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Techniques – Markets – Trends Volume 13 – 3/2019

Alasting

legacy

WITTMANN innovations (Volume 13 – 3/2019)Quarterly magazine of the WITTMANN Group. The magazine appears to meet the informational demands of staff and customers.Address: WITTMANN Kunststoffgeräte GmbH, Lichtblaustrasse 10, 1220 Vienna – Editorial office, layout, graphic production:Bernhard Grabner – tel.: +43-1 250 39-204, fax: +43-1 250 39-439 – e-mail: [email protected] 4/2019 of “WITTMANN innovations” will appear at the beginning of the forth quarter 2019. – www.wittmann-group.com

Articles that appeared in WITTMANN innovations so farAutomation/Control Technology• Medicalproductionandcontrol1/2007• Largestructuralfoamparts2/2007• ThenewR8robotcontrol3/2007• High-end:Seatadjustmentrods1/2008• Driveengineeringforrobots1/2008• Transponderpinproduction2/2008• Automatedremotecontrolkeys3/2008• AutomationatCarclo,UK4/2008• Theflexibleautomationcell1/2009• Growthwithrobots2/2009• Brudertoywheelproduction4/2009• PalletproductionatUtz,Poland1/2010• EcoModeforefficientrobots2/2010• Automatedoillevelsensors2/2010• Automatingrotationwelding3/2010• ThenewR8.2robotcontrol4/2010• Linearrobotsinthecleanroom1/2011• Super-fastpartremoval2/2011• Automationofcupsandlids3/2011• Superiormulti-componentparts4/2011• Automatinginsertmolding1/2012• Theexpertautomationoflids2/2012• LSRpartsatSilcotech(CH)3/2012• Zero-rejectproduction4/2012• SmallestpartsatJENOPTIK2/2013• TheSchrambergautomation3/2013• TheBusch-Jaegerautomation1/2014• AutomatingIn-MoldDecoration2/2014• AutomationatPortEriePlastics3/2014• AutomatingSTARPLASTIK4/2014• JonesPlasticandWITTMANN1/2015• RobotsatGreeland/Singapore2/2015• SEBtandemrobots(F)3/2015• TheSacelautomation(I)3/2015• AutomationinKorea4/2015• SuzukiIndiaandWITTMANN4/2015• IMIspecialsolution(Bulgaria)1/2016• InnowareinIndonesia2/2016• 2robotsatSanwa,Singapore2/2016• 7,000thW818atKroma(D)3/2016• COMBI-PACKautomatesIML4/2016• JaegerPowayinChina1/2017• RenyMed’sautomationsolution3/2017• Digitalrobottwin4/2017• Cybersecurity4/2017• PLASSON’srobotsinIsrael1/2018• WITTMANN4.0Plug&Produce2/2018• Green,China,has180robots2/2018• Intertech’sWITTMANNrobots2/2018• WhiteHorsePlastics(UK)2/2018• Midwest,USA:Robots3/2018• LEIFHEITandWITTMANN4/2018• Plastisud(F):high-speedrobots1/2019• Theevolutionofrobotcontrols1/2019• TheDMT4.0workingcell2/2019• TheEPGrobotsinRussia2/2019• TheAlfmeierrobotsinChina2/2019

Conveying/Drying/Entire Systems• CentralsystematBOSCH1/2007• Qualitycontrolofdryers1/2007• Kromberg&Schubert'ssystem2/2007• Costefficientmaterialdrying2/2007• FEEDMAXforthecleanroom3/2007• ThenewDRYMAXED803/2007• Focusonmaterialfeeding1/2008• NetworkcontrolatArge20002/2008• Changingparametersconveying2/2008• Optimizingaconveyingsystem3/2008• Dryerswithenergyrating3/2008• TheMetchemcentralsystem4/2008• AuxiliariesatDelphiinChina1/2009• LISICOSMETICS'centralsystem2/2009• Planningofcentralsystems3/2009• TestingenergyclaimsatFKT4/2009• ThenewFEEDMAXB1001/2010• Greiner’sdryerssavingenergy2/2010• TheA.C.S.conveyingsystem3/2010• FEEDMAXPrimusconveyor4/2010• ThenewDRYMAXAton2/2011• TheBKFconveyingsystem2/2011• WDKunststofftechniksystem4/2011• PETprocessor’sconveying1/2012• ThePLASTICOMsystem2/2012• TheNICOMATICsystem3/2012• Savingenergyinmaterialdrying4/2012• TheBespakmaterialhandling2/2013• VisionTechnicalMolding3/2013• WPCinjectionmolding1/2014• NewPollmanncentralsystem2/2014• TheHELLAMexicosystem3/2014• TheProcopisystem,France4/2014• TheSLMmaterialmanagement4/2014• WITTMANNinSlovenia1/2015• AlliancePrecisionPlastics,USA2/2015• OurSpanishcustomerFushima2/2015• InjectionMoldingatTielke2/2015• TheWiBaQuickLookApp2/2015• FRANKplasticcentralsystem3/2015• Johnsoncentralsystem(China)1/2016• DryingatLekSun(Malaysia)1/2016• GOTMARsystem(Bulgaria)2/2016• TheHavells(India)system4/2016• FCplusmodulefordryers1/2017• Axjo+BATTENFELDSweden1/2017• TheREINERTcentralsystem2/2017• ThePT.WIKcentralsystem3/2017• ThenewATONplusHdryer4/2017• 3APlastics(F)centralsystem4/2017• Thefortellcentralsystem(CZ)1/2018• Stadelmann,Austria:energysaving2/2018• NaturalfibersfromtheATON3/2018• Vignesh,India,andWITTMANN3/2018• Simon(E)countsonWITTMANN3/2018• WAREMA(H)centralsystem4/2018• TheCornaglia(I)dryingsystem1/2019

Granulation/Recycling• Inlinerecyclingofsprues1/2007• GiantgranulatorMCP1002/2007• ThenewMASgranulator3/2007• Challengingrecyclingprocess1/2008• TheMC70-80atCentrex2/2008• GiboPlastenforcesrecycling2/2009• MCgranulatorswithAFauger4/2009• Grindingofferrite1/2010• Grindingcriticalmaterial3/2010• TheTMPCONVERTsolution1/2011• InlinerecyclingwithMinor23/2011• Granulatorsunderthepress2/2012• Largesolutionsforlargeparts1/2013• Minor2atJECOBEL,Belgium2/2016• MIHBandJUNIOR3Compact4/2016• ARaymondandtheG-Max333/2017• LiebherrBulgariacentralsystem1/2018• ThenewS-Maxgranulatorseries3/2018• Feedingshaftforgranulators1/2019

Blending• ThenewGRAVIMAXseries2/2007• Blendereconomics3/2007• GRAVIMAX14Vblender3/2009• Theartofblendingregrind3/2011• Dosingonthehighestlevel1/2013• Precisionforsaferailtraffic4/2013• Howtogettobetterblending4/2015

In-Mold Labeling• IMLstackmoldsystems3/2007• WITTMANN2+2stackmold1/2008• ATMd.o.o.inSerbia3/2009• PLASTIPAKinCanada4/2010• TeaPlastinAlbania3/2012• EcoPower:fourfoldIML1/2013• IMLasamultifacetedprocess4/2013• IMLatAMRAZinIsrael4/2015• 3D-IMLatVERTEXinPoland1/2016• TheW837IMLlid-system2/2017• Stiplastics(F):furthergrowth4/2018

News from the Subsidiaries• Australia2/2008, 2/2013• Austria2+3/2008, 1/2010, 3/2011, 4/2012,

3/2013, 2/2015, 3/2015, 2/2016, 3/2016, 1/2019• Benelux3/2008,2/2009,3/2017• Brazil3/2007,1/2009,2/2017• Bulgaria2/2009• Canada1/2007,1+2/2008,3/2009,1/2018• China2/2010• Colombia2/2012• CzechRepublic/Slovakia4/2009,3/2014, 1/2017,3/2017,4/2017,4/2018• Denmark1/2009, 1/2013• Finland4/2008+1/2012• France2/2007,3/2008,4/2015,2/2017,4/2018• Germany1/2007, 3/2012, 4/2013,3/2014,1/2018,2/2019• GreatBritain2/2009,2/2010,3/2017• Greece2/2014• Guatemala1/2013• Hungary1/2008,4/2015• India2/2008,3/2010, 2/2012, 3/2018• Israel1/2012• Italy4/2008, 1/2010, 4/2011• Mexico3/2007,3/2009, 1+2/2011, 3/2018• Morocco, 1/2017• Poland2/2013, 3/2013,4/2015, 3/2016,3/2017• Russia4/2012• Serbia/Kosovo/Albania1/2017• Slovenia/Croatia1/2010• SouthAfrica1/2016• SoutheastAsia2/2007• SouthKorea3/2010,2/2017• Spain3/2007, 1/2017,1/2018• Sweden2/2009,4/2018• Switzerland1/2008, 2/2012• Taiwan4/2009,4/2015• Turkey3/2008, 2+4/2011• Ukraine1/2019• USA2/2008,3/2009, 1/2011, 4/2013, 4/2014, 2/2016, 4/2016,4/2017• Vietnam4/2015

Flow Control/Temperature Control• Advantagesofpulsedcooling1/2007• Comparingwatertooil2/2007• ThenewTEMPROplusCseries3/2007• COOLMAXcoolingunits2/2008• TEMPRO“guarding”IMMs3/2008• TEMPROwithDUOcooling4/2008• Variothermaltempering1/2009• TEMPROplusC1802/2009• TEMPROdirectC120[C250]3/2009• WFC:WaterFlowControl4/2009• TEMPROplusC1801/2010• TEMPRO:Universalbenchmark2/2010• BFMOLD®moldcooling3/2010• TEMPROplusD4/2010• Online-thermography1/2011• TemperingatFuchs&Sohn2/2011• TEMPROplusDinautomotive1/2012• Oscilloscopefunction2/2012• Compacttemperaturecontroller4/2012• Optimaltempering=quality1/2013• TheStarlingerspecialsolution2/2013• NewWITTMANNequipment4/2013• TEMPROusesheatwaste1/2014• CleansolutionatDELPHI4/2014• Blumusingaspecialsolution1/2015• ThenewFLOWCONplus4/2015• TEMPROplusDatFischer(D)1/2016#• WFCretrofitkitisavailable2/2016• FLOWCONplusatCOLOP(A)3/2016• TEMPROplusD180atWethje4/2016• ThenewTEMPRObasicC1201/2017• RejlekGroupusesTEMPRO3/2017• TEMPROplusDwithSpeedDrive4/2017• Water:high-temperaturemedium4/2017

Injection Molding• Injectionmoldingonestopshop4/2008• MIMatIndo-USMIM4/2008• Costoptimization:EcoPower1/2009• ITassistedservices1/2009• Thewaterinjectionprocess2/2009• TheKronaIndústriaequipment2/2009• Micro-parts:Microsystem503/2009• wolfcraft:multi-component4/2009• Processdataacquisition4/2009• Thenewall-electricEcoPower 4/2009• TheThomasDudleycompany1/2010• IMLwithTMXpress1/2010• AIRMOULD®/AQUAMOULD®1/2010• DesignMoldedPlastics2/2010• StadelmannreliesonWille2/2010• ThenewMicroPower3/2010• AQUAMOULD®+projectiles3/2010• Newbenchmark:MacroPower4/2010• TheSTELLAcompany4/2010• TheServoDrivetechnology1/2011• The75thmachineforKrona1/2011• PackagingspecialistTMXpress2/2011• WAVIN(CzechRep.)3/2011• SANITmoldingasuccess3/2011• WEPPLER'smoldingmachines4/2011• MacroPowerproducingcableties1/2012• TheCELLMOULD®process2/2012• The43ESMINmachines3/2012• Remoteconnectivity3/2012• Foamedhigh-qualityparts4/2012• LECHNER'MacroPower4/2012• MacroPoweratGTLINE1/2013• Praiseforthestandardmachine!1/2013• VerticalmachinesatElectricfil2/2013• BECK'smoldingtechnology2/2013• ESCHAusingHMmachines3/2013• HofferPlastics'HMmachines3/2013• GuppyusingtheEcoPower3/2013• TheBackhaussuccess4/2013• Incapsulation:cleanandsafe4/2013• Multi-componentparts1/2014• Successthroughversatility1/2014• ThetriedandtestedatPhilips2/2014• Light-weightfoamedparts2/2014• TheKRESZ&FIEDLERSystems3/2014• SMEmolderAutenrieth3/2014• TopmicropartsfromKüngAG3/2014• Openingupefficiencyreserves4/2014• HiQShaping4/2014• ServoPowersavesenergy1/2015• Bestqualityathünersdorff1/2015• TheGripItFixingssuccessstory1/2015• GerresheimersysteminChina2/2015• MicroPoweratTessy(USA)3/2015• MoldingatInterplex(China)3/2015• RT-CADTiefenböck(A)4/2015• DieterWiegelmann(D)4/2015• OneSealApSinDenmark4/2015• DenkKunststofftechnik(D)1/2016• ELASMOSystems(A)1/2016• REUTTERGroup(Germany)2/2016• P.P.H.LIMAKinPoland2/2016• MacroPoweratStüdli(CH)3/2016• EverRichFountain,Taiwan3/2016• TheAckermannproduction(D)4/2016• MicromoldingatEltek,Italy4/2016• MotoTassinari,USA1/2017• LinearPlastics,UK1/2017• LMBK(D)compactcells2/2017• Teflonmicroprecisionparts2/2017• TheHIDROTENcompany(E)2/2017• PLASTIKABEVC,Slovenia3/2017• BuzekprocessesPVAL3/2017• FakumaHighlights20174/2017• Hybridtechnology:highprecision4/2017• EPC(USA)isstillgrowing4/2017• MEScooperation1/2018• JSCApexinRussia1/2018• PerfectsurfacesatBoryszew(D)2/2018• Oldrati(I)andWITTMANN2/2018• MIMatMimestinItaly3/2018• PowerSeriesatPrewag(CH)3/2018• DAIGLER(D)recipeforsuccess4/2018• HIRT(D):microhigh-techcell4/2018• Winkelmann(D):automotiveparts1/2019• STIEBELELTRON,Eschwege(D)1/2019• Metak(D)andthePowerSeries1/2019• FröbelinBlaufelden(D)1/2019• CooperStandard,Poland2/2019• PWF,Germany:Automotive2/2019• WITTE(D):Verticalcompetence2/2019

WITTMANN innovations – 3/2019 3

DearReader,

280characterswhichchangetheworld.–USPresidentDonaldTrump’searly-morningtweetsdonotevenneedtotakeupthemaximumlengthoftexttoexertamorepronouncedinfluenceonindustrythanthemuch-describedfourthindustrialrevolutionwhichhasalreadysetin.Whileontheonehand,tradebarriersarebeingthreatenedandimposed,thestandardizationcommitteeoftheEngineeringAssociation,ontheotherhand,successfullydismantlesthecommunicationbarriersbetweenappliances.Sotheunevenmatchcanbedescribedasdeglobalizationintradeversusglobalizationintechnologicaladvancement.Andtheclearwinnerhereis…thepolicyofimposingtraderestrictions.Theglobalspurtofgrowthwhichshouldhavestartedlongagoasaresultofthefourthindustrialrevolutionwillprob-ablybesomewhatdelayed.Forhowlongcanbereadinthestars–orratheronTwitter.Tobecontinued…forsure!

Inlinewithmyprecedingcomments,wearedescribinginthisissueofinnovationsamongotherthingsasuccessfulexampleofcross-productandcross-brandcommunicationforthebenefitofusers.TheMESsolutionTEMI+hasbeeninstalledatMAFLEXinItalyandenablesclearvisualizationofproductioncellsaswellascommunicationbetweeninjec-tionmoldingmachinesofdifferentbrands.WITTMANN4.0auxiliaryappliancesarealsoconnectedtotheMESserverviatheproductioncellcontrolsystemsbuiltintoourinjec-tionmoldingmachines,andarethusalsoavailableforthecalculationofaproductioncell’stotalefficiency.Sofarauniquefunction.MAFLEXwasabletorealizeasubstantialincreaseinefficiency,fullyinlinewiththeconceptproposedbythe“fathers”ofIndustry 4.0.

Thatwewereabletoenjoyaperiodofhealthygrowthinrecentyearsiseasytoseebythenumerousextensionsandnewbuildingsrealizedwithinourgroup.Ournewbuild-inginItalywascompletedattheendoflastyear,andwewereabletopresentournewpremisesandshowroomsofWITTMANNBATTENFELDItaliatoourcustomersatthebeginningofMay.AndthiswouldnotbeItaly,iftheofficialopeningceremonyhadnotalsobeenaccompaniedbyanattractiveprogramofmusicandexquisitefood.Areportaboutthiseventcanbefoundinthisissueofinnovations,aswellasapresentationofourteaminTurkeyandacolor-fulselectionofreportsaboutinterestingapplications–forexamplefromItaly,GermanyandSouthKorea.

Iwishyougreatpleasureinreadingthisissueofourinnovationsmagazine.

Sincerely,MichaelWittmann

Editorial

MichaelWittmann

Content

Andrea SelvaandNicolettaBoniