km made by 1 2010 eng - Home - KraussMaffei
Transcript of km made by 1 2010 eng - Home - KraussMaffei
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“Technology
advances mark the
way forward.”Dr. Dietmar Straub,
KraussMaffei CEO.
EDITORIAL
made by KraussMaffeiPublished by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, 80997 Munich, Germany Phone + 49/89/88 99-0, Fax + 49/89/88 99-2206, www.kraussmaffei.com Responsible: Matthias Andreesen Viegas
PUBLICATION DATA
EDITORIAL | NEWS
Editorial office: mk publishing GmbH, Döllgaststraße 7–9, 86199 Augsburg, Phone +49/821/3 44 57 0, Fax +49/821/3 44 57 19, www.mkpublishing.de Photo credits: Becker Kunststofftechnik, Bikkoplast/Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunst-stofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM
02 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Dear Readers,
Forcing down costs, increasing efficiency and boosting productivity – these
are key concerns right now throughout the plastics industry. It takes new-
generation machines and systems to gain a key competitive edge; technology
advances mark the way forward.
This holds true for KraussMaffei as much as for the rest of our industry. It’s
why we’ve recently invested a substantial amount to boost quality and
productivity in our main production plant in Munich. Our new Surface
Treatment Center opened just a few days ago, replacing our previous paint
shop. All in all, the new facility cost around four million euros – you
couldn’t ask for a stronger sign of our conviction that the economy can and
will recover. Experts tell us that you’d have to look a long way to find the
equal of our new facility anywhere in the world. For example, we now
move parts and modules weighing up to 32 tonnes through the paint line on
an overhead track system synchronized with the rest of the assembly line.
When the system is operating at full capacity, it is handling the equivalent
of the take-off weight of an Airbus. As you see, we never let up in our
pursuit of quality and productivity for our machines and processes. But
your vote is the decisive one – as our customer you have the final say in
whether we’re offering you the right solution at the right time!
If you’re among the customers who currently have no plans for major
investments, we can nonetheless show you affordable options for increasing
the efficiency of your production. Our retrofit packages and upgrades can
significantly improve the productivity and energy efficiency of your installed
machines. You might opt for a higher level of automation with a robot from
our expanded portfolio, or for reduced energy consumption with one of our
efficiency packs. Especially in recent years, KraussMaffei has taken up the
theme of energy efficiency; today “BluePower” stands for the products and
upgrades we offer to help you reduce energy consumption. To add even
more momentum to this strategy, KraussMaffei has now launched the
BluePower Award, which will honour energy- and resource-efficient
production solutions. We’ll be announcing the winners during the world’s
biggest plastics show, the K2010, at the end of October. We’re looking
forward with great interest to your competition entries.
With best regards,
Dr. Dietmar Straub
BluePower is the
concept that bundles
our continuing
endeavours to
promote the
development
of energy- and
resource-efficient
production
solutions. As part
of this effort, KraussMaffei has now launched
the BluePower Award inviting entries from all
the innovative plastics processors among our
customers.
We’re looking for new developments that deliver
a significant increase in energy- and resource-
efficiency. They can be anything from individual
applications and processes to complete concepts
– and they can come from any area of the plastics
processing industry. We’re especially interested in
processes that make sustainable use of synergies
through intelligent combinations of different
technologies, such as injection moulding, reaction
moulding and extrusion. The entries will be
evaluated and the winner selected by an independent
jury panel made up of high-ranking representatives
from science and industry. KraussMaffei employees
will not be eligible to vote on this panel. The winner
of the BluePower Award 2010 will be announced on
October 28, during the world’s biggest plastics show,
the K2010 in Düsseldorf, Germany. Closing date for
entries, which must be in writing, is May 31, 2010.
More information and details of how to enter are
contained in a questionnaire that you can request by
email. p
KraussMaffei sets up a prize for efficiency!
BLUEPOWER AWARD 2010
CONTACT
Dr. Reinhard SchiffersPredevelopment/EnergyPhone +49/89/[email protected]
KraussMaffei Berstorff is now offering complete
systems for continuous production of PU-
insulated pipes. One, or two, plastic media pipes
is encapsulated in an insulating polyurethane
layer plus a protective polyethylene sheath.
The insulated pipes can transport either hot or
cold media. With this single-vendor production
solution, the company, a world leader in
plastics and rubber processing machinery,
once again demonstrates its multitechnology
competence – in this case in pipe extrusion and PU processing – built on
many decades of engineering excellence. This unique know-how enables
us to develop complete production solutions by skilfully integrating
modules from different technologies. p
NEWS
Events through to autumn 2010
TRADE SHOWS
19. – 22.04. Chinaplas Shanghai, China
19. – 23.04. Expoplast Algiers, Algeria
11. – 14.05. RusChem Moscow, Russia
11. – 15.05. Technics Belgrade, Serbia
13. – 16.05. Plastex Cairo, Egypt
25. – 28.05. Plastpol Kielce, Poland
26. – 28.05. PU China Shenzhen, China
14. – 16.09. Composites Essen, Europe Germany
27.10. – 03.11. K 2010 Düsseldorf, Germany
COVER
03
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Perfectly paired off:pipe plus insulation
Bavarian Economics Minister
Martin Zeil (right) and
Dr. Dietmar Straub,
KraussMaffei CEO, at the
opening of the new Surface
Treatment Center.
KraussMaffei has recently completed a future-oriented project in our main
production plant in Munich. Guest of honour at the opening of the new Surface
Treatment Center (STC), on March 5, 2010, was Bavarian Economics Minister
Martin Zeil. The new facility replaces our previous paint shop. In his address,
Martin Zeil commented, “The German plastics machinery sector has been
especially hard hit by the turbulence of the economic crisis. This is why I’m
absolutely delighted with every Bavarian company that has taken the crisis
as a spur to look ahead, modernize and invest. With its new and innovative
paint facility, KraussMaffei is among the leaders in this area too.” Despite the
economic crisis, KraussMaffei invested around four million euros in building and
equipping the STC. As Dr. Dietmar Straub, CEO of KraussMaffei AG, pointed
out, “With the new Surface Treatment Center we’re improving the transparency
of our entire assembly process; it will enable us to work more efficiently and
cut our turnaround times – our customers will benefit significantly.” The STC
was planned and built in a close collaboration between KraussMaffei and
Rippert Anlagentechnik GmbH & Co. KG, from Herzebrock-Clarholz/North
Rhine-Westphalia. Rippert, a systems engineering company with around 300
employees, has almost 40 years’ experience in planning and installing painting
and filtering systems and industrial ventilation units. Complex coating systems
are among its core competences. p
MULTI-MILLION INVESTMENT
New Surface Treatment Center opened
04 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Cleanroom Competence Center in Rosenheim,
opened on January 29, 2010, provides an excellent
environment for researching this field,” emphasizes
Martin Würtele, Manager Predevelopment New
Technologies at KraussMaffei. Under the aegis of
Prof. Peter Karlinger, researchers in Rosenheim
are working on a complex production cell based
on a KraussMaffei all-electric EX 80/380. “Our
cooperation with the university in Rosenheim has
already generated a large number of successful
projects and graduate theses across all three key
technologies – injection moulding, extrusion and
reaction moulding,” says Martin Würtele. Much
of this research is aligned with KraussMaffei’s
“Technology to the Power of Three” strategy. With
the opening of the competence center, Rosenheim
University became part of the PRIMUS Network
for Innovation set up by KraussMaffei (responsible
for the focus area “Life Sciences”).
Focus on energy efficiency
The University of Duisburg-Essen (UDE) is
also a member of the PRIMUS Network. Since
January 15, 2010, there’s been a cooperation
agreement between the university’s Faculty of
KNOW-HOW SHARING DRIVES DEVELOPMENT
Development engineers in mechanical engineering companies are not the only people working on solutions to tough challenges in plastics processing – there’s a lot of academic research going on too. In Germany alone, KraussMaffei supports over 20 universities and other research institutions with machinery and know-how. Life sciences, lightweight structures and energy efficiency are among the key research topics.
One strong trend in
plastics research is
the increased focus on
the life sciences sector
– medical technology,
pharmaceuticals and
cosmetics. There’s
a long-standing
cooperation in
this area between
KraussMaffei and
Munich’s University
of Technology (TU), with ordinarius professor
for medical technology, Prof. Dr. Dr. Erich
Wintermantel. TU researchers and students have
two injection moulding machines, including an
EX 50/55, and a compounder at their disposal for
experiments.
Relatively new, by contrast, is the cooperation
agreement between KraussMaffei and Rosenheim
University of Applied Sciences. It’s also focused
on the life sciences field and especially on
cleanroom technology. “One of the main concerns
in this sector is to develop processes that make
post-mould sterilization unnecessary. The new
FOCUS
Industry and research hand-in-hand
Celebrating another
recent cooperation
agreement: Prof. Dr.
Dieter Schramm and
Prof. Dr. Johannes
Wortberg from the
University of Duisburg-
Essen with Dr. Karlheinz
Bourdon and Georg
Holzinger, from
KraussMaffei (l. to r.).
05
Engineering and KraussMaffei with the specific
goal of improving the energy efficiency of plastics
processing machinery. The strategic cooperation
partner on the university side is the chair of
Engineering and Plastics Machinery headed by
Prof. Dr.-Ing. Johannes Wortberg. The cooperation
partners have agreed on regular information
exchange and supporting engineering students and
researchers. One specific area of cooperation will
be developing and optimizing alternative drive
technologies for plastics processing machinery. The
remit for this project includes energy consumption,
energy recovery, precision and efficiency.
KraussMaffei is mainly concerned with developing
and optimizing components, in particular with the
practical implementation and with application-
related process engineering.
Combined process for function-integrated
lightweight systems
The cooperation between KraussMaffei and the
Institute for Lightweight Structures and Plastics
Technology at Dresden University of Technology,
headed by Prof. Dr. Werner Hufenbach, dates
back to 2008. One important area of research
here is fiber-composite lightweight elements and
the development of new resource-efficient process
chains for manufacturing them. The researchers
in Dresden have at their disposal an innovative
LFI (Long Fiber Injection) system, including a
shuttle mould carrier, supplied by KraussMaffei’s
Reaction Process Machinery division. The research
encompasses multitechnology and multiprocess
solutions.
The Center for Integrative Lightweight
Technologies (ZIL) at the Chemnitz University
of Technology is working in related fields. For
example on the development of a new combined
process for reinforcing plastics with long fiber
materials and fabric intermediates in injection
moulding. These types of lightweight composites
are used in making anything from aircraft to
rolling stock and road vehicles, because their
lighter weight reduces fuel consumption and
carbon dioxide emissions. The ZIL, headed
by Prof. Dr. Lothar Kroll, operates a total
of six KraussMaffei machines, including a
multicomponent spin-platen machine, a RIM
polyurethane system and an IMC injection
moulding compounder. A new addition to the
center’s machine park is a ZE 40 A x 50 D UTXi
twin-screw extruder from KraussMaffei Berstorff
engineered for high-performance compounding
tasks. “Basic research is very important for us
as a mechanical engineering company, because
it paves the way for adapting our extruders
to market requirements and to continuously
developing them,” points out Prof. Dr. Bernd
Poltersdorf, head of Foam, Film and Sheet
Extrusion at KraussMaffei Berstorff. p
FOCUS
CONTACT
Martin WürteleManager PredevelopmentNew Technologies/Process EngineeringPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Prof. Dr. Bernd PoltersdorfManager Foam, Film and Sheet ExtrusionPhone +49/511/[email protected]
Prof. Dr. Lothar Kroll,
Dr. Wolfgang Kempt and
Dr. Wolfgang Nendel
(from left) of the TU
Chemnitz with the ZE
40 A x 50 D UTXi twin-
screw extruder from
KraussMaffei Berstorff,
Hanover, which offers
new scope for research.
06 MADE BY KRAUSSMAFFEI 1 ¦ 2010 FEATURE
– adding up to around 14 in total. “Thanks to our
joint project with Evonik, we can now offer our
customers a far more cost-effective process,” says
Dr. Karlheinz Bourdon, head of KraussMaffei’s
Injection Moulding Machinery division. And Josef
Renkl, R&D Manager for the company’s Reaction
Process Machinery division adds, “Thanks to our
multitechnology know-how – in this case injection
moulding and PU processing – we’ve been able to
develop the process to market readiness. It will
dramatically shorten the process chain. The new
CoverForm process has just four steps: incoming
check, injection moulding and coating in the same
mould, quality control, final assembly. All these
steps are performed in one and the same machine.
The process saves time, costs and production space.
In addition, the surfaces produced in this way are
often more scratch-resistant than those that are
COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK
Display panels in mobile phones, appliances,
consumer electronics and automotive instrument
panels are made of transparent polymers.
The displays must remain transparent despite
exposure to mechanical and chemical impact, for
example, through cleaning agents or handcreams,
otherwise they are not fit for purpose. The
material most used for these applications is
polymethyl methacrylate (PMMA) often known
by the tradename Plexiglass. The PMMA must
be specially coated to protect the surface from
scratches and chemical damage. In conventional
production, this coating is applied in a post-
mould paint process.
A far shorter process chain
A conventional process comprises multiple steps
including quality controls, storage and transport
Joint project in surface treatment technology
Dr. Karlheinz
Bourdon, member of
KraussMaffei’s Board of
Management (left) and
Gregor Hetzke, head of
Performance Polymers
at Evonik, at the opening
of the CoverForm
Competence Center.
The CoverForm process, developed by KraussMaffei, as machine supplier, and Evonik, as material supplier, substantially shortens the process chain for the production of transparent, scratch- and chemical-resistant parts. Processors save transport effort, time and production floor space – in the last analysis they save costs. The quality is often better than can be achieved in a conventional painting process.
COVERFORM PROCESS STEPS Inl ine scratch-resistant coating of PMMA
Inject PMMA
Compression/cooling
Open cavity & inject coating
Compression & heating 100%
Compression & cooling
Compression & start heating
FEATURE 07
conventionally painted. It couldn’t be simpler. This
is how CoverForm works – after injection of the
special PMMA, a mould stroke forms the surface
to be coated. The part cools in the mould. The
cavity is then enlarged slightly, creating a space for
the surface coating layer. This gap is flooded with
a liquid reactive system, ideally matched to the
PMMA material, and the mould closes in a second
compression stroke. The high-performance Dynamic
Temperature Control (DTC) ensures that the
temperature profile in the mould, required for the
different process stages, is exactly repeated in each
cycle. The only post-mould process is UV curing
which takes place immediately after demoulding.
The parts are then ready for assembly.
Competence center
for award-winning process
In November 2009, a CoverForm Competence
Center was opened at the Evonik plant in
Darmstadt – it’s the ideal
place to demonstrate
the new process. The
center was opened by
Gregor Hetzke, head of
Performance Polymers at
Evonik and Dr. Karlheinz
Bourdon. Evonik is using
the new center both for demonstrations and for
further development of reactive systems. Among
the possible candidates are new anti-reflective or
electrically conducting coatings. In addition, the
center is the ideal training environment for the
technicians in Evonik’s worldwide service teams.
despite its relatively short time on the market,
CoverForm has already won an award. At the
Materialica trade show, last autumn in Munich,
it won “Best of” award in the category Surface
and Technology. In its review, the jury noted
that CoverForm is a forward-looking,
market-ready process which is the
result of productive interaction between
materials, engineering expertise and design.
CoverForm is a system solution available
exclusively from the joint partners Evonik
and KraussMaffei. It’s yet another example
of the sustained increase in productivity
that can be achieved by joining up
processing technologies, as advocated by
KraussMaffei’s “Technology to the Power
of Three” strategy. p
KraussMaffei injection
moulding machines are
at the heart of CoverForm
production cells.
CONTACT
Marco GruberManager Application Engineering,Process Development IMMPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Sven Schröbel, Evonik
Industries, Martin
Eichlseder, KraussMaffei,
and Arne Schmidt, Evonik
Industries (from left),
showing off the “Best of”
award at the Materialica.
Demoulding Final curing (UV curing)
08 MADE BY KRAUSSMAFFEI 1 ¦ 2010FEATURE
LIFE CYCLE SERVICE
Technologies change over time. Part of KraussMaffei’s full-service offering is our commitment to maintaining and upgrading plastics processing machinery over the whole life cycle, so that it is always fit for purpose in fast-changing markets.
Multitechnology processes – such as CoverForm
(see page 6/7), nanoskin (see page 9) or inline
compounding – are an important way forward
for plastics processors. Production cells for these
processes are all based on a KraussMaffei injection
moulding machine. Our customers know they can
count on our many decades of experience with
injection moulding machines, which are one of
our core businesses. Our expertise goes beyond
developing and supplying highly productive ma-
chines; we also have the engineering skills to make
sure they stay that way over long service lives and
in the face of changing products and markets. “A
processor buying a machine today generally has
only the vaguest idea of what he’ll be producing in
five or ten years’ time. He would be well advised
to invest in KraussMaffei machinery, because we
can make sure that his production solution will
grow with his changing applications – even for
decades ahead,” says Josef Hammerschmid from
Service Marketing at KraussMaffei.
Retrofit, overhaul, move
A production cell may undergo many changes over
the years. The experts in our Service teams can
help our customers cope with them all. A pro-
cessor might come to us with a request to adapt
an existing machine for a new application, perhaps
with a MuCell package for physical foaming at low
unit cost. Or he might want to expand into multi-
component moulding. This upgrade can be achieved
relatively simply with a bolt-on unit. Hydraulic and
electric bolt-on units are completely self-sufficient,
so only minor changes, if any, need be made to the
machine.
Combining an upgrade with a planned machine
move saves production time. “We’re professionals in
moving and transporting machines – we do it all the
time,” points out Josef Hammerschmid. “Our com-
mitment to our customers is to move any machine
any distance, on time and within budget. And to see
the job through from start to finish.” Occasionally,
the machines make a detour to the KraussMaffei
plant in Munich for a general overhaul. We also op-
erate a practical trade in used machines. In our skilled
hands machines get a new lease on life. p
CONTACT
Josef HammerschmidService SalesPhone +49/89/[email protected]
Always fit for purpose
KraussMaffei Service
professionals have
the expertise to make
a complete success of
any task, however big.
LIFE CYCLE
SERVICE FROM
KRAUSSMAFFEI
• Plasticizing units
• Refurbishing
• Functionality upgrades
Moving machinery •
Technology upgrades •
Consulting and advice •
Bolt-on units are a
fast, sure route into
multicomponent
moulding.
Teleservice •
• Robots, handling systems, automation
09FEATURE
NANOSKIN PROCESS
Integrated multitechnology processes are often the answer to the challenge of producing polymer parts with durable, functional surfaces at a competitive cost. The new CoverForm process (see page 6/7) is an example of this type of integrated process. Another new process – nanoskin – is approaching market readiness. Again teaming injection moulding with PU processing, the nanoskin process is being developed by KraussMaffei and a number of project partners.
Functionalizing materials by generating a finely
structured surface – a nanostructure – is among the
dominant trends in process engineering. There are
well-known examples of nanostructures with useful
properties in nature, like the self-cleaning leaves of
the lotus flower or the anti-reflective surface layer
of moths’ eyes. The quest is on to develop a process
for transferring the moth’s-eye effect to transparent
polymer parts so as to make them inherently anti-
reflective – in other words to eliminate the need
for a post-mould anti-reflective coating. The part
would also need to be resistant to mechanical and
chemical damage. Possible applications include
covers for dashboard instruments and displays.
The nanoskin process supplies the answer.
Injection moulding and RIM
The nanoskin project partners set themselves
the task of developing a cost-effective technical
solution for a one-step multicomponent moulding
process which would combine thermoplastic and
chemically crosslinking polymer materials. The
core of the part can be produced in a conventional
injection moulding process. Only the nanostruc-
ture surface is generated in a parallel RIM process,
using a chemically crosslinking polymer which also
guarantees the necessary mechanical and chemical
resistance. The nanoskin research and development
project received funding from the German Federal
Ministry of Economics
and Technology as part
of the government’s
InnoNet concept, which
aims to promote and
support networks for
innovation. It was carried
out with organizational
and technical support
from the project sponsor,
the VDI/VDE. “Now,
well ahead of the planned
project end in autumn
2010, we can already say
that KraussMaffei and
our partners are writing
the first chapter of a suc-
cess story. Together we
have taken the nanoskin
process to a point where we’ll be able to offer it to
our customers for concrete production applications,”
says Martin Eichlseder, who is leading KraussMaffei’s
contribution to the nanoskin project. p
CONTACT
Martin EichlsederProcess DevelopmentSystems & SolutionsPhone +49/89/[email protected]
Finely structured
The nanoskin process
generates transparent
parts with finely
structured surfaces.
NANOSKIN PARTNERS
• Plasmatreat GmbH and Fraunhofer IWM:
Regenerative hybrid layer systems and process-
integrated atmospheric plasma treatment
• Hochschule Heilbronn: Process integration
• Mast Kunststoffe GmbH & Co KG:
Durable, functional components, tested under
production conditions
• FHR Anlagenbau GmbH:
Mould coating and surface structuring
• Krallmann Holding & Verwaltungs GmbH:
Moulds with highest precision and rigidity
• RÜHL PUROMER GmbH and KraussMaffei:
Tough, transparent polyurethane systems
for surface functionalization and technology
development – flow moulding
MADE BY KRAUSSMAFFEI 1 ¦ 201010 KEYNOTE | NEWS EXTRUSION
“We supply complete
systems exactly tailored
to your requirements with
all system components
engineered to operate
perfectly together.”
Manfred Reichel,
General Manager,
Extrusion Technology.
KEYNOTE
Dear Readers,
KraussMaffei is the only company worldwide to unite
under one roof three technologies of key significance
for the plastics and rubber processing industries
– extrusion and injection and reaction moulding. You,
as our customer, profit in many ways from this bundled
competence. In this issue of our magazine, we offer you
an impressive example of a multitechnology solution
– our new systems for continuous production of pipe
with foamed PU insulation. These systems build on
our engineering know-how and the experience of many
years in the fields of pipe extrusion and PU processing
to deliver successful, integrated production solutions.
They are just one example of our ability to supply
systems exactly tailored to your requirements with all
the components engineered to operate perfectly together
Our engineering expertise in multitechnology solutions is
only one aspect of our holistic approach. In addition to
supplying machines, we support our customers in every
way – right through to planning complete production
plants. Our goal is to ensure you a long-term competitive
advantage in your markets. There is an increasing
awareness, around the world, that the capital cost
of an individual machine must be compared with the
impressive return on investment possible with a complete
system solution. This was emphasized most recently at
the Interplastica 2010 in Moscow, where KraussMaffei
Berstorff achieved considerable success.
Manfred Reichel,
General Manager,
Extrusion Technology
In 2009, KraussMaffei Berstorff, Hanover,
booked its biggest order to date for compounding
machines. The Chinese company AGT
Compounds, previously known mainly for
flame retardants, ordered 50 ZE Basic twin-
screw extruders for a new plant in Changzhou.
AGT will install 44 of these lines to compound
technical polymers in a vast plant with 90,000
sqm production floor and 7,500 sqm laboratory
area. The remaining machines will be deployed
as laboratory machines in product development.
“AGT was especially interested in quality with
a ‘Made in Germany’ label,” explained Claas
Uphoff, Sales Manager China at KraussMaffei
Berstorff. “Thanks to a very high level of
standardization, our ZE Basic carries a very
attractive price tag.” p
50 at onceZE BASIC – BIG ORDER FROM CHINA
AGT Compounds ordered 50 ZE Basic twin-screw
extruders for its new plant in Changzhou, China.
