made by 2008 02 eng - Krauss-Maffei · pipe extrusion ... units are another source of energy loss....

2 ¦ 2008 made byA MAGAZINE FOR ALL CUSTOMERS

OF KRAUSSMAFFEI WORLDWIDE

Large-diameter pipe extrusion

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

02

“Our success

depends

totally on your

success.”Dr. Dietmar Straub,

KraussMaffei CEO

EDITORIAL

Dear Customers, dear Readers,

In terms of sales, KraussMaffei is the world’s biggest manufacturer

of plastics machinery. In the fiscal year now ending, we again

generated strong growth, with sales passing the one billion mark

for the first time. I’d like to take this opportunity of thanking you,

our customers, for your loyalty and trust; because only your success

makes our success possible. We are the only machine supplier

worldwide with huge expertise in three major areas of technology

for plastics and rubber processing – and we see ourselves as full line

suppliers. Our Injection Moulding Machinery division is likely to

cause a furore at the Fakuma with our new, all-electric AX series.

With this machine we’re offering our experience and quality at a

very attractive price/performance ratio. The market for small, all-

electric, injection moulding machines is fiercely competitive, but we

are certain that the AX will do well. AX machines are outstandingly

energy-efficient. Reducing energy costs is also one of the main

topics running through this edition of made by KraussMaffei and it

will also be a lead topic in October at the Fakuma – it‘s a forward-

looking topic that concerns us all.

I look forward to meeting you some of you personally in

Friedrichshafen at the Fakuma!

With best regards,

Dr. Dietmar Straub

EDITORIAL | NEWS MADE BY KRAUSSMAFFEI 2 ¦ 2008

Trade shows 2008/9COMING EVENTS

Expanding market for very large pipe

COVER

In pipe extrusion there’s a strong trend to

large-diameter plastic pipes which are used, for

example, in water supply and district heating

networks. With our high-performance machinery

and complete lines for extruding large-diameter

pipe, KraussMaffei Berstorff supplies customers

with complete solutions capable of delivering

quality and high returns. KraussMaffei Berstorff

has been very successful in this market. For

example we recently commissioned two extrusion

lines producing large-diameter HDPE pipe, one

in the United Arab Emirates and one in Iran. This

is yet another indication of how we are steadily

expanding our position in the strong growth

markets of the Near and Middle East and the

Arabian peninsula. p

Oct. 14–18 Fakuma Friedrichshafen, Germany

Oct. 23–26 Plastex Cairo, Egypt

Oct. 20–24 Equiplast Barcelona, Spain

Nov. 19–22 DMP Dongguan, China

Dec. 04–06 Tyres & RubberTec Shanghai, China

Jan. 10–13 Arabplast Dubai

Jan. 27–30 Interplastica Moscow, Russia

Feb. 04–09 Plastindia New Delhi, India

Feb. 17–19 Tire Technology Expo Hamburg, Germany

Mar. 04–07 Tires & Rubber Moscow, Russia

Mar. 24–28 Plast Milan, Italy

Mar. 25–26 Kunststoffe im Mannheim, Automobilbau Germany

made by KraussMaffei

Published by:

KraussMaffei Technologies GmbH,

Krauss-Maffei-Straße 2,

80997 Munich, Germany

Phone + 49/89/88 99 0,

Fax + 49/89/88 99 22 06,

www.kraussmaffei.com

Responsible:

Matthias Andreesen Viegas

PUBLICATION DATA

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: Baumgarten,

Gerresheimer Wilden, Stephan Görlich,

KraussMaffei, Messe Friedrichshafen,

mk publishing/mk Archiv, pixelio.de/ugub

03

KraussMaffei is

investing in Slovakia;

our new Engineering

Center will initially

employ 20 engineers.

Investment in Slovakia

NEW ENGINEERING CENTER

cabinets in its plant in Martin, around 30 km

from Zilina. In the first roll-out phase, the Zilina

Engineering Center will employ 20 engineers

designing application- and customer-specific

machines for all three of its technology

divisions by the end of 2008. Subsequent

expansion phases will increase this number

to around 80 engineers by the end of 2010.

Another cornerstone of KraussMaffei’s growing

involvement in this region is a recently agreed

cooperation with the mechanical engineering

faculty of the University of Zilina. p

Stronger presence in Eastern Europe – KraussMaffei

is expanding its presence in Slovakia by setting

up an Engineering Center in the university city of

Zilina. With orders escalating, we are looking to

expand our design and engineering capacity – in

addition to existing facilities. Dr. Dietmar Straub,

KraussMaffei CEO, pointed out, “With our new

Engineering Center we are creating the framework

for continuing growth – and reinforcing our

commitment in the strong and emerging markets

of Eastern Europe.” The company already

employs over 100 people building switching

KraussMaffei and Dresden University of

Technology are looking to work more closely

together in the future. The cooperation

agreement was signed on June 11, 2008, by

Dr. Otto Urbanek, KraussMaffei CTO, and

Prof. Dr. Werner Hufenbach, Director of

the Institute for Lightweight Structures and

Plastics Technology in Dresden. The main

cooperation areas will be in education, on

R&D projects and in support for young

engineers keen to undertake research in this

area. Undergraduate students from Dresden TU

will be able to do internships at KraussMaffei

and to work towards their final theses while

with the company. KraussMaffei employees

will undertake teaching tasks at the university.

One concrete goal is to develop machine

concepts for new types of composite structures

for lightweight products that help to conserve

resources. p

Partnership for education and R&D

COOPERATION WITH DRESDEN TU

NEWS

Trade shows 2008/9

A handshake seals a

new partnership: Prof.

