, this makes sealing possible without problems in otherwise critical high-angled areas. The entire sealing path remains the same for ventilating / degassing the component and the risk of residual inclusions is minimized. Cost-effective manufacturing and easy handling Thus, not only is the SealStar a top performer in terms of sealing, but it is also an attractive option thanks to cost-effective manufacturing and easy handling. The SealStar is a seal end and connection piece with a relatively simple structure and is made of silicone rubber. Manufacturing them is significantly more cost-effective compared to all mechanically operated systems on the market, Beyl states to summarize the cost-effective advantages. It can be replaced quickly and easily during ongoing production without any additional tools. YOUR CONTACT: Dieter Bühler Sales Interior Trim dieter.buehler@kraussmaffei.com

24 24 Processes & Products AHEAD Issue NEW CLOSE-TO-PRODUCTION MANUFACTURING CELLS FOR FIBERFORM TECHNOLOGY LIGHTWEIGHT CONSTRUCTION WITH A ROBOT BALLET Complex technologies have to be easy to operate in order to become accepted, such as in the production of fiber-reinforced lightweight components. KraussMaffei has perfected its FiberForm process even further and is presenting a close-to-production manufacturing cell at K 2016 in Düsseldorf. Trade show visitors can observe the manufacturing of a prototype component for the automotive industry. TEXT: DR. SABINE KOB, PETRA REHMET PHOTOS: KRAUSSMAFFEI F iberform entails the thermoforming and over-molding of organic sheets, which are plate-shaped semifinished products with continuous fibers made of glass, carbon or aramid embedded in a thermoplastic matrix made of polyamide (PA), polypropylene (PP) or other matrix systems. In this process, these semifinished products are first heated, reshaped in the injection mold and then back-injected with a fiber-reinforced polymer. Parts with integrated organic sheets have significantly better mechanical properties compared to those that are purely composed of short-fiber-reinforced injection molding material. For example, manufacturing complex structural components results in completely new design options, explains Thomas Marufke, Managing Director of Automation Technology at KraussMaffei. A significant part of the process is heating the organic sheet, because overheating the organic sheet leads to thermal degradation of the matrix and, therefore, to scrap. Thus, KraussMaffei developed a control process for infrared emitters that is fully integrated into the MC6 machine control system. Here, the new control process not only enables a fast heating process without exceeding the set temperature, but also makes it possible to check the current heating curves in process data acquisition. Finally, heating time and actual temperatures are stored for each individual component. This is important for customers who have to produce safety- related articles and document all process steps. Intelligent automation concept saves cycle time Another new innovation concerns automation within the manufacturing cell. Within the protective housing of the CX-300 machine, two LRX-250 linear robots were installed, which are coupled on a shared Z-axis. They do something that may be seen as inefficient at first glance: they transfer the organic sheet. Actually, this trick saves cycle time, because the semifinished product is heated and the finished component is removed simultaneously.

25 KraussMaffei Processes & Products 25 LIVE DEMONSTRATION OF INDUSTRY 4.0 Live at the KraussMaffei trade show booth, the FiberForm system will demonstrate how the vision of Industry 4.0, the networking of machines and production processes, can be implemented efficiently in plastics processing and highlight the advantages this creates. All quality-oriented process data for example, organic sheet heating curves or injection pressure curves is not only recorded in a KraussMaffei database, but also documented individually using a QR code on the component. A printer integrated into the machine housing prints the QR codes immediately during manufacturing; the respective QR code is affixed to the component. This makes it possible to seamlessly trace all product and process data for each component globally, online via mobile phone, tablet or PC. Robot 1 picks up the organic sheet and hands it to robot 2. Then, the robot moves to the position for component demolding. Robot 2 feeds the semifinished product into the infrared oven and brings it into the injection mold after heating it. From there, robot 1 removes the finished part. Compared to earlier versions of automation, the process was able to be harmonized even further. This improved the process capability even more, explains Thomas Marufke, Managing Director of Automation Technology at KraussMaffei. The robot 2 grippers were also optimized further to be able to transport the organic sheet which is approximately 280 C and, therefore, flexible from the oven into the injection mold without fluttering. By integrating all handling processes into the standard machine housing, there is now space for six machines, where previously, only five could be accommodated. YOUR CONTACT: Michael Flurl Product Management michael.flurl@kraussmaffei.com

26 26 Processes & Products AHEAD Issue NEW MOLD CARRIERS OF KRAUSSMAFFEI A NEW DIMENSION IN VERSATILITY AND FLEXIBILITY The requirements for state-of-the-art mold carriers are diverse and complex. Design has to take into account high clamping forces and the greatest precision, mold weights on the order of tonnes, and fast driving and swivel motions for the process, as well as ergonomics. At K 2016, KraussMaffei will be showing particularly innovative mold carriers. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI

27 KraussMaffei Processes & Products 27 RIM/ROM MOLD CARRIERS FOR A WIDE SPECTRUM OF APPLICATIONS RIM/ROM MOLD CARRIERS Represent a new generation of carriers that can be used in particularly versatile ways. The new mold carrier was specially designed for Reaction Injection Molding (RIM) and Reaction Over Molding (ROM). A particular feature is the extremely variable use. Depending on the processing task, one or two mixing heads can be docked on the mold for foaming into place. The mold-halves can also be located opposite the operator for perfect ergonomics. The layer to be foamed in is to be continuously adjustable between zero and 90 degrees. The very large parallel stroke of 1,000 millimeters also enables foaming in when the mold carrier is open. The electrically operated carrier works without a hydraulic system, so it is quiet and exceptionally clean. Nevertheless, up to three hydraulic mold functions can be implemented. That is made possible by using the mixing head hydraulic system installed on the mold carrier. The carrier is designed for using either one mixing head with up to five colors or two mixing heads. In both cases, the pipework is cleanly routed across the pivot points of the mold carrier. enables molds to be changed without a forklift. Then the molds are moved in and out using special trolleys. The overall planning of the foaming system accommodates a special feature of the carrier. It can be configured as a mirror image, so that the planner can arrange multiple carriers in a way that is particularly friendly for the process and the operator. Michael Schulze, Team Manager for Project Engineering and Project Management, proudly states, This mold carrier represents a new generation of carriers that can be used in particularly versatile ways not only in applications in the automotive industry, but also in many other areas. And with its performance data and features, it is another contribution from KraussMaffei to the overall equipment effectiveness. The new flexible generation The carrier is suitable for molds with a total weight of up to 4,200 kilograms. The strong mold fixing platens allow for use of a broad range of mold sizes and weights. The adjustable clamping force of up to 50 tonnes is built up using only pneumatic force. The very open design enables the use of a robot to apply the release agent onto the two mold halves; the robot is positioned behind the mold carrier. The configuration of a roller system also YOUR CONTACT: Michael Schulze Team Manager for Project Engineering and Project Management michael.schulze@kraussmaffei.com

28 28 Processes & Products AHEAD Issue Swivel range between 0 and 90 degrees STEERING WHEEL MOLD CARRIER Clamp tilt position can be adjusted continuously and individually. FLEXIBLE, SCALABLE AND EASY TO OPERATE: THE NEW STEERING WHEEL MOLD CARRIER When developing the new steering wheel mold carrier, the engineers of KraussMaffei pursued three essential goals: high flexibility, high ergonomics and maximum machine availability. They completely achieved these goals. The individual mold carrier provides high flexibility plus good operability, since the clamp has a tilting option that is continuously and individually adjustable. Both for the foaming and for the response phase, the swivel range expanded with the new mold carrier is between zero and 90 degrees. The 90-degree foam position enables the mold to vent air through the separating half. As a result, there is less waste and the material consumption can be reduced. The machine operator also benefits from the option of tilting because the handling position is freely adjustable in a range from zero to 40 degrees. Modular design The production system for steering wheels can be easily scaled depending on the capacity requirements. The modular design provides for that, as each station has its own hydraulic unit and its own proportional controller. Thus, the user can arrange multiple units of this kind side by side at will and have them run in both individual as well as synchronous cycles, which are programmed using the touch panel. Thanks to this independent control of multiple mold carriers, the system achieves the greatest machine availability. In addition, the greatest flexibility in factory planning is provided by the option of simply shifting each mold carrier from one system to the next. The mold carriers can be quickly installed on-site, and the expansion of existing systems is possible without any significant production interruptions. The mold carrier can handle both hydraulic and pneumatic mold functions. The clamping forces of the mold reach up to ten tonnes and are variable throughout the mold carrier cycle. The customer can personally and conveniently program this cycle using the control system s touch panel. YOUR CONTACT: Simon Eckart Project Engineering, BU Molded Flex/Interior Trim simon.eckart@kraussmaffei.com