At the Interplastica in Moscow (January 26-
29, 2010), it was obvious that the plastics and
rubber industries are beginning to recover and
that demand for extrusion systems is picking
up. Many intensive discussions with customers
confirmed that KraussMaffei Berstorff is still
the Number 1 in the Russian market. Visitors
to the Interplastica showed strong interest
in a number of topics – polymer processing,
film and sheet production, glassfiber pipe
production, direct extrusion and PU-insulated
pipe. p
Still Number 1INTERPLASTICA 2010
UDI (United for Developed
Industries), the second recent
Egyptian customer, is part of the Lasheen Group,
the regional leader in plastics production. UDI
ordered four PVC pipe extrusion lines from
KraussMaffei Berstorff for the production of
pressure and waste water pipe. “Before awarding
us the contract, UDI made extensive enquiries from
other companies in the Arab-speaking world about
KraussMaffei Berstorff and our competitors,”
reports Albert Brunner, Sales Manager for Egypt.
“In the last analysis, our reputation and our proven
quality were decisive in winning the contract.” p
11
Two important orders from companies in
Egypt illustrate how KraussMaffei Berstorff is
opening up new markets with mature extrusion
technology “Made in Germany”. The large,
Cairo-based Al Amal already operates a
pelletizing system from KraussMaffei Berstorff.
Now the company has placed an order for six
extrusion lines to produce U-PVC, C-PVC and
PP-R pipe. The company aims for very high
quality standards, especially in the area of
C-PVC pipe. So it was logical to turn again to
KraussMaffei Berstorff when the time was ripe
for expansion.
MAJOR ORDERS FROM EGYPT
NEWS EXTRUSION
Albert Brunner, Sales
Manager Egypt (2nd
from left) and Project
Planner Dominik Prechsl
(front right) with Al Amal
representatives during
acceptance tests for the
pipe extrusion lines.
downstream components. Output is up to five tonnes an
hour. The customer plans to produce rubber belts, up to
2,850 millimeters wide and between 3 and 18 millimeters
thick, as the upper and under layers of conveyor belts. A
special doubling unit can bond two of the rubber belts
to produce one thicker intermediate product. Conveyor
belts of these dimensions are used mainly in mining and
open-cast mining to transport coal and ores. p
In mid-2010, KraussMaffei Berstorff will ship one of
the four biggest roller-head lines installed in recent
years to a conveyor belt manufacturer in Eastern
Europe. The line is 60 meters long and includes a
250-mm-screw-diameter rubber extruder with a wide
slot die (slot width 3050 mm), a 2-roll calender and
ROLLER-HEAD LINE FOR EASTERN EUROPE
A really big one
sales and marketing for this part of the product
range. He also has overall responsibility for the
die engineering, project planning and process
engineering teams and for the pipe TechCenter.
Peter Oswald heads up the Profile Extrusion
product group, with additional responsibility for
project planning, process engineering and the
profile extrusion TechCenter. p
The Munich arm of KraussMaffei’s Extrusion division
has a new sales management team. Now structured
even more clearly by product group, the organization
is closely aligned with customer expectations. Andreas
Kessler is the new General Sales Manager, with overall
responsibility for orders and sales and for the German
and international sales subsidiaries of Munich Extrusion.
He’ll be working closely with Ralf J. Dahl who holds
the same position at the Hanover arm of KraussMaffei
Berstorff. Michael Hofhus has been appointed Product
Manager Pipe Extrusion in Munich, responsible for
MUNICH EXTRUSION
The roller head line can
process up to five tonnes
an hour.
Andreas Kessler Michael Hofhus
“Made in Germany” a success factor
Effective, focused organizational structure
Peter Oswald
MADE BY KRAUSSMAFFEI 1 ¦ 2010
CONTINUOUS FOAM ENCAPSULATION FOR PIPES
KraussMaffei is the only company in the market with expertise in the three major machine technologies for plastics and rubber processing: injection moulding, reaction processing and extrusion. The company’s new systems for the continuous production of pipe with PU insulation are a convincing example of our ability to supply complete multitechnology solutions as a single vendor.
From media pipe to a complete pipe element
The media pipe produced on a conventional
extrusion system is made of HDPE or PE-X, to
suit the application. A barrier layer can also be
applied. Coming off the line, the pipe is wound
onto large steel drums. Alternatively the pipe can
be bought in and then have the insulation layer
added on the second section of the production
system. Here, the pipe is unwound from the
steel drums, centered, heated if necessary, and
fed under tension into a shaping conveyor with
a mixing head dispensing the polyurethane mix
at the inlet throat. The aluminium shaping jaws
limit the foam volume to define the outer diameter
of the insulation layer. A film layer prevents the
polyurethane from adhering to the aluminium
shaping jaws. Once the PU insulation layer has
cured, the pipe leaves the shaping conveyor and
a PE outer sheath is applied using a single-screw
extruder with a sheathing die. This outer sheath
is cooled, and the whole pipe element is hauled
KraussMaffei Berstorff
has the advantage
of many decades of
technology competence
and experience in
pipe extrusion and
PU processing. We are
uniquely positioned to
supply complete systems with
perfectly matched components for continuous
production of pipe with PU insulation. Our
production system has two sections. The first
section is a conventional line that extrudes the
media pipes; in the second section the media pipe
(one or two) is encapsulated in PU insulating
foam and then sheathed in a protective
polyethylene layer. By contrast with some other
systems on the market, KraussMaffei Berstorff
systems are characterized by sharply reduced
wear on all system components, high system
reliability and a high-quality end-product.
New production system concept from a system partner
The PU metering
system ensures that
the components are
homogenously mixed.
12 FOCUS EXTRUSION
Key components of
the system for foam
encapsulation and
sheathing of media pipes
are the unwinder (1) …
… retarder (2), center-
ing and prewarming
station for the media
pipe (3), …
13FOCUS EXTRUSION
off and wound on a drum. The system makes it
possible to integrate anti-diffusion barrier layers,
and also wires to monitor leakage.
No limits on pipe length
Continuous production of insulated pipe, as in
this KraussMaffei Berstorff system, has a number
of important advantages compared with dis-
continuous production. One major advantage
is the relatively high level of automation that
results in lower labour costs. Furthermore,
there are virtually no limits on the length of the
pipe being produced. This is largely due to the
way the mixing head is engineered to eliminate
stoppages for cleaning and mixing-head changes.
Longer pipe sections reduce the number of prod-
uction system restarts and also the number of
connections needing to be made when the pipe is
laid. This in turn eliminates the risk of thermal
bridges and leaks, and makes pipe laying far
easier.
Outstanding insulating properties
The standard version of this production system
can be used to produce pipe with an outer
diameter between 20 and 110 millimeters. In
the diameter range 20 to 63 millimeters, the
integrated pipe element usually contains two
pipes (outflow and return). The exterior dia
meter of the pipe element will be between 75
and 180 millimeters, depending on the diameter
of the media pipe(s) and the thickness of the
insulating layer.
Outstanding mixing head performance produces
a PU foam layer with extremely low thermal
conductivity – between 0.02 and 0.03 W/(m x K),
depending on the type of foam and the supplier.
This highly efficient insulation makes these
pipes the ideal solution whenever a significant
temperature differential must be maintained
between the medium flowing through the pipes
and the ambient temperature. In some cases,
the medium being transported is hotter – such
as supply lines for combined heat and power
or geothermal plants, or hot water pipelines
in general. Insulated pipes are also sometimes
required for potable water transport if there is
a risk of the pipes freezing. The second major
application area is the transport of cold or cool
media in warmer ambient temperatures, for
example, in air conditioning or refrigeration
systems, or pipes for transporting liquefied gas.
With the current focus on energy savings, strong
growth in demand can be expected in all these
application areas. p
CONTACT
Daniel LachhammerProduct Manager Pipe ExtrusionPhone +49/89/[email protected]
The outer diameter
of the PU foam is
defined by the shaping
conveyor during the
chemical reaction.
… shaping conveyor and mixing
head (4), single-screw extruder with
sheathing tool (5), spray bath for
cooling (6), haul-off (7) and winder (8).
The media pipe is
produced on a conven-
tional line headed by a
single-screw extruder.
The outer PE protective
layer is applied via a
sheathing tool.
MADE BY KRAUSSMAFFEI 1 ¦ 201014 APPLICATION
MATERIAL DEVELOPMENT WITH THE ZE 25 A UTXi LABORATORY EXTRUDER
Headquartered in Pirmasens, Germany, Framas Kunststofftechnik GmbH is a leading global supplier of plastic components for the athletic footwear industry. To promote the development of new materials for increasingly better products, the company is now investing in a KraussMaffei Berstorff ZE 25 A UTXi twin-screw laboratory extruder.
task. In addition, it supplies all data required for
scale-up to a production line and ensures low
operating cost owing to easy maintenance and
highly efficient wear protection.
Measuring melt quality directly
The ZE 25 S UTXi laboratory extruder has a
D/d screw diameter ratio of 1.46 and thus offers
the optimum relation between intake volume
and torque. It achieves screw speeds of up to
1,200 rpm, which make it ideal for high-perfor-
mance compounding. A processing unit length of
42D allows additives to be injected at any point
along the barrel and the melt to be degassed if
necessary. In other words the extruder offers
maximum flexibility. The extruder is fitted with
an Ultra-Glide drive unit that allows the screws
– even when completely filled with melt – to
be pulled out from the rear of the stationary
processing unit, so that the melt quality can be
directly evaluated. p
Framas has long been aware of the correlation be-
tween perfect plastics and maximum comfort and
functionality when it comes to sports shoes. The
company, with offices in Germany, Asia and the
USA, supplies major brands such as adidas, Nike,
Puma and Reebok with plastic components. About
400 single-component and multi-component
injection moulding machines are currently used to
produce mainly lasts, soles and bootlegs for sports
shoes.
The company promotes material development in
close cooperation with Kaiserslautern University
of Applied Sciences. For this purpose, Framas
ordered a ZE 25 A UTXi twin-screw extruder
from KraussMaffei Berstorff and placed it at the
disposal of the university on a loan basis. The
joint development activities are focussed on ma-
terials providing weight reduction combined with
enhanced stability and improved damping proper-
ties. Thanks to the sophisticated equipment, the
laboratory extruder is particularly suited for this
The interaction of
the ultra-functional
materials in sports shoes
provides support for the
athletes.
On track for the perfect plastic
The ZE 25 UTXi
laboratory extruder
is ideal for the
development of new
polymer formulations.
CONTACT
Gerhard SchmittSales Manager Twin-screw ExtrudersGermany, Austria, SwitzerlandPhone +49/511/[email protected]
15 APPLICATION
EXTRUSION LINES FOR BRAZILIAN PIPE PRODUCER
Corr Plastik Industrial Ltda., one of Brazil’s major producers of PVC pipe, has substantially increased production capacity with a new factory in the north east of the country. The extrusion lines for the new plant were supplied by the German extrusion specialist KraussMaffei Berstorff, long-time supply partners for Corr Plastik.
Corr Plastik doubles production capacity
Corr Plastik has
built and equipped
a new plant for pipe
production near
Maceió.
Ever since its founding 17 years ago, Brazilian
pipe and fittings producer Corr Plastik has
used extrusion lines supplied by KraussMaffei
Berstorff. Certified to ISO 9001/2000, the
company aims to supply premium quality
products. Testing products in an in-house
quality lab is one of the measures it takes to
achieve this goal. In the intervening years, the
company has grown rapidly, it is now doubling
pipe production capacity, and once again
installing extrusion lines from KraussMaffei
Berstorff.
The new Corr Plastik site near Maceió, the
capital of Alagoas state, covers an area of
60,000 square meters. In a first construction
phase, the company has built a 7,500 square
meter plant to produce water, sewage, irrigation
and drainage pipes. In late 2009, KraussMaffei
Berstorff shipped four pipe extrusion lines for
the new plant. Two of the lines were double-
strand lines headed by KMD 75-36/R twin-
screw extruders from KraussMaffei Berstorff’s
Performance series. The other two were single-
strand lines with KMD 90-36/R Performance
twin-screw extruders.
Five new extrusion lines
The lines are configured to produce pipe with an
outer diameter of 20 to 250 millimeters. Together,
the four lines can produce up to 2,800 tonnes PVC
pipe a month. A fifth line, also headed by a KMD
90-36/R Performance extruder, began producing
corrugated pipe in January 2010. This new line
boosts total production volume at Corr Plastik’s new
plant to 3,100 tonnes a month. Together with the
output from the main plant in Cabreúva in São Paulo
state, Corr Plastik now has a production capacity
of 6,000 tonnes a month. This has catapulted the
company, which employs 330 people, into the ranks
of the three largest pipe producers in Brazil. p
CONTACT
Bruno SommerExtrusionPhone +55/11 4612 [email protected]
The four new pipe
extrusion lines at Corr
Plastik can produce up
to 2,800 t of PVC pipe a
month.
MADE BY KRAUSSMAFFEI 1 ¦ 201016 APPLICATION
The profile
extrusion line
at Sauermann
is headed by
a single-
screw ex-
truder.
The core business of Sauermann Franz Spritzguß-
technik e.K., based in Schrobenhausen north of
Munich, is the production of components for
commercial vehicles. The company’s product
portfolio of truck
components
includes plastic
tanks, containers
and mudguards.
Sauermann has
long sourced its
injection moulding
machinery from
KraussMaffei and
currently operates
several machines
from this manufac-
turer in its prod-
uction processes.
Trust in reliability
“Throughout their long service
lives, these injection moulding
machines have proved to be very
reliable, high performance machines
and the customer is very satisfied,”
comments Peter Oswald, head of the
Profile Extrusion team at KraussMaffei
Berstorff. “The strong relationship of trust
built up between Sauermann and
KraussMaffei was a decisive factor in the
company’s decision to turn to KraussMaffei
Berstorff when it needed a profile extrusion
line in order to add technical profiles to its
product range. The new line, supplied
complete by KraussMaffei Berstorff, is
headed by a KME 60-36 B/R single-screw
extruder. A typical representative of
KraussMaffei Berstorff’s single-screw
extruder range, this extruder has an extra-
long processing unit. The extra length
delivers three big benefits: higher output,
more homogenous melt and lower melt
temperature. In other words, the KME 60-
36 B/R supplies the profile die with the melt
quality essential for a quality product.
Sauermann is using the line to produce PO
anti-splash guards and their fixing profiles
for trucks, as well as side rail covers. p
TECHNICAL PROFILE EXTRUSION LINE FOR AUTOMOTIVE COMPONENTS SUPPLIER
Automotive components supplier Sauermann Franz Spritzgußtechnik e.K. has long produced a large number of parts for commercial vehicles on KraussMaffei injection moulding machines. Now the company, located in Schrobenhausen, Germany, has added technical profiles to its product range. As a satisfied KraussMaffei customer, the company turned to KraussMaffei Berstorff to supply the necessary profile extrusion line.
The full spectrum of machine technologies from a single contract partner
Sauermann has
added tech-
nical profiles
to its product
spectrum.
CONTACT
Peter OswaldManager Profile ExtrusionPhone +49/89/[email protected]
17FEATURE
FIRST MODULAR PRODUCTION SYSTEM FOR TIRE INNER LINERS
Thanks to their modular engineering, the plug-in production lines which KraussMaffei Berstorff offers manufacturers of tire components are ready for operation within a very short time of arrival at the customer’s plant. All essential line components, such as the extruder, control system, calender and winding stations, are shipped fully-wired, mounted on base frames. They undergo extensive testing at KraussMaffei Berstorff’s Hanover headquarters prior to shipment.
Fast production start-up
Tubeless tires have an inner liner, an impermeable
layer of rubber that prevents air from escaping,
instead of the old inner tube. A production
system for inner liners typically consists
of several separate components, including
extruder, control system, calender and winding
stations. KraussMaffei Berstorff has developed
a sophisticated modular concept to supply
these components as a complete package. In
this building block system, once the individual
modules are connected up, they are ready to go.
The individual components, eg, the GE 150 KS
rubber processing extruder with slot die, the
control unit, the whole roll system and the four
winding and unwinding stations, are assembled
and mounted on separate base frames with all the
supply lines and cables in the factory in Hanover.
For shipment, the connections are unplugged, the
winder trestles disassembled to fit the container
and the entire system is transported in oversea
containers to the customer’s premises. The
customer only has to provide the power and water
connections.
Increased operational reliability
thanks to early fault detection
The modular concept makes it possible to
carry out installation, pre-commissioning
and the software components check in the
manufacturer’s works. This sharply reduces
the personnel and time required for on-site
installation. In addition, operational reliability
is increased as potential interface problems are
detected at an early stage and can be eliminated
rapidly and at low cost. Furthermore, the future
operating and maintenance technicians can be
trained in Hanover during equipment pre-
commissioning. A major benefit of the modular
concept is drastically reduced total cost,
because the use of standardized modules results
in lower engineering expenses. In addition,
shipping complete transport units helps to
cut the costs for disassembly,
packaging and reassembly. p CONTACT
Harald HepkeDivisional Manager Rubber TechnologyPhone +49/511/[email protected]
Cooling system and
receiver conveyor.
The full spectrum of machine technologies from a single contract partner
Unwinders and
conveyors, part of the
modular inner-liner
production line.
MADE BY KRAUSSMAFFEI 1 ¦ 201018 FEATURE
NEW KMD 43 K/P FOR LOWER OUTPUT APPLICATIONS
KraussMaffei Berstorff has extended its new range of conical profile extruders with the lower-output KMD 43 K/P. The new extruder is a typical member of the conical series – reliable, flexible, low maintenance, compact and with an excellent price/performance ratio.
of materials. The air-cooled barrel and an AC
motor in the standard versions help to keep
maintenance effort extremely low and make the
KMD 43 K/P a very adaptable machine.
Despite the longer processing unit, the KMD 43
K/P is a very compact machine; overall length
has even been reduced slightly. The new design
and the flexible positioning of the drive unit
make it easy to configure a number of space-
saving coextrusion concepts, such as piggyback
configurations. Even the standard version of
the KMD 43 K/P, with its compact switching
cabinet and the option of a swivel control panel,
is extremely narrow. This is a strong advantage
in engineering coextrusion solutions. The
advanced C5 controller with its sophisticated
control, monitoring and feedback systems
supports a stable and reliable production
process. And finally, the new extruder, like the
whole conical series, has an excellent price/
performance ratio. p
One of the hallmarks
of KraussMaffei
Berstorff’s conical
extruder range is very
good plasticizing
and homogenization
performance. The new
KMD 43 K/P delivers
this performance
thanks to a redesign
of the conventional
conical screw from
the feed to the
compression zones.
Heat transfer in these zones has
also been significantly improved. The result is
optimal temperature homogeneity across the PVC
powder. The extra length of the screw’s preheating
zone contributes to an very stable process and
optimal melt homogeneity.
Flexible, compact and hardworking
The drive unit has been optimized to increase
specific throughput without increasing screw
speed. The result is output up to 100 kg per
hour. The extruder is targeted at profile extrusion
applications with lower output requirements.
Flexible temperature control, self-regulating
internal temperature balancing and hardened
screw surfaces make it possible to process a range
The ideal addition to the conical extruder series
The KMD 43 K/P conical
twin-screw extruder
adds a lower output
machine to KraussMaffei
Berstorff’s conical
extruder series.
CONTACT
Peter OswaldManager Profile ExtrusionPhone +49/89/[email protected]
The new KMD 43 K/P is
an extremely compact
machine.
19FEATURE
The ZE-UTX twin-screw extruder series from
KraussMaffei Berstorff, Hanover, has several
hallmarks that make it ideal for processing natural-
fiber-reinforced polymers. These include intensive
material and heat exchange, a narrow dwell time
window, effective degassing and speed-independent
throughput. Building on our vast experience, we
have systematically developed this series and made
a wealth of minor improvements to produce an
extruder which is perfect for processing undried
natural fibers. The deep-cut screw flights of this
R model, which has a D/d of 1.74, have plenty of
volume and thus help ensure that the water vapour
released during processing is reliably removed.
Economical and simple
When combined with the special, 6D barrel
elements, natural fibers containing up to 12%
moisture can be effectively degassed and processed.
The benefits of processing undried materials include
low operating costs, which come from eliminating
expensive pre-drying processes, and simplified
handling without the risk of dust explosion.
Patented KraussMaffei Berstorff dual-process screw
elements ensure that the natural fibers are gently
incorporated during extrusion. Neither high shear
rates nor temperature peaks occur that would
thermally damage the natural fibers. Nevertheless,
the special mixing elements provide the desired
level of homogenization and dispersion, and thus
ensure that the end products have comparable
mechanical properties. Finally, low housing-
wall temperatures are important in natural-fiber
Extruded natural-fiber-
reinforced plastics can
incorporate any of a
wide range of natural
fibers.
compounding for preventing
local overheating of the
melt. To this end, the
company has developed
a heat-treatment
process for the
figure-8 bore of the
housing elements. This
process has reduced
the distance between
the cooling holes and
the process chamber,
thereby guaranteeing
very effective cooling
performance. The natural
fiber compounds are converted particularly
economically and gently into the film, profile
or panel end product direct by attaching the
shaping die and the downstream equipment to
the twin-screw extruder itself. KraussMaffei
Berstorff supplies a melt pump for this
constellation that ensures pulsation-free melt
flow at the end of the extruder, combined with
constant pressure. p
The R model of the ZE-UTX twin-screw extruder series from KraussMaffei Berstorff is the perfect extruder for extremely cost-effective compounding of natural-fiber-reinforced plastics. What makes it ideal is the large free volume, special mixing elements and locally variable barrel heating.
The perfect extruder
CONTACT
Lars DarneddeProcess EngineerRenewable Raw MaterialsPhone +49/511/[email protected]
The R model from the
ZE-UTX twin-screw
extruder series makes
light work of natural
fibers with up to 12%
moisture content.
EXTRUSION OF NATURAL-FIBER-REINFORCED PLASTICS
Anz_EX_ZEBasic_DE.indd 1 09.02.2010 14:28:25 UhrAnz_EX_ZEBasic_DE.indd 1 09.02.2010 14:28:25 Uhr
ZE Basic twin-screw extrudersSimply good for compounding
INJECTION MOULDING
REACTION PROCESSING
EXTRUSION
The ZE Basic series of twin-screw extruders is the simplest
solution on offer from KraussMaffei Berstorff for any basic
compounding task – like plastifying, or filling and reinforcing.
Available in 6 sizes, from 26 – 77 mm screw diameter, the ZE Basic
series covers an output range from 5 kg/h to 2.7 t/h. These rugged
machines can be relied on to operate dependably and economically
over their entire service lives. By standardizing many components,
KraussMaffei Berstorff is able to offer you our proven quality
at a budget price.
Anz_EX_ZEBasic_GB.indd 1 09.12.2009 13:39:45 Uhr
ZE Basic twin-screw extrudersSimply good for compounding
INJECTION MOULDING
REACTION PROCESSING
EXTRUSION
The ZE Basic series of twin-screw extruders is the simplest
solution on offer from KraussMaffei Berstorff for any basic
compounding task – like plastifying, or filling and reinforcing.
Available in 6 sizes, from 26 – 77 mm screw diameter, the ZE Basic
series covers an output range from 5 kg/h to 2.7 t/h. These rugged
machines can be relied on to operate dependably and economically
over their entire service lives. By standardizing many components,
KraussMaffei Berstorff is able to offer you our proven quality
at a budget price.
Anz_EX_ZEBasic_GB.indd 1 09.12.2009 13:39:45 Uhr