Dr. Werner Hufenbach

from Dresden University

of Technology (l) and

Dr. Otto Urbanek,

KraussMaffei CTO.

New head for Extrusion Technology

DR. JENS LIEBHOLD MOVES TO MUNICH

On June 1, 2008,

Dr. Jens Liebhold

took over as head

of KraussMaffei’s

Munich-based

extrusion activities.

Jens Liebhold (48)

took a degree in

mechanical engineering

and a Ph.D. in materials

science before joining

Berstorff GmbH in 1990. Specializing

in process engineering for twin-screw

extruders (ZE), he became manager of

the ZE Process Engineering team (1995)

and subsequently head of the whole ZE

business area (2001). Since December

2006, Dr. Liebhold has also held the

post of CTO for the KMB subsidiary

Burgsmüller GmbH in Kreiensen. p

Dr. Jens Liebhold,

new head of Munich

Extrusion.

04 MADE BY KRAUSSMAFFEI 2 ¦ 2008

a major factor in manufacturing cost and it must be

addressed if costs are to be controlled.

Energy efficient solutions

Energy efficient configuration of new machines is

routine for our engineers. Less widely known is

that we also offer a range of solutions to boost the

energy efficiency of already installed production

systems. The aim is process-orientated optimization

for the entire life cycle of a machine or system. We

offer modular solutions, ranging from upgrades for

single components to

customized system

modifications. The

heat balance is an

essential aspect for

reducing energy con-

sumption and costs

in injection moulding

and extrusion. One

simple and effective

measure is the in-

stallation of EcoPac

sleeves for the heat-

ing bands of screw

barrels. At the other

end of the scale are

alternative heating

systems, such as na-

tural gas or induction

heating, which can

deliver cost savings

ENERGY EFFICIENT PLASTICS PROCESSING

Energy management can significantly increase the economic viability of injection moulding machines and extrusion lines. KraussMaffei offers customers individual modular solutions to save energy.

Energy efficiency is moving up the agenda – or it

will do when you check the latest power bill. In

addressing the problem, we need to look at energy

costs over the whole machine life cycle. Escalating

energy prices are going to be an issue for all of

us for the foreseeable future. This means that we

must also look at improving the energy efficiency

of already installed machines. At KraussMaffei,

we already offer our customers a range of services

and products for this purpose – from consulting to

commissioning. Energy consumption is going to be

FOCUS

Conserve resources and save costs

Electric drivesFluid management Gas heating Economiser Variable delivery pumps

Plasticizing unitCalibration service Application engineering Energy audit Insulated heating pads

ENERGY MANAGEMENT

Building blocks in

efficient energy

management.

05

of around 40%. “Reduced consumption and lower

connected load mean that these investments pay

off very quickly and make retrofitting a viable

proposition,” explains Josef Hammerschmid, in

charge of energy management at KraussMaffei Ser-

vice. “The synergy effects for planned production

expansions are obvious and the latest energy price

developments as well as imminent C02 emissions

directives will provide further incentive,” he points

out.

Optimising extrusion

Energy costs also play an important role in the

extrusion process – especially, if they continue to

rise. “In pipe and profile extrusion, energy costs

rank third in the total manufacturing cost,” says

Robert Breitenberger, head of spare parts sales at

KraussMaffei.

Extruders use a combined heating/cooling unit.

Ideally, their energy input is close to zero, because

the extrusion process itself should produce an

optimum processing temperature requiring neither

heating nor cooling. In practice, it is difficult to

achieve this ideal state over the entire output

range of an extruder. In co-operation with WEMA

Beheizungstechnik, KraussMaffei has developed

an EcoPac retrofit package for counter-rotating

twin-screw extruders. The package consists of

seven insulation elements and three convection

flap systems. The drop of between 5 and 10% in

total energy input has been demonstrated in field

trials and in production conditions. Extruder drive

units are another source of energy loss. Direct

drive systems, with the extruder screw connected

directly to the electric motor, have proved to be

the most economical. Depending on the machine

configuration, an AC motor can be more energy

efficient than the ubiquitous DC motors. The

choice of energy efficiency measure is as individual

as your applications and machine configurations.

Here – as in all questions of system planning and

optimization – KraussMaffei has the competent

experts. p

FOCUS

Optimizing energy

consumption in extrusion

systems

• Retrofit EcoPac kit

• AC technology

• Direct drive

• Reactive current

compensation

• KraussMaffei Berstorff

energy consulting

CONTACT

Josef HammerschmidSales Injection Moulding Machinery ServicePhone +49/89/8899 [email protected]

Robert BreitenbergerSales Manager Spare Parts Extrusion Technology MunichPhone +49/89/8899 [email protected]

Solutions to increase the efficiency

of injection moulding machines

• Energy-saving software

• Calibration service

• Fluid management

• Retrofitting an electric screw drive

• Conversion to variable delivery

pumps

• Barrel heating systems

• EcoPac insulating sleeves

• Plasticizing units

• KraussMaffei Economiser

• On-site application engineering

• EDP, lightning strike and overvolta-

ge protection

• GSM, radio module

• Energy consulting

AT A GLANCE:

>

Josef Hammerschmid, Sales IMM Service and

Ralph Lindner, Project Engineer IMM, make

their expertise available to customers through

face-to-face discussions.

CONSULTING

06

KraussMaffei

Now in

Hall A7

Stand 7205

Focus on: energy savings

The main theme of the KraussMaffei stand is

“energy savings”. We’re showing ways of

optimizing energy management in extruders and

injection moulding machines. A screen will

display the current energy consumption of each

KraussMaffei injection moulding machine at the

show. This option is open to all KraussMaffei

customers, energy-consumption displays are

available as an optional extra for every machine.

“You can’t optimize your machine if you don’t

know how much power it’s consuming,” says

Josef Hammerschmid, from Injection Moulding

Sales Service at KraussMaffei. The KraussMaffei

stand will feature energy-saving concepts already

implemented elsewhere that illustrate the scope

for cutting consumption.

Other highlights

KraussMaffei will also be showing the CX 200-

1400 injection moulder along with an electric

TwinComet metering system and a small-volume

mixing head for C.A.S.E. applications (Coatings,

Adhesives, Seals, Elastomers) using high-pressure

polyurethane technology. Other exhibits will be

EX 240-1000 injection moulding machines with

SR-80 side entry robots and a host of other

products. p

This year’s Fakuma, to be held in Friedrichshafen

from October 14 to 18, is expected to attract some

40,000 visitors. Many of them will make their way

to stand 7205 in Hall A7 to find out more about

the all-electric AX injection moulding machine.

With up to 60% greater energy efficiency and a

25% smaller footprint for a fully automated,

completely enclosed production cell,

KraussMaffei’s new AX injection moulding

machine series will help to slash manufacturing

costs in standard applications. A standard electric

machine with 50 to 350 tonnes’ clamp force, the

AX rounds out the current high-end range of

customizable all-electric machines. The AX boosts

productivity through a combination of energy

efficiency and operator friendliness.

MADE BY KRAUSSMAFFEI 2 ¦ 2008 FOCUS

FAKUMA HIGHLIGHTS

Kraussmaffei will be taking a large number of highlights to the 19th Fakuma international trade show for plastics processing in Friedrichshafen, Germany. Aside from the world premiere of the all-electric AX series, the stand in the new hall A7 will focus on energy savings.

Electrifying show presentation

The AX is a new,

extremely energy-

efficient injection

moulding machine series

from KraussMaffei.

07FEATURE

C.A.S.E. high-

pressure metering

technology is ideal

for mass production

of gaskets, bondings

and castings.

INNOVATIVE C.A.S.E. HIGH-PRESSURE METERING

KraussMaffei’s innovative low-volume high-pressure mixing system is used for processing fast-reacting chemical systems for coatings, adhesives, sealants and elastomers (C.A.S.E.) applications. High-pressure metering, combined with self-cleaning, transfer mixing heads, provides cost-competitive solutions for mass-producing liquid seals and for other C.A.S.E. applications.

Sealing under high pressure

“The target sectors for our C.A.S.E high-pressure

metering technology are undoubtedly in the

automotive and electrical industries, as well as in

filter applications – in short, wherever seals,

bondings or castings are required in quantities of

150,000 units and more,” says Thomas Elfroth,

Product Manager at KraussMaffei.

High-pressure mixing is more cost-effective than

its low-pressure counterpart. Using faster-reacting

chemical systems cuts production and curing

times, minimizing the need for buffer zones and

interim storage. Moreover, the high-pressure

mixing heads are self-cleaning, so that seals can

be produced without material wastage, and

independent of cycle time. By contrast, mixing

heads in low-pressure systems need to be cleaned

at regular intervals.

High efficiency

Two mass production systems are already up and

running in the automotive industry. “The systems

are very stable. We are absolutely convinced that

we can use this technology to help many

companies increase their efficiency,” affirms

Elfroth. “In high-pressure production, the

technology enables tiny quantities of material in

to be metered and mixed with the utmost

accuracy. It’s cutting edge technology,” he adds.

Making the whole combination possible are

KraussMaffei’s self-cleaning small-volume

mixing head and the TwinComet metering

machine specificially developed to team with it.

To tap into the huge potential market for high

pressure technology in seals and gaskets

production, KraussMaffei is currently

developing another new unit that can meter

even smaller volumes. We expect to pilot-test it

in Munich next spring. The system will then

be made available for individual customer

trials. p

CONTACT

Thomas ElfrothProduct ManagerPhone +49/89/8899 [email protected]

08 MADE BY KRAUSSMAFFEI 2 ¦ 2008FEATURE

PIRACY PROTECTION FOR SMALL PLASTIC ITEMS

pharmaceuticals. “For the pilot project, we

took an existing infrared pigment from 3M and

incorporated it into the manufacturer’s material.

We fitted a co-rotating twin-screw extruder from

the ZE A UTX series with a special processing

unit to ensure that the very small pigment content

was uniformly dispersed,” says Betsche. The ZE

A UTX machines are capable of compounding

plastics for a wide range of processing methods.

These include the manufacture of masterbatches,

plasticizing and alloying of plastics, and the

incorporation of reinforcing materials, mineral

fillers and natural fibres into polyolefins and

engineering plastics. The modular engineering of

the screws and barrels makes it a simple matter to

configure the extruders for specialist compounding

tasks. “The result was that we were able to

produce an optimal infrared masterbatch within

a short time,” recalls Betsche. Dr. Gösta Pretel,

Plant Manager at Gerresheimer Wilden GmbH,

adds, “Now we can create a customized, concealed

marking that cannot be counterfeited, but can

be quickly and reliably identified by authorized

personnel using a verifier.”

“It is estimated that annual losses due to

counterfeiting and product piracy around the

world amount to 250 billion US dollars. The

principal targets are high-quality products from

the medical and automotive sectors,” says Markus

Betsche, Product and Marketing Manager at

KraussMaffei. The scale of the economic damage

and the safety risks for those who innocently

use counterfeit products has created a great need

to find a way of marking high-quality branded

products that users can readily identify but

counterfeiters find difficult to copy.

A united front

KraussMaffei, together with 3M and Gerresheimer

Wilden GmbH, has developed a

successful process for marking

syringe caps used by

a global leader

in specialty

Product piracy wreaks enormous economic damage and, in extreme cases, threatens the very existence of OEMs. It doesn’t help either that the forgeries are usually sub-standard and can pose serious safety risks. KraussMaffei GmbH has joined forces with 3M and Gerresheimer Wilden to develop a process that provides effective counterfeit protection for small, mass-produced plastic articles

Combating counterfeits

Fully automated

injection moulding

cell with integrated

part testing.

Authenticating a screw

cap with laser-verifiable

pigments.

09FEATURE

Infrared batches in practice

KraussMaffei demonstrated how well the ready-

made infrared batch works by using it to produce

a medical screw cap at a trade show. The 4-cavity

mould had a full hot-runner system and a hydraulic

unscrewing device for demoulding the threaded

part. The caps were produced in a cell comprising

an injection moulding machine and a linear robot.

The machine, for which we offer a wealth of

options, can be used to manufacture a wide variety

of standard products. The infrared masterbatch

is automatically admixed to the original material

in the right quantity on the machine itself, where

it is melted and homogenized in the plasticizing

unit. The parts are demoulded by a linear robot

which passes them in front of an automated test

cell. The mould’s fitness for purpose was checked

by integrated verifiers, which scanned each cavity

for the security feature. “This shows beyond doubt

that counterfeit protection can be readily integrated

into the mass production of small articles,” stresses

Betsche.

Clever modular compounders

For flexibility and fast start-up times, KraussMaffei

mounts the individual components in a type of

freight container. The wired and piped modular

system features a KraussMaffei Berstorff extruder

plus all the peripheral units, such as raw material

handling, mixers, hoppers, metering units, vacuum

pump, cooling unit and switching cabinets.

Pelletizing, pellet drying and classification have

all been modularized. The individual modules

are easy to transport, assemble and to put into

operation. Customers save time and money

because they can easily relocate the modules to

another production site as the need arises.

Building block system for

injection moulding cells

In addition to preparing compounded infrared

masterbatches, an IMC can be used to incorporate

the infrared batch into the plastic on the injection

moulding machine itself and to process it without

intermediate cooling. This approach eliminates

the steps of granulation, drying, packaging and

storage. It lends itself especially for applications

with high shot weights and material throughput.

Infrared security technology is also suitable

for medical parts produced under controlled

cleanroom conditions. Custom manufacturing

solutions and cleanrooms up to Class 5 (ISO

14644) are available. Where parts are packaged

inside the cleanroom, downstream steps, such

as sterilizing, become unnecessary. Says Markus

Betsche: “Laser-verifiable infrared marking of

mass-produced items tips the balance back in

favour of manufacturers and users. Counterfeiters

have no chance.” p

CONTACT

Markus Betsche Product and Marketing Manager Phone +49/89/8899 [email protected]

AT A GLANCE: Anti-counterfeit technologies for mass

production of small plastic articles

Microtagging Laser-verifiable

pigments

Product marking Visible/hidden Hidden

Position of the marking In the plastic In the plastic

Marking size 44 to 600 µm 44 to 600 µm

Incorporation During parts production During parts production

or compounding or compounding

Security High Very high

Testing Microscopic analysis IR tester

Checking effort Very high Low

Information Color-coding Frequency spectrum

Conspicuousness of the test Very conspicuous Inconspicuous

Minimal product dimensions Small Small to tiny

MADE BY KRAUSSMAFFEI 2 ¦ 200810 KEYNOTE | NEWS EXTRUSION

“Our engineering

expertise enables us

to pioneer customized

solutions.”

Manfred Reichel,

General Manager

Extrusion Technology

KEYNOTE

Dear Customers, dear Readers,

Thanks to KraussMaffei and Berstorff having recently merged

their extrusion operations to form KraussMaffei Berstorff, our

company now commands a wide range of technologies. The

production system for plastic roof membranes described in this

edition of made by KraussMaffei is an impressive example.

We are the world‘s leading manufacturer in this field, offering

our customers application-specific engineering solutions

tailored precisely to their specific to production process. Our

applications report looks at the extruders installed at aluplast

in piggyback combinations. It illustrates our engineers’ capacity

to come up with a number of system solutions, differing in key

details, for a single customer. Our developers also focus on

automation components and ease of operation – read about our

control solution for foam extrusion systems.

In addition to orders for individual modules, we’re seeing

strong growth in demand for complete extrusion lines. The two

high-performance lines for very large pipes, recently installed

in the United Arab Emirates and in Iran, demonstrate clearly

the enormous capacity of KraussMaffei Berstorff solutions

to combine lower manufacturing costs with optimal product

quality.

Our engineering expertise puts us in a pioneering position

whenever the focus is on developing and implementing

innovative solutions for your special requirements.

Manfred Reichel,

General Manager Extrusion Technology

Ecopac, a package of products and services

from KraussMaffei Berstorff, substantially

increases the energy efficiency of extruders.

One example is the flap unit developed by

KraussMaffei Berstorff to cut heat losses around

the blow-off dome of the insulated barrel with

its combined heating/cooling system. The flap

unit significantly reduces this heat loss, without

affecting the properties of the extruded profile

in any way. Extruder drive systems also offer

potential for energy savings. Under normal

operating conditions, synchronous three-phase

motors are more efficient than DC motors.

Higher energy efficiency means lower operating

costs. On a KMD 90-32D profile extruder, for

example, reducing heat loss and using the most

efficient drive technology can cut total power

consumption by more than 15% without any

reduction in output. The investment usually pays

off within less than two years. KraussMaffei

Berstorff demonstrated its energy-saving system

at K2007 on a KMD 133-32/P twin-screw

extruder. The barrel’s heating/cooling zone was

fitted with the Ecopac kit. With manufacturers

around the globe seeking to maximize energy

savings, we’ve received numerous orders to

retrofit 32D profile extruders.p

The way to energy-efficient extrusion

ECOPAC FROM KRAUSSMAFFEI BERSTORFF

Temperature distribution of an insulated barrel with

a combined heating/cooling system. Left: temperature

peaks lead to heat losses. Right: preventing natural

convection reduces energy consumption.

In support of our customers’ drive for tight

control of manufacturing costs for plastic pipe,

KraussMaffei Berstorff develops machinery and

systems that help to cut the cost and consumption

of raw materials. On June 19, 2008, over 70

customers gathered at our Munich plant for one

of the company’s in-house Spotlight events. This

time the spotlight was on a complete PVC pipe

extrusion line in action producing foamcore

pipe. The line, with twin-screw extruders KMD

90-36 B/R and KMD 75-36 B/R and the totally

reengineered KM 3 LRK 43 multilayer pipehead

achieves throughput of 900 to 1,000 kg/h of

PVC foamcore pipe with 400 millimetre diameter

and 11.7 millimetre wall thickness. The line

included all downstream components through to a

socketing machine and palletizing unit. Interesting

background information from Daniel Lachhammer,

KraussMaffei Berstorff Product Manager Pipe

Extrusion, and

Dr. Udo Anders,

Technical Product

Manager at

Baerlocher GmbH,

rounded off the

event. p

11

Know-how from Germany plus machines and systems built in China

make an outstanding combination. The success story of KraussMaffei

Extrusion Technology (KMET), a company in the KraussMaffei

Berstorff Group, is a good illustration. At the KMET Open House 2008

on April 16, over 400 visitors took the short trip from Shanghai to the

KMET plant in Haiyan county to find out more about the company’s

products and services. The visitors toured the ultra-modern, 12,000

sqm production floors, opened in 2006, where

KMET builds pipe and profile extruders and

extrusion line components. With its KMET

subsidiary, KraussMaffei Berstorff has

successfully united the best of both worlds:

know-how from Germany – for premium

quality – and production capacity in China

– for extremely cost-competitive production

processes. The KMET plant in Haiyan is

building machines targeted at the requirements

of Asian markets. p

KMET OPEN HOUSE 2008

The best of two worlds

NEWS EXTRUSION

Praise for innova-tive PVC foamcore pipe line

IN-HOUSE SPOTLIGHT EVENT

KraussMaffei Berstorff has appointed Ralf J.

Dahl as the new manager of its Twin-Screw

Extruder Business Area, operating out of

the company’s Hanover plant. Departments

include Sales, Process Engineering, Design and

Project Management. Ralf Dahl takes over

from Dr. Jens Liebhold, who has relocated to

Munich as director of KraussMaffei Extrusion Munich. Ralf Dahl (47) is

an engineering graduate (Diplom-Ingenieur) with many years’ experience

in sales and management. He joined what is now KraussMaffei Berstorff

GmbH in 2000 as Technical Manager for the product area Twin-Screw

Extruders. When this unit became a largely autonomous profit centre in

2002, Ralf Dahl took on a management role and became a member of the

company’s executive team. p

Ralf J. Dahl takes over at the top

BUSINESS AREA

TWIN-SCREW EXTRUDERS

Festive opening for the

open house at KMET,

China.

Over 70 customers took advantage of an in-house

Spotlight event to find out more about the PVC foamcore

pipe extrusion line.

Since June 1, the Twin-

Screw Extruder business

area at KMB has been

headed by Ralf J. Dahl.

12 FOCUS EXTRUSION

EXTRUDING ROOF MEMBRANES

Plastic is proving its potential in the building industry, too – for example, as roof membranes. The production machinery for plastic

roof membranes comes from KraussMaffei Berstorff − with the advantage that KMB offers a variety of machine technologies and thus supplies every customer with a highly customized system solution.

standards. Both PVC and TPO satisfy all the

demands made on a contemporary construction

material.

Application-specific solutions

KMB is the world’s leading supplier of extrusion

machinery for producing roof membranes. The

manufacturer supplies not only the extruders, but

complete system solutions and turnkey

production lines. System solutions begin with the

raw material silos and include the mixing station,

the extrusion line – sometimes with co-extruders

– and all additional and downstream

components, such as metering equipment, the

screen changer and melt pump, sheet dies,

polishing stacks, winders and packaging stations.

The extrusion lines reach throughput rates of up

to 4,500 kg/h for a three-metre-wide membrane.

PVC and TPO roof membranes are traditionally

extruded using co-rotating twin-screw extruders.

By pooling engineering expertise from two

production plants, KraussMaffei Berstorff can

now also offer counter-rotating twin-screw

extruders to produce PVC roof membranes.

Professor Bernd Poltersdorf explains the benefits

of each technology: “A counter-rotating extruder

creates processing conditions that are gentle on

the material. This is especially important for

PVC, which is sensitive to thermal and

mechanical stress. The great strength of a co-

rotating extruder is in homogenizing the raw

material efficiently, which is essential for TPO

formulations.

Large roof areas,

especially flat roofs,

are traditionally

covered with

bituminous

membranes or

corrugated sheets of fibre cement. As resource

conservation becomes ever more important,

however, a new product with greatly improved

properties is making inroads. Plastic roof

membranes made of PVC or TPO save energy and

reduce carbon dioxide emissions, particularly

where they are used in regions with very intense

sunlight. TPO or PVC roof membranes with a

white surface absorb less sunlight than

bituminous membranes. The rooms underneath

heat up less and need less intensive air-

conditioning.

Apart from delivering this environmental benefit

and being cost-effective to produce, roof

membranes must also be easy to weld and must

possess certain mechanical and climatic

properties. One of the most important of these is

suitability for use over a temperature range from

-40 to +70 °C. “TPO and PVC roof membranes

are now being used the world over,” explains

Prof. Bernd Poltersdorf, who is head of foam,

film and sheet extrusion machinery at

KraussMaffei Berstorff in Hanover. “Significantly,

major areas of use include the USA (for example,

California) and Russia – where entirely different

climatic conditions prevail. The membranes must

also meet international flame-resistance

Energy-saving plastic

KraussMaffei Berstorff is

the global market leader

for roof-membrane

extrusion lines.

MADE BY KRAUSSMAFFEI 2 ¦ 2008

13FOCUS EXTRUSION

Depending on the material used and the specific

application, KraussMaffei Berstorff can offer the

perfect engineering solution. This gives us a

unique position on the market, and, above all,

benefits our customers.”

Versatile product, flexible production

The main use for plastic membranes is for

covering large roof areas. Typical examples are

industrial buildings, such as warehouses and

production and exhibition halls, administrative

buildings and multi-storey car parks. Plastic is

also being used on a steadily growing number of

single-family homes with flat or low-pitch roofs.

It helps such houses to meet criteria for low-

energy housing.

Extrusion technology from KraussMaffei Berstorff

offers great flexibility in the production of roof

membranes. For example, both TPO and

plasticized PVC can be processed with a co-

rotating twin-screw extruder on one and the

same production line.

Inline compounding produces material

formulations which exactly suit the specific

application. The individual polymer membranes

can be calibrated very accurately and laminated

with a fabric backing. The multilayer films

formed in this way are suitable not only for

roofs, but also for other waterproofing

applications such as swimming pools,

tunnels, canals, dams and large water

reservoirs.

The trend towards integrating plastic roof

membranes in solar roofs will give the

product a further boost. p

CONTACT

Prof. Dr. Bernd PoltersdorfBusiness Unit ManagerFoam, Film and Sheet Extrusion SystemsPhone +49/511/5702 [email protected]

Plastic membranes are

the first choice for sealing

flat green roofs, too.

Plastic membranes are

being used increasingly for

covering large roof areas.

MADE BY KRAUSSMAFFEI 2 ¦ 2008

deliver maximum output rates of 760 kg/h for PP

and 1,100 kg/h for HDPE, achieving a very

attractive price/performance ratio. The longer

processing units (L/D ratio 36) boost specific melt

throughput and total output. This screw design

also delivers a very stable process and high

product quality. It improves the thermal and

physical homogeneity of the melt and makes it

possible to run the process at relatively low

temperatures. The inner and outer layers of the

pipe, made of unfilled PP, are produced on a KME

45-30 B/R coextruder. The compact design of this

coextruder facilitates integration in a production

line. The layers are joined in a KM3L RKW 75

3-layer pipehead.

The system is due to go into operation shortly.

Riccini is a long-standing KraussMaffei

Berstorff customer, operating two extrusion

lines with a total of four KME 90-36 B/R

extruders to manufacture PP well shafts. p

Well shafts form part of well systems that extract

drinking water from groundwater. The section of

the shaft that reaches into the groundwater has

apertures through which water enters the pipe.

Sand, soil and other large particles are filtered

out. Previously well shaft pipe was made of PVC.

The new KraussMaffei Berstorff extrusion line

for PP pipe offers Riccini a viable alternative.

Impressive output

The middle layer of the

pipe, with CaCO3 filler, is

produced by the main

KME 105-36 B/R extruder.

The new extruders are

KraussMaffei Berstorff’s

largest machines for

polyolefin pipe; they

14 APPLICATION

CONTACT

Daniel LachhammerProduct Manager Pipe ExtrusionPhone +49/89/8899 [email protected]

NEW LARGE EXTRUDER ROUNDS OUT THE SERIES

Italian pipe manufacturer Riccini S.r.l., Perugia, will shortly begin operating a new extrusion line from KraussMaffei Berstorff to produce multilayer PP well shafts. The PP pipe is a cost-competitive alternative to conventional PVC pipe for this task.

PP multilayer pipe new alternative for well shafts

KraussMaffei Berstorff’s

36D single-screw pipe

extruders deliver high

output and premium

product quality.

Complete high-

performance

extrusion

lines from

KraussMaffei

Berstorff for

production of

large-diameter

plastic pipe combine optimal

quality with the prospect of high return on

investment. The extrusion line that went into

operation in the United Arab Emirates in early

2008, for example, is producing large-diameter

HDPE pipe with an outer diameter of 1,200 mm.

Production on this scale is made possible by

combining a single-screw KME 125-36 extruder

with RKW 36 and RKW 38 pipeheads. Currently

the line is producing jacket pipes – with an

insulating PU layer inside an outer jacket pipe.

These pipes are used to transport cooling medium

for air conditioning systems in large buildings and

also for water supply networks. The customer,

Emirates Preinsulated Pipes Industries (EPPI) from

Abu Dhabi, praised the effective line concept:

“Markedly better than any competitor’s reference

line.”

In Iran, the largest extrusion line KraussMaffei

has ever built has been producing large-diameter

HDPE pipe up to 1,600 mm diameter since

late 2007. The line was supplied to P.E.S. Co.,

the leading private polyethylene pipe producer

in Iran. “These are some of the biggest pipes

currently used for pressure applications,” points

15 APPLICATION

EXTRUSION LINES FOR BIG HDPE PIPE

The market for large plastic pipe is growing steadily. Two lines for large HDPE pipe have recently gone into operation in the United Arab Emirates and in Iran. They’re another sign that KraussMaffei Berstorff is forging ahead with sales in the strong growth markets of the Near and Middle East and the Arabian peninsula.

Success on a large scale

CONTACT

Daniel LachhammerProduct Manager Pipe ExtrusionPhone +49/89/8899 [email protected]

The KraussMaffei

Berstorff team

responsible for the

project in the United

Arab Emirates.

Extrusion line for large-

diameter PO pipe.

out Daniel Lachhammer, Product Manager Pipe

at KraussMaffei Berstorff. The big HDPE pipes

are used in drinking water supply networks and

wastewater systems.

In early June, Daniel Lachhammer described

theses two projects in a presentation on large pipe

extrusion to over 150 people at the Middle East

Plastic Pipes 2008. As he said, “The two extrusion

lines have proved to be excellent reference projects

for us. During the conference we made some

excellent contacts to plastics processors around the

world.” p

MADE BY KRAUSSMAFFEI 2 ¦ 200816 APPLICATION

EXTRUDERS IN PIGGYBACK CONFIGURATIONS

aluplast GmbH, Karlsruhe, Germany, is a major manufacturers of PVC window systems. The company operates over 45 KraussMaffei Berstorff extruders at its production plants around the world, including several piggybacked systems configured specifically especially for their conditions.

and moved if necessary. Among the highlights,

and not only in this respect, is the combination of

two 90-32/P twin-screw extruders with a KMD

50 K/P as coextruder. The configuration takes

up floorspace measuring just 2.5 m by 5.4 m.

Each processing unit has its own separate base

frame, so that it can be repositioned with the

utmost flexibility. KMB took a number of steps to

save space. The main switching cabinet for each

unit stands at the end of the unit and only small

switching cabinets with the necessary control

zones and operator panels take up space near

the die. Attaching the converters for the water-

cooled AC motors above the gearbox also saves

space. The switching cabinet for the coextruder

is mounted on rollers and can be moved aside to

allow access to the main motor. The unit is not

only mechanically flexible; the control system is

also configured for extra flexibility, allowing the

two main extruders to be controlled together or

separately by a defined master. This extremely

compact, double-strand system for extruding core-

technology window profiles achieves throughput

of over 900 kilograms an hour. It’s typical of

KraussMaffei Berstorff’s outstanding competence

in delivering exactly what the customer needs. p

Founded in December 1982, aluplast GmbH

has achieved stellar growth. Through a

rigorous product strategy, cooperation with

partner companies, and through flexibility and

innovation, aluplast has become one of the most

successful companies in the industry. Today the

company’s brand ranks third in Europe and fifth

worldwide.

Compact and flexible

Since 2005, aluplast has used high-performance

extruders from KraussMaffei Berstorff. It

currently operates over 45 machines at its

different production plants. Some of them are

single machines, others are special compact

piggyback combinations. KraussMaffei developed

a number of different solutions for aluplast; all of

them met the company’s stipulation for compact

extrusion lines for that can be flexibly installed

Top performance with a small footprint

CONTACT

Annette BeierlingProduct Manager Profile ExtrusionPhone +49/89/8899 [email protected]

Two KMD 90-32/P

twin-screw extruders

with a KMD 50 K/P co-

extruder.

aluplast produces its

plastic window systems

on extruders from

KraussMaffei Berstorff.

17FEATURE

The KMB product range has been expanded to

include extrusion lines, complete with extru-

ders, for small-to-medium profiles. Downstream

equipment in various configurations is also

available separately. The central component of

these complete profile extrusion lines is always

a 45/60-30 D single-screw extruder, fitted with a

general-purpose screw. The 45 extruder module

has an output of 50 kg HDPE, 40 kg PP, 60 kg

ABS or 50 kg TPE per hour, while the 60 module

has an output of 70 kg HDPE, 60 kg PP, 85 kg

ABS and 70 kg TPE per hour.

Modular downstream line components

Immediately downstream of the extruder with

the die is the calibrating table. This is equipped

with a water/vacuum tank. The longitudinally

adjustable table accommodates the dry calibra-

tor, while the water/vacuum unit cools the pro-

file. A smart zone for connecting any peripheral

equipment which the customer may require is

integrated in the calibration table. The combined

take-off/sawing unit can be fitted with a belt or

caterpillar take-off system. The latter generates

a higher pulling force. After cutting to length in

the sawing unit, the profile moves to the tilt-type

collection table. A PLC using the asynchronous,

serial CAN-bus system and including a touch-

screen makes for easy operation of the profile

lines and their high-performance extruders.

We offer a choice of six operating languages

as standard. The system displays the machine

status in clear text and can also display all the

relevant maintenance information. Thanks

to the line’s modular design, each line with

its extruder and downstream equipment can

be tailored precisely to specific requirements.

Each customer gets an individually customized

production system. p

EXPANDED PRODUCT RANGE FOR PROFILE EXTRUSION

Complete or as modules

A complete profile

production line from

KraussMaffei Berstorff,

including a single-screw

extruder, combined

water/vacuum tank,

smart zone, combined

belt take-off/saw unit,

and tilt table (from the

right).

CONTACT

Annette BeierlingProduct Manager Profile ExtrusionPhone +49/89/8899 [email protected]

KraussMaffei Berstorff has expanded its range of production machinery for small-to-medium profiles, and is now able to offer every customer a solution tailored precisely to the customer’s production process.

MADE BY KRAUSSMAFFEI 2 ¦ 200818 FEATURE

PVC SHEET EXTRUSION IN RUSSIA

In Russia, demand for plastic sheet is rising steeply. The country’s two largest and best known sheet manufacturers, Rosstar in St. Petersburg and United Extrusion in Moscow, rely on sheet-extrusion machinery from KraussMaffei Berstorff.

are the largest and most prominent sheet

manufacturers on the Russian market,” stresses

Munich-based Michael Hofus, head of sales in

Russia. “We are proud that part of their success

is due to our machine technology,” he adds.

KraussMaffei Berstorff maintains its own office

in Moscow, where Yuri Kashtanov can be relied

on in all issues relating to sheet, pipe and profile

extrusion. With a local presence, KraussMaffei

Berstorff can provide optimum customer service.

In Russia and around the world, KraussMaffei

Berstorff has built a reputation as an expert

supplier of complete extrusion lines using mature

technologies. The 32 D twin-screw extruder

series has proved excellent for manufacturing

top-quality thermoformable sheets, including

expanded sheets. With its C5 control system,

KraussMaffei Berstorff also offers its customers

one of the most advanced control and monitoring

systems available for extrusion. All these benefits

have helped the company to gain a strong footing

in this young market. p

The Russian market for plastic sheets is growing

fast. The construction, advertising and home

appliances industries report continuously

increasing demand for these products. Until now,

demand has been met primarily by imports, but

the number of plastic-sheet manufacturers in

Russia itself is growing rapidly. PVC processing, in

particular, is experiencing a strong upward trend.

However, the demand for PVC feedstock cannot

be met by domestic producers; in 2007, Russia had

to import about 30% of the feedstock it processed.

Customer proximity

To satisfy the demand for high-quality products,

Rosstar and United Extrusion use KraussMaffei

Berstorff machinery

for manufacturing

PVC sheet. Rosstar

already has two of

these extruder lines

in operation, and

United Extrusion is

set to install a second

one soon. “These

two manufacturers

From market leader to market leader

CONTACT

Ralf PühlerProduct Manager Sheet ExtrusionPhone +49/89/8899 [email protected]

The KMD 114-32/PL

twin-screw extruder

for manufacturing PVC

sheet.

19FEATURE

Modern tandem foam extrusion lines consist of a

co-rotating twin-screw extruder, for compounding

and incorporating the blowing agent, and a

single-screw extruder for cooling the expandable

melt.

The twin-screw extruder is starve-fed via a

gravimetric metering system, capable of metering

up to eight formulation constituents. Screw

speed can be varied within limits dictated by the

extruder’s feed capacity and the back-pressure

length. Reducing the speed at a fixed throughput

rate increases specific throughput, ie, the ratio

of polymer throughput to screw speed. The

specific throughput of the KE cooling extruder

can also be varied within set limits to influence

melt temperature and the pressure in the entire

line. The specific throughput rates make it

possible to link extruder speeds and polymer

throughput via the control system. Changes to

specific throughput will automatically cause

extruder speeds to be adjusted. The amount of

blowing agent is usually defined as a percentage

of polymer throughput, which means that it, too,

can be linked with polymer throughput via the

control system. As throughput changes, keeping

the percentage of blowing agent constant

necessitates adjusting the absolute amount

of blowing-agent. This parameter is relayed

automatically to the metering-pump controller.

Highly automated

KraussMaffei Berstorff‘s control system allows

typical adjustments to operating parameters

to be highly automated, This includes changes

to throughput or start-up and shut-down of

the entire line. A mouse-click from the central

control panel sets the target extruder-line

throughput. The operator no longer

needs to adjust individual components

manually. This significantly reduces

operator errors during production

switchovers. Machine parameters

are logged continuously, and can be

displayed as trend curves, allowing

the operator to keep a close check on

the progress of operating parameter

adjustments. p

CONTROL SYSTEM FOR FOAM EXTRUSION LINES

KraussMaffei Berstorff links up the individual components of its modern foam extrusion lines by means of a sophisticated control system. Typical adjustments to operating parameters are now automated – it’s a big advantage compared with conventional manual adjustment.

Foam under control

Setting the target

throughput rate for the

foam extrusion line

(left) by mouse-click

at the central control

panel (above). Screen

displays (below) enable

the operator to monitor

the process closely.

CONTACT

Matthias ReimkerProduct Manager Sheet ExtrusionPhone +49/511/5702 [email protected]

Otto DesekeProduct Manager Sheet Extrusion Tel.: +49/511/5702 162 [email protected]

The Extrusion Technology division bundles the high-calibre know-how of KraussMaffei and Berstorff in the KraussMaffei Berstorff brand (since 2007). The division is uniquely placed to cover almost the whole spectrum of extrusion applications as a single-vendor supplier of solutions for all plastics and rubber processes. This includes compounding, pipe, profi le, fi lm and sheet extrusion, physical foaming, and production of technical rubber articles and tire intermediates. Our product portfolio includes extruders and complete extrusion lines for the bulk chemicals, automotive, construction, furniture and pharmaceuticals industries.

KraussMaffei is a worldwidepremium partner for the plasticsand rubber processing industriesworldwide.

Adding up to successKraussMaffei + Berstorff.

KraussMaffei Berstorff Phone +49 511 5702 -0 ··· Phone +49 89 [email protected] ··· www.kraussmaffei.com

ANZ_Extrusion-210x280+3.indd 1 31.07.2008 16:33:51 Uhr

made by 2008 02 eng - Krauss-Maffei · pipe extrusion ... units are another source of energy loss....

Documents

Transcript of made by 2008 02 eng - Krauss-Maffei · pipe extrusion ... units are another source of energy loss....