29 KraussMaffei Processes & Products 29 The personal commitment of the employees at KraussMaffei exceeded the classic supplier-customer relationship. THOMAS VOLZ POLYURETHANE FOAMING OF SMALL TO LARGE SERIES VERSATILITY AS A RECIPE FOR SUCCESS Foamed PUR parts are the specialty of Volz GmbH in the Swabian city of Balingen-Frommern. For mixing and metering machines, the company has always relied on the systems expertise of KraussMaffei Reaction Process Machinery. TEXT: DR. HARALD SAMBALE, PETRA REHMET PHOTOS: VOLZ T he range of products from Volz GmbH includes parts made from soft, semi-rigid and hard foam, as well as sandwich components, where the polyurethane foam is combined with materials such as metal or thermoplastics. All polyurethane propellants including pentane are used in the processing. Volz produces order- specific components in very small quantities, but can also manufacture large series with hundreds of thousands of components per year. This flexibility is the company s strength. KraussMaffei system expertise For the mixing and metering machines, as well as the mixing heads, we rely on the systems expertise of KraussMaffei, states Thomas Volz. In addition to the safe process control and the high component quality, the fast supply of spare parts also plays an important role. The importance of a trusting relationship between a machine manufacturer For the mixing and metering machines, as well as the mixing heads, we rely on the systems expertise of KraussMaffei. THOMAS VOLZ and polyurethane processor is clearly shown in extreme situations. When the production facilities of Volz were completely destroyed by a fire in 2013, the existence of the company was at stake. In order to observe supply agreements, emergency production facilities were set up in the former warehouse with active support from the KraussMaffei team. Thanks to the quick delivery of replacement machines production was up and running again on seven machines within a few weeks. In difficult situations like these one needs a strong and reliable partner, adds Thomas Volz in retrospect. The personal commitment of the employees at KraussMaffei exceeded the classic supplier-customer relationship. The quick resumption of production meant that we didn t lose a single customer as a result of the fire. In the meantime, production at Volz GmbH has returned to normal. The production systems cover a very broad range of products. Volz says, The product range also includes parts weighing only a few grams, as well as

30 30 Processes & Products AHEAD Issue Shift lever knob for commercial vehicles 02 Floor mat 03 Fitting supports 04 Housing paneling for the laboratory area 03 The product range also includes parts weighing only a few grams, as well as large-size polyurethane components with an area of several square meters. THOMAS VOLZ 04

31 KraussMaffei Processes & Products 31 large-size polyurethane components with an area of several square meters. The customer base is also just as diverse. The companies that have their parts manufactured here come from various industries, such as medical technology, construction engineering, labora tory technology, aerospace, furniture making, as well as the automotive and commercial vehicle industry. Eleven machines in various sizes from the EcoStar series of KraussMaffei are currently in operation in the company s production halls. The EcoStar metering machines are equipped with premium-quality components, thus offering superb quality at low investment costs. A different foam system is processed on each machine. In order to make optimal use of the machines, in many cases three to four orders are processed in parallel on each machine. The EcoStar machines are ideally suited for the extensive product range of Volz, as they can be deployed universally in polyurethane processing. The transfer mixing heads of KraussMaffei also contribute to the consistently high product quality. They can be flexibly adjusted to various material systems and can also process difficult-to-mix components at the highest level of quality. For this type of mixing head the discharge tube is attached at a 90 angle to the mixing chamber and relaxes the mix as it is poured. Transfer mixing heads are therefore exceptionally well suited to laminar, splash-free pouring of the mixture into open molds. Hybrid machines for corrosive flame retardants The polyurethane parts have to comply with stringent fire safety requirements in many applications. At Volz, phosphorous flame retardants are used, which are added to the polyol components. As they are chemically integrated in the polyurethane foam, these flame retardants cannot escape from the polyurethane foam during the service life of the component. However, the flame retardants in the polyol component have a corrosive effect, meaning they cannot be metered using normal pump systems. This is why Volz uses two different versions of hybrid machines from KraussMaffei for these material systems. With the hybrid machine the polyol component containing the flame retardant is introduced using a metering piston. The Hybrid E-Tandem model is equipped with two electric metering pistons for the polyol component, thus creating a continuous stream, explains Steffen Bauer, Head of Sales & Marketing in Germany for Reaction Process Machinery at KraussMaffei. Automation with rotary table system In order to satisfy the wide variety of customer requirements with even greater speed and flexibility in the future, an additional rotary table system from KraussMaffei with ten stations was put into operation in January This system is supplied with material from a RimStar Compact mixing and metering system. The challenge lies in the fact that different components are manufactured at the individual stations, explains Steffen Bauer. The machine must recognize the respective mold and deliver the variety of the correspondingly diverse fill quantities. Good examples are molded structural foam parts for furniture, such as backrests. Here, both the front and back exposed faces (the surfaces on both sides of the component) must be nonporous. This can be achieved during the manufacturing process by tilting the mold into a closed position after the polyurethane introduction. In doing so, the polyurethane can wet the mold surface completely. The tilting program must be adapted to the component geometry so that flawless surfaces take shape. This tilting process must be performed manually before the commissioning of the rotary table. Thanks to the automation, the component quality was increased and the reject rate was reduced significantly, Volz says in summary. YOUR CONTACT: Steffen Bauer Head of Sales in Germany for Reaction Process Machinery steffen.bauer@kraussmaffei.com

32 32 Processes & Products AHEAD Issue WINDOW ENCAPSULATION FAST CYCLE FOR SEALING EDGES When you need to fit panes of glass in car or utility vehicle bodies so that they are sealed, secure and easy to install, recasting the window edge with PU foam is an optimum solution. The window encapsulation technology (WinCap) from KraussMaffei provides a maximum of efficiency. TEXT: JOACHIM WEBER PHOTOS: COLOURBOX T he sealing material polyurethane (PUR) has a range of advantages in auto making. It is durable, flexible and easily compensates for tolerances. As encapsulation for securely mounted glass panes, PUR also ensures that the window edge is well protected against isolated loads, providing process reliability and easy installation. KraussMaffei has developed a special process for encapsulating panes called Window Encapsulation, or WinCap for short. WinCap is an optimized production concept for the entire process from material processing and filling to the metering machine (RimStar Compact including mixing head) and various mold carriers, to the mold technology and post-mold processing of the pane. Our new, modular mold carrier design lets us reproduce all occurring mold sizes from a design toolkit. CORD HAGENMEYER, PROJECT MANAGER AT KRAUSSMAFFEI Technological leadership through cooperation Together with its cooperation partner, the mold specialist Jaeckel Modell- und Formenbau GmbH, KraussMaffei is capable of implementing the entire process chain from component design to the

33 KraussMaffei Processes & Products 33 completely encapsulated pane in turnkey production lines. The intersection of combined areas of expertise is between the mold (from Jaeckel) and the mold carrier (from KraussMaffei). This results in customized, turnkey series systems consisting of material processing and supply, a metering machine with multiple mixing heads, mold carriers and mold. The interaction of the two is not limited to the mechanical area. An intuitive operator guidance system makes it incredibly easy to program the mold functions and mold carrier movements on the touchscreen display. Saved mold programs can be imported and exported at the touch of a button. Turnkey production line for large-scale series production WinCap mold carriers are specially designed for the requirements of series production. Simultaneous movements (moving straight, tilting) provide for minimum cycle times. The carriers also provide high flexibility and speed when changing molds, Our new, modular mold carrier design lets us reproduce all occurring mold sizes from a design toolkit. This brings the customer a wealth of synergy effects for operation, maintenance and spare parts stocking of the mold carriers, explains Cord Hagenmeyer, Project Manager at KraussMaffei. YOUR CONTACT: Wolfgang Hinz Product and Sales Manager Business Unit Composites and Surfaces wolfgang.hinz@kraussmaffei.com

34 34 Partners & Projects AHEAD Issue Partners & Projects MULTIPLE KINEMATICS SUPPORT MULTI-DAYLIGHT MOLD PRODUCTION AT AUTOMOTIVE SUPPLIER ARKAL AS A TWIN PACK Left and right in a single shot: The automotive supplier Arkal Automotive GmbH produces two door side panels simultaneously on an MX injection molding machine from KraussMaffei at its Crock location in Thuringia. This is made possible through the use of a multi-daylight mold. The unique feature is two LRX linear robots, mechanically coupled on a single axis and centrally operated via a single control system, ensure that components are demolded and deposited quickly and reliably. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI A t Arkal, cycling through production is handled well. The automotive supplier manufactures approximately 3,600 door side panels per week in three shifts. The customer is a large tier 1 supplier. Primary requirements here include high precision and short cycle times. Thirty- percent fiberglass-reinforced PP is processed. Another special feature is that the two components are produced simultaneously on the MX injection molding machine, namely, side panels for the left and right-side front or back door. The combination of MX with an LRX twin robot is ideal for this application and provides our customer Arkal with the shortest cycle times and maximum precision, explains Thomas Marufke, Managing Director of KraussMaffei Automation. The MX series from KraussMaffei excels here thanks to its high melt quality and particularly reliable shot weight consistency. The hydromechanical two-platen clamping unit developed by KraussMaffei ensures fast production. The platen parallelism of the MX series in particular proves the worth of the AS A TWIN PACK The two door side panels on the left and right.

35 KraussMaffei large multi-daylight molds used by Arkal. The molds do not get damaged and are thus protected against wear. High-quality components can be produced over a long period of time. The MX series also ensures that the large multi-daylight molds do not tilt. The matching multi-daylight mold was customized for this application. It is equipped with a flying platen and mold cooling. Complex automation solution A particular challenge is the complex automation of component demolding and depositing. The two LRX 350 linear robots, which are arranged on a shared Z-axis, demold the components in a parallel process, and move them to, and deposit them in, the component storage area. This TwinZ design is ideally suited for transferring components (handshake) during fast component demolding and stacking. This configuration also provides significant space and time savings for automation processes with overlapping motion ranges. The combination of an LRX twin robot with multiple kinematics from KraussMaffei provides us with considerable advantages here when it comes to durability, flexibility and convenience, explains Thomas Reichl, Manager of Production & Maintenance at Arkal. More operating convenience thanks to a single central control system The premiere for this robot type in this design has been extremely successful. For the first time, two mechanically coupled X/Yaxes of the LRX series have been combined on a Z robot axis with a new control concept. Thanks to this design, both linear robots as well as the MX 1600 can be programmed and controlled via the central MC6 control system. This provides a high level of convenience in operating the complex system, explains Reichl. The robots are programmed via the LRX LINEAR ROBOTS Provide for fast and reliable component demolding and depositing. The combination of LRX twin robots with multiple kinematics provides us with significant advantages with regard to durability, flexibility and convenience. THOMAS REICHL, MANAGER OF PRODUCTION & MAINTENANCE AT ARKAL shared program editor. Program commands and parameters can be assigned to individual robots with minimal effort. A joint coordinate system for all axes makes it easier to control specific robots in individual operating modes. YOUR CONTACT: Michael Flurl Product Management michael.flurl@kraussmaffei.com

36 36 Partners & Projects AHEAD Issue RUSSIAN LIGHTWEIGHT CONSTRUCTION RESEARCH CENTER RELIES ON KRAUSSMAFFEI S SYSTEM EXPERTISE IT S A LIGHTER DRIVE WITH COMPOSITES Maximum lightness and first-class surfaces: The large tailgates in the awardwinning electric buses of the Budapest Transport Company (BKV) are the result of the successful combination of LFI (Long-Fiber Injection) and in-mold primer processes from KraussMaffei. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI, NCC High strength, dimensional stability and fitting accuracy combined with low weight: These are the trademarks of large-format components made of fiber-reinforced plastics manufactured with the LFI process from KraussMaffei. If first-class surfaces are also required, then a combination with an in-mold coating process speaks for itself. Our most recent reference is the NCC (Nanotechnology Centre of Composites) in Moscow. The Russian lightweight construction research center invested in the combination of LFI and in-mold primer and is using the system solution for manufacturing a tailgate in a self-supporting composites structure for a public bus. And the concept has proven its value. The modular buses, which NCC has jointly developed with the Hungarian Evopro Group, won over the panel for the JEC Innovation Award 2016 as well as the Budapest Transport Company (BKV). Electric buses with this concept have been operated in Budapest since March The system solution from KraussMaffei offers us maximum flexibility in the choice of colors and surfaces and with simple and cost-optimized processes. DR.-ING. PETER MOLNAR, TECHNICAL DIRECTOR NCC Quick color change and wide range of colors An important component of the public bus is the particularly large-format, two-colored tailgates 2.2 meters in width and 1.4 meters in height. The customer s requirements were clearly defined. The customer asked for a substantial weight reduction and Class A surface quality together with a rigid, high-strength component. A quick color change and, thus, a wide range of colors were also requested. All of this had to be achieved in short cycle times and with cost-optimized production, said Wolfgang Hinz, Product and Sales Manager in the Composites/Surfaces Business Unit at KraussMaffei. A joint decision was made with the customer to use a combination of the LFI and in-mold primer processes. This has one advantage: the surfaces prepared perfectly for individual painting are produced directly and fully automatically in the mold. This allows cycle times to be reduced to a minimum. Firstclass surfaces from high-gloss to matt and a wide range of colors are possible. Thanks to the use of self-releasing primers, there is also no need for external mold separating agents. In the Daimler stone-impact test, components produced using the process perform up to 600 percent better than painted glass-fiber reinforced plastic (GFRP) components.

37 KraussMaffei Partners & Projects 37 Step by step to the desired component The primer is sprayed on in the first process step and the polyurethane barrier coat in the second process step. LFI technology is then used in the third step. The glass fiber strands from the roving and the corresponding PU components are simultaneously discharged controlled by a robot into the open mold in a one-step process. This causes the glass fibers and the carrier matrix to bond into a highstrength composite. That results in significant cost advantages with no need to cut and preshape fiber mat. By comparison with the sheet mold compounding (SMC) process or the Dicyclopentadiene (DCPD) process that were also discussed by the customer, the LFI process offers considerable cost savings, added Hinz. In terms of component weight, the LFI process also scores better than SMC with a density that is up to 55 percent lower. Other advantages of the LFI process are the high fiber volume content of up to 50 percent, which ensures high strength, and the high degree of flexibility in choosing fiber lengths. This permits a wide COMBINATION OF LFI AND IN-MOLD PRIMER Electric buses with this concept have been operated in Budapest since March range of component designs, for example of ribs or function integration. In the last step, compression molding takes place without material flow and there is a reaction in the closed mold. The finished components are then removed and are now ready immediately for additional clear coating or final individual coating. Intermediate treatment or additional pretreatment is no longer necessary. Maximum flexibility for selecting color and surface The system solution developed for NCC by KraussMaffei provides a lot of leeway for additional process combinations, such as with in-mold painting. In this approach, the final paint is applied in the open mold starting in the first step. The spray system can consist of one or two components. Thanks to this wide range of processes, we offer our customers maximum flexibility in the choice of colors and surfaces. These processes are simple and cost- optimized, concluded Hinz. YOUR CONTACT: Wolfgang Hinz Product and Sales Manager Composites/Surfaces Business Unit wolfgang.hinz@kraussmaffei.com

38 38 Partners & Projects AHEAD Issue TURNKEY SYSTEMS FOR VORWERK NEW LOOK FOR THE NEW THERMOMIX The new Thermomix TM5 by Vorwerk features a premium-quality design and more functions intended to make cooking even easier. A success with KraussMaffei s involvement, primarily in the design and implementation of four turnkey systems for manufacturing the rugged high-gloss covers. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI, VORWERK

39 KraussMaffei Partners & Projects 39 S tirring, mixing, chopping, shredding and even cooking, the new Thermomix TM5 by Vorwerk is the multifunctional food processor par excellence. And a real sales hit. The Vorwerk Semco S.A. plant in Cloyes-sur-le-Lori, France, produces one million units of this smart kitchen helper, and the plant in Wuppertal, Germany, produces another 500,000. A total of 24 KraussMaffei injection molding machines operate in the Vorwerk plant in France and produce a wide variety of components, ranging from the lid to the handle. However, the four MX series machines delivered in late 2013 and May 2014 will take over the lion s share for the new Thermomix. Two pairs of twins, each with a clamping force of 11,500 kn, use the three-component process to manufacture the lid for the new food processor. The requirements are high. The lid needs to satisfy high visual requirements in addition to providing resistance to scratches and every kind of corrosive food and spice. The use of three types of plastic make this teamwork a success: PC from Covestro for the white area and a PC/ABS blend for the light gray, recessed part. A PMMA coating from Evonik provides for the necessary visual properties, scratch resistance and chemical resistance. And production moves right along. The MX machines produce the lids in the threecomponent injection molding process with a 59-second cycle. Three injection units provide the mold with the three different plastic melts. Secondary injection unit 1 is in a piggyback arrangement (Z) and secondary injection unit 2 is arranged in a vertical position (V). This injection unit combination provides clear cost advantages for multi-component injection molding. The screw for the PMMA components receives a special coating due to the stringent requirements for an absolutely flawless appearance for the plastic. The three-cavity mold, with a hot runner system from Incoe, comes from the mold-making company Hofmann GmbH from Lichtenfels, Germany, and rotates 120 degrees after each shot in a precisely timed cycle. All of this takes place on an integrated servo-electrically driven rotary table from KraussMaffei. This table works quickly and precisely with outstanding energy efficiency. Even large molds with a maximum weight of approximately 16 tonnes Production using the new injection molding machines was a technological leap forward for us. THOMAS RÜSCHENSCHMIDT, DIRECTOR OF ENGINEERING AT VORWERK SEMCO THE NEW THERMOMIX TM5 Features a premiumquality design and increased functionality.

40 40 Partners & Projects AHEAD Issue THREE-CAVITY MOLD Rotates 120 degrees after each shot in a precisely timed cycle. can be handled just as safely and easily, explains Andreas Handschke, Product and Technology Manager at KraussMaffei. Post-mold processing in a twin pack And manufacturing continues. Two injection molding machines share one post-mold processing system positioned between them. This saves space and optimizes post-mold processing, especially the sprue cutting of the PMMA components. Since the cutting edge is also an exposed edge, ensuring precise cut guidance is absolutely essential. Not even dust can be created during this process, as this may contaminate the transparent PMMA coating. We sell an innovative product and provide our customers with excellent quality as well as premium design, explains Thomas Rüschenschmidt, Director of Engineering at Vorwerk Semco. Then the covers, which are still warm, are carried onward by conveyor to quality assurance and hot embossing with the Vorwerk logo so that they can then be transported to final assembly and assembled for global shipping. The investment pays off Thanks to the further development of Thermomix, Vorwerk has achieved a true top-seller. Production using the new injection molding machines was a technological leap forward for us. KraussMaffei has excellent service and technology. Everything is running smoothly and the machines have an availability level of over 90 percent, summarizes a satisfied Rüschenschmidt. YOUR CONTACT: Andreas Handschke Product and Technology Manager andreas.handschke@kraussmaffei.com COLLABORATIVE PROJECT The engineering teams at KraussMaffei and Vorwerk are more than satisfied with the result.

41 KraussMaffei KraussMaffei Group 41 KraussMaffei Group 10 YEARS OF KRAUSSMAFFEI RE ACTION PROCESS MACHINERY IN JAPAN KraussMaffeiʼs location in Japan is celebrating its 10th anniversary this spring. Since it was founded in 2006, the Reaction Process Machinery subsidiary of KraussMaffei has enjoyed continuous growth and has become established on the market as a leading supplier of premium-quality products and reliable services, particularly in the field of polyurethane soft foam systems and composites solutions. In Japan, KraussMaffei primarily serves customers in the automotive industry with its extensive portfolio of reaction process machinery. A focus here is the field of soft foam systems. KraussMaffei s second area of focus is the growing market for fiber- reinforced plastics. With our advanced products and technologies and highly qualified workforce here, we are able to respond quickly and individually to the needs of our Japanese customers. That is most certainly the key to KraussMaffeiʼs success in Japan. We currently supply numerous major Japanese corporations and suppliers to the automotive and other industries not only in Japan, but also at their international locations, says Nicolas Beyl, President of the Reaction Process Machinery segment of the KraussMaffei Group. Since 2015, KraussMaffei has also been producing customer-specific HP-RTM (High-Pressure Resin Transfer Molding) systems in Japan. AICHI JAPAN KRAUSSMAFFEI USA LOOKS BACK ON A 50-YEAR SUCCESS STORY USA FLORENCE, KENTUCKY The KraussMaffei Group in the USA celebrated its 50th anniversary with a gala open house. The subsidiary welcomed more than 400 customers to the event at its headquarters in Florence, Kentucky on May 18 and 19. The event featured a large number of applications with live demonstrations of the injection molding, extrusion and reaction process machinery divisions, including an Netstal Injection Compression Molding Cell and the new ZE 65 BluePower twin-screw extruder. In addition, new customer-specific technologies, service offerings and informative presentations about optimizing productivity were presented. The Krauss-Maffei Corporation has so much to be proud of. We are the world market leader and have excellent employees and colleagues worldwide. Weʼre passionate about working for this company and this passion is evident every day, says Paul Caprio, CEO and President of the Krauss-Maffei Corporation. He adds, We have highly successful customers who are the focus of our business. We are confident that our company will continue to enjoy this success in the coming decade and beyond. Thanks to all who have contributed to this effort and helped us grow and develop! The company has grown continuously since its founding in 1966 and has become established as a leading provider of plastic and rubber machines on the North American market. Today, it represents all three brands: KraussMaffei, KraussMaffei Berstorff and Netstal.

42 42 KraussMaffei Group AHEAD Issue YEARS OF ROBOT ENGINEERING IN SCHWERIN RENZO DAVATZ IS NEW CEO OF NETSTAL In 2000, the decision was made to found a second location of KraussMaffei Automation GmbH. The development and production of demolding robots in Schwerin were launched on January 1, Over the years that followed, a few new robot types were brought to the market that are updated and evolved continuously. The current linear robot product portfolio includes four robot sizes, and a modular construction system enables up to 350,000 variants. Customer requirements for aspects such as the stroke lengths of the robot axes can be implemented individually by the 27-employee team. The cooperation between north and south Germany is exemplary. The decades of experience in robot construction from Schwerin will be combined ideally with expertise in injection molding technology from Munich, says Jürgen Brands, plant manager in Schwerin. SCHWERIN GERMANY RENZO DAVATZ New CEO at Netstal since July 1, On July 1, 2016, Renzo Davatz became the new CEO of Netstal. He assumed the duties of Dr. Hans Ulrich Golz, who had been managing Netstal as CEO since I am delighted that I was able to acquire Renzo Davatz as my successor. He is held in high esteem by both customers and employees. In recent years, he played a pivotal role in establishing an excellent global position for the service business area of Netstal. I am convinced that he will be successful in managing the Netstal company and further developing the company from a strategic perspective, states Dr. Hans Ulrich Golz. Davatz has been working at Netstal for 25 years and has progressed steadily in the company. He joined the company in 1989 as an apprentice electrical engineer and quickly assumed managerial roles, including Head of Technical Service and subsequently Head of After Sales. Since 2012, Davatz has been Vice President of Service both at Netstal and in the overall segment Injection Molding Machinery of the KraussMaffei Group. He will continue this task. Dr. Hans Ulrich Golz becomes the new Chairman of the Board of Directors of Netstal. With the personnel changes Netstal focuses on continuity and stability in the global positioning of the company and the Netstal brand. Netstal is regarded by customers around the world as a premium supplier of high-performance and high-precision injection molding machinery. I would like to strengthen this leading position and the operational business success together with Markus Dal Pian as Vice President of Sales & Marketing, with whom I have enjoyed a very good working relationship for many years, highlights Davatz. With the expansion of the international competitive position in an increasingly cost-intensive environment, Davatz also wants to safeguard the Näfels site over the long term as a competence center for high-speed premium products with short cycle times and ultimate precision. My goal is to offer our customers the best products and services also in the future. In this respect, I trust in the performance and the exceptionally high commitment and dedication of the global Netstal team. The safeguarding and development of the Näfels site over the long term is especially important to me. Netstal should continue to be a key employer in the canton of Glarus. Because the heart of Netstal has been beating here in Näfels for over 150 years. And it should remain this way, adds Davatz. Netstal-Maschinen AG has been part of the KraussMaffei Group since 1992.