Consumer Packaging

10 Innovative Ways to Achieve

Efficient Consumer Packaging

1 Machine designs to perfectly match requirements

Withourscalingofmachine models,weprovidetheequiva- lentofacustom-builtsolution foreachmanufacturing scenario.

3 High production capacity

KautexMaschinenbauequipment isabletooperateconsistentlyathigh productionrates,duetotop-quality materials,superiorworkmanship,and preciselycontrolledclosed-loopprocesses.

4 Intuitive controls

Amachinecontrolsystemthat hasbeendevelopedwithhelpof continuouscustomerinputenables youtoeasilyoptimizeproduction forthebestpossibleresults.

2 From basic to complex

Wesupplyequipmentfor differentneeds–fromabasic machinetoacomplete turnkeysolution,readyfor production.

Ways to Efficiency 02

10 Ways to Efficiency. 5 Schnelle Markteinführung

InderZusammenarbeitmit unserenSpezialistenvom TechnikumentwickelnwirIhre Prototypenschneller,einfacher undkostengünstigerbiszur Marktreife.

6 Energie- effizienz

EnergieistbeiKautex MaschineneinkostbaresGut. MitallenMittelnwirdsie gespart–inwelcherForm auchimmer.

03

Global competition, global opportunities. Manufacturers

ofconsumerpackagingproductsrecognizethatglobalop-

portunitiescomewithchallenges.Asastrategicpartnerin

thefieldofmachinebuilding,wewould like toofferour

supporttosignificantlystrengthenyourpositionamongthe

internationalcompetition.

The basis of our partnership is our portfolio of consumer

packaging machines for the production of a complete

range of packaging applications. Characteristics such as

flexibility, repeatability,andreliabilityareourhallmark in

conjunctionwithcomprehensivesupportservicesprovided

byouremployees–priortoandafterpurchase.Ouraimis

toprovideafoundationforyourlong-termsuccessincon-

sumerpackaging.

The daily work of our employees is aimed at allowing

your production to progress as smoothly and efficiently

aspossible,alwayswithavisionofthefutureinmind.We

relyonmorethan60yearsofexperience,ourknow-how,

numerouspatents,andtheinventivenessofourengineers.

Yourinvestmentcombinedwithourthoughtfulinnovations

willbecomethefoundationforyourproductivity.

Madetomoveyourbusiness

Ways to Efficiency

Kautex Maschinenbau –

your partner for successful

consumer packaging.

1Machinedesigns toperfectlymatch requirements

Withourscalingofmachine models,weprovidetheequiva- lentofacustom-builtsolution foreachmanufacturing scenario.

3Highproduction capacity

KautexMaschinenbauequipment isabletooperateconsistentlyathigh productionrates,duetotop-quality materials,superiorworkmanship,and preciselycontrolledclosed-loopprocesses.

4Intuitive controls

Amachinecontrolsystemthat hasbeendevelopedwithhelpof continuouscustomerinputenables youtoeasilyoptimizeproduction forthebestpossibleresults.

2Frombasic tocomplex

Wesupplyequipmentfor differentneeds–fromabasic machinetoacomplete turnkeysolution,readyfor production.

Ways to Efficiency 02

10WaystoEfficiency. 5Fastmarket introduction

Incollaborationwithour labspecialists,wedevelopyour productsintomarketable ones–rapidly,economicallyand inaclear-cutmanner.

6Energy efficiency

Energyisahighlyvalued commodityinallKautex machines,anditissaved withallmeansand whereverpossible.

7Easeof operation

Ourmachinesaredesigned foreaseofoperation,allowing youtoworrylessaboutthe equipment’stechnicaldetails andtofocusonproduction instead.

8Flexible production

Withourquickchangesystems, weminimizechangeovertimes andmakemaximumuseofthe flexibilityofyourequipment.

10Maximum availability

Wesupportyoueverywhere andanytime–in45countries, 24hoursaday,andsevendays aweek–sothatyourmachines aresuretorunallthetime.

9Savewith precision

Youwillsavematerials,cycle time,andenergy,because ourmachinescarryoutallsteps oftheprocesswithmaximum precision.

03

Effizienz-BroschüreKautex Consumer Packaging 00

Kautex offers application-specific

solutions for all requirements.

From XXS to XXL.

Ways to Efficiency

– Packaging series KLS, availablemachinemodels: 6-100,8-100,10-100,12-100, and14-100 – Packaging series KCC, availablemachinemodels: 5,10,15,20 – Packaging series KEB, availablemachinemodels:10,20 – Single-ordouble-station machines – Choiceofcenterdistances – In-Mold-Labeling – Multiplecalibrationfeatures – Pneumaticorhydraulic deflashing – Parisondieheadsforupto sevenlayers,alsoavailablewith view-stripeequipment – Therightmachinesizeforevery application

Machine designs to perfectly match requirements

Do you need equipment for manufacturing different articles, each with

different dimensions and different production quantities? By choosing

Kautex, you have an experienced partner on your side. We would be

pleased to work with you to configure equipment from se-

lected standard machine modules. This unique benefit is possible,

because our machines are sized with small increments between models.

Eachmachinemodelaccommodatesavarietyofmolds,resultinginalarge

rangeofdifferentconfigurations.Wewill customizemodulesordevelop

completely custom-built, dedicated equipment. Nevertheless, you will re-

ceive an economic solution, readily available and suitable for manufac-

turingmanydifferentarticles.

04 From basic to complex

Basic or complex, depending

on our customers’ needs.

We offer the solution.

Ways to Efficiency

– Planningandrealization – Teamofexperiencedspecialists – Flexibilityinselectingthe systemcomponents – Thoroughanalysisofexisting conditions – Closecollaborationwiththe customer

05

Communication issues, inherent inefficiencies, conflicts within the pro-

duction process: these are only a few examples of side effects that can

occurifamanufacturingsystemisassembledwithequipmentcomponents

supplied by different manufacturers. However, machines and peripheral

equipmentfromasinglesuppliercancauseproblems,too,ifthesystemisnot

sufficiently coordinated. A manufacturing system from a single source is

therefore the most efficient solution. Thanks to many years of practical

experience and substantial know-how, Kautex Maschinenbau can supply

the optimum solution for each scenario. From a basic machine for small

volume production to a complete turnkey system, our product portfolio

coversitall.Engineeredtothesmallestdetailandconfiguredforindividual

requirements,equipmentmodulesandprocessesarematchedsothatthe

resulting system works as a complete unit. The entire system represents

more than the sum of its components and succeeds because of better

reliability,greaterefficiency,andhigheruptimeavailability.

Effizienz-Broschüre 07Intuitive controls

“Kautex Control Easy®”: tested

by the most rigorous critics.

Our customers.

Ways to Efficiency

– Intuitiveset-upscreens – RAIDcontrollerharddrives – Largedisplay (19"touchscreen) – Customizablepasswordlevels (operation,setup,service) – Remoteaccessvia Ethernet/TCP/IPandmodem – Proactiveandpreventive onlinemaintenanceplan – Processdatacollection

The best control systems are developed in a continuous exchange with

those individuals who have to work with them on a daily basis – the

operators. This is why we listen to our customers with the continuing

development of Kautex Control Easy®. We benefit from suggestions,

preferences,constructivecriticism,aswellasexperiencefrompracticaluse

in further enhancing and perfecting our controls platform. For instance,

KautexControlEasy®iscapableofcollecting,monitoring,andcontrolling

allpre-andpost-moldingprocessparameters.Furthermore,allprocesspa-

rametersareloadedquicklyforproductchangeover.Ourcontrolsystemis

tunedtotheneedsoftheequipmentuser.Theuserbenefitsbytakingad-

vantageoftheimprovedproductioncapacity–anddoessoeasily.

06

Our engineers only have one

thing on their mind: shortening

cycle time and downtime.

Ways to Efficiency

– Shortcyclesthrough high-speedoperation – Componentsprecisely manufacturedtotight tolerances – Optimizedsequenceprogram tominimizenon-productive times – Machinefunctionswith closed-loopcontrolfor maximumrepeatability – Testfacilitiesforevaluation ofcomponentsunder real-lifeconditions

High production capacity

Our engineers are focused on how to further increase the capacity of

ourequipment. To shorten cycle timesand toachievehigherproduction

capacities,everyhundredthofasecondcounts.Togiveyoufulluseofthe

production capacity of your Kautex machine, we manufacture compo-

nentsandentiremachinestothehighestdegreeofprecision.Onlyprecision

componentsallowaperfectlyharmonizedinteractionofallmachinefunc-

tions. Even if operated continuously at maximum capacity, our machines

will require less maintenanceand achieve a longer service life. Anything

elsewoulddeviatefromourtraditionofmaximizingefficiency.

09

Energy is least expensive

when it isn’t needed.

Ways to Efficiency

– Higherplasticizingcapacity extruders – AC-drivenextruders – High-efficiencymotors – Individualcoolingcircuits – Parisonlengthcontrol – Insulationofextrudersand parisondieheads – Accumulator-assisted hydraulicsystem – Application-specificmachine configuration

Whether it isheat,airpressure,motion,orelectricity,noproductcanbe

manufactured without the use of energy. Our engineers make sure that

the least amount of energy is lost during the manufacturing process. As

a result, Kautex equipment operates at a high degree of efficiency and

convertsenergyeffectively intotheproductsmanufactured.Thus,energy

requirementsincreaseonlymarginallyathighproductioncapacities.

Withadedicatedapplication-specificmachine configuration,wealsoen-

surethatyourmachineisanexactmatchforyourrequirements.Yourcost

calculations will only show the energy cost actually used for manufactu-

ringyourproducts.Usingenergyonlyasneededisaprinciplethatnotonly

protectstheenvironment,butyourmostimportantresourceaswell:your

finances.

Energy efficiency08Fast market introduction

The fastest way from an idea to

marketability.

Ask our lab specialists.

Ways to Efficiency

– Development(molddesign, productoptimization) – Prototyping – Labfacility – Strategicallianceswith variousmoldbuildersandresin suppliers – Convenientsolutionsfor pre-productionandsmall productionruns

The development of an application from the first brainstorm to start of

productionrequiresmanysteps.Itcanbealongjourneytothefinalgoal.

Togettherefaster,getintouchwithourlabspecialists.Theywillassume

theroleofaprojectmanager,seekadvicefromotherexperts,ifrequired,

manufacture, and test prototypes under various aspects such as resin

selection,design,andfunction.Basedonthetestresults,youwillreceive

valuable recommendations with respect to your production-ready appli-

cation. Single-sourceprojectmanagementand coordination shortens the

time to marketability. With Kautex as a partner, you also benefit from

establishedstate-of-the-artfacilities,resultinginlowerdevelopmentcosts.

Nolackofexpertiseshouldkeepyoufromdevelopinganewapplication.

Effizienz-Broschüre

Quick changeover pays off.

And provides flexibility.

Ways to Efficiency

– Optimizedscrewdesigns allowawiderangeofresins tobeprocessed – Quickchangeoversystemsfor blowmolds,blowpins,and headtooling – Moldchangedevice – Pre-heatingstationsfor parisondieheads – Shortcolorchangetimes

Flexible production

All common resin types can be processed on Kautex equipment which

makesa singlemachine suitable formanufacturingall kindsofdifferent

products and keeps overall investment costs low. However, each product

change-overrequiresamoldchange. Iftheresinhastobechanged,too,

thoroughpurgingisessential,causingalossofvaluableuptime.Keepingef-

ficiencyinmind,KautexMaschinenbauhasdevelopedquickchangesystems

and improved mold designs that minimize changeover times. Resin and

colorchangesarecompletedintheshortesttimepossiblethankstorheo-

logicallyoptimizedextrudersandparisondieheads.Asa result, youwill

benefitequallyfromtheflexibilityofyourequipmentandfromamaximum

utilization of production time. All in all, a minimum of downtime and a

maximumofproductivity.

1110

Smart and accessible.

That’s what Kautex machines

are like.

Ways to Efficiency

– Wide-openingsafetygates – Easilyaccessibleclampingunits – Standardset-upmode – Electricalheightadjustment ofextruderplatformand parisonknife(manual) – Moldindexsystem – Quick-clampingsystemfor blowmolds

Ease of operation

Efficientmanufacturingultimatelydependsonhoweasilytheequipment

canbeoperated.Ifmachinedesignsdonotreflectthisaspect,themanu-

facturingprocess isboundtosuffer.Wepayagreatdealofattentionto

easeofoperation.Forinstance,allmachineareasimportantforprocessing,

maintenance,orproductchangeoverarereadilyaccessible.Moreover,ma-

chinesettingscanbeadjustedwhiletheequipmentisinoperation,which

keepsset-uptimestoaminimumandmaximizesuptimeavailability.

We march to the beat of a different

drummer when it comes to service.

Because less does not mean more.

Ways to Efficiency

– 24-hourhotlineservice – Standardonlinediagnostic capability – Localservicein15countries worldwide – Globalnetworkofserviceand salessubsidiariesin45countries – Retrofits – Productivityandefficiency consultation – Customizedtraining courses(e.g.BlowMolding TechnologySpecifics, ProcessingTechniques, Maintenance,andTrouble Shooting)

Maximum availability 13

We are at your disposal around the clock. You can contact our technical

expertsviaaservicehotlineanytime.Expertsdiagnosetheconditionofyour

machine online and guarantee that a service technician from our global

supportnetworkarrivesonsitewithin24hours.Incaseyouneedreplace-

mentparts,regionalsubsidiariesofferimmediateassistance.

Through our comprehensive service program, we not only assure high

productivity, but also offer to increase the capacity of your equipment.

Retrofits allow us to keep your machines up to date at reasonable cost.

Weeducateyourpersonnelthroughcustomizedtrainingprogramsgeared

towards a material-saving, low-wear machine operation. Because two

things are dear to our heart – the efficiency of your operation and the

satisfactionofyourcustomers.

12Savings with precision

The 100-point savings program.

For even greater efficiency.

Ways to Efficiency

– Wall-thicknesscontrol – Parisonlengthsandweights individuallyadjustable – Co-extrusionprocess – Closed-loopsystem – Flashhandlingguides – Statisticalprocesscontrol – Consistentplasticizingcapacity ofextruders – Electricalverticalpositioningof parisonlengthcontroldevice – Electricalheightadjustmentof extruderplatformandparison knife(manual)

Kautexmachineshelp yourarticle-cost calculation.Wall thickness canbe

set and controlled very precisely at one hundred points of a packaging

article.SmalldeviationsguaranteehighCPKvalues.Datacanbeanalyzed

separately for each individual article. The result is identical bottles with

optimized wall thickness, meaning lighter bottles that not only save

material,butalsocycletime.

Flash costs money, too, but our machines handle flash efficiently. Flash,

which isalreadykepttoaminimumthroughprecisecontrols, isfedback

intotheprocessviaaclosed-loopcircuit.

WithKautexmachines,youwillbeabletoeasilysavesignificantresources.

Asavingsprogramwithmorethan100points–thehighestscoreforyour

efficiencycalculation.

For the world of consumer packaging:

three product lines for an accurate match

with your production requirements.

Three different product lines with 20 extrusion blow molding machines

provideawiderangeofmachinesizesandmanufacturingsolutions.The

machinesoftheproductlinesKLS, KCC,andKEBaredesignedtomeetsigni-

ficantlydifferentproductionrequirements.

KLS long-stroke blow molding machinesareknownforcapacity,speed,and

flexibility.Duetotheirthroughputandversatility,theyareideallysuitedfor

manufacturingdemandingconsumerpackagingproductswithuptosevenla-

yers(CoEx)athighvolumes.Theyareflexiblewithrespecttoarticledischarge,

thesingledischargepointofdouble-stationmachinesminimizefloorspace,

and no article conjunction system is needed. KLS machines are available

witharangeofaccessoriesforspecificpurposes.

To satisfy different production requirements more accurately, you can

choosefromtwoadditionalproductlines:

14 15Machine product linesMachine product lines

The construction of KCC blow molding machines is based on a machine

designbyKautexMaschinenbauGermany.

Themachinesofferhighversatilityfortheproductionofawiderangeof

packaging applications and can be configured to exactly match required

productioncapacities.Theseriesconsistsof theKCC5S,10S,15S,and20S

modelsandthedouble-stationmachinesKCC5D,10D,15D,aswellas20D

foruptotwosetsoftencavities.

Machine product lines 16 Machine product lines

KEB blow molding machinesareuniquethroughtheirspace-savinglayout.

They are suitable for a variety of packaging products and are able to

produce more demanding applications. Although excellent jerry can ma-

chines, they are also suitable for consumer packaging. The KEB machine

seriescombinestheworldofindustrialandconsumerpackaging.

Due to a sophisticated scaling of machine models of each of the three

above product lines, as well as available options, we can offer tailored

manufacturing solutions for almost any production requirement: the basis

for efficient manufacturing.

17

18Corporate philosophy

Success does not happen

overnight. But it is more likely

to – after more than 60 years of

innovative development work.

For over 60 years, Kautex has accumulated engineering

know-how. With a continuously growing international

patent portfolio, the company shows that its innovations

are a significant contribution to the development of ex-

trusionblowmoldingtechnology.Morethan5,500Kautex

Maschinenbau packaging machines are already in opera-

tionworldwide.Withsuchhigh-qualityequipment,ween-

ableour customers tohandle simpleand complex jobs in

a highly cost-efficient way. Through our global logistics

networkandoursalesandservicesubsidiaries,wesupport

ourcustomerseveryday.Globalpresenceenablesustopro-

vide rapidon-site service.Weofferadviceand support in

allmatters regardingequipmentoperationaswell as the

realizationofnew,innovativeproductideas.

The basis for our success is the expertise and inventive-

nessofourengineers,ourfirst-classworkmanship,andthe

comprehensive service prior to and after the purchase of

equipment. Kautex Maschinenbau is committed to sup-

portingyouwithentrepreneurialvisionandaction.

Madetomoveyourbusiness

Corporate philosophy 19

Kautex Maschinenbau GmbH Kautexstraße 54 53229 Bonn, Germany

Phone:+49228489-0Fax :+49228489-414

www.kautex-group.com

Kautex Maschinenbau GmbHUfficiodiRappresentanzaperl’ItaliaViaCarloFerrari1221057OlgiateOlona(VA)ItalyPhone/Fax:+390331642046

Kautex Machines Inc.201ChambersBrookRoadNorthBranch,NJ08876USAPhone:+19082529350Fax :+19082539565

Shunde Kautex Plastics Technology Co., Ltd.Fu´AnIndustrialDistrict,Shunde,Foshan,Guangdong,528322P.R. Chinawww.sdkautex.com

Kautex Maschinenbau GmbHShanghaiOfficeRoom5B,QihuaTowerNo.1375MiddleHuaihaiRoadXuhuiDistrictShanghai200031P. R. China Phone:+862162495806Fax:+862154180366

RepresentativeOfficeKautex Maschinenbau GmbH MedovyPereulok5,Building1,5thFloorBusinessCenter“ULEJ”Moscow107023Russian FederationPhone:+74999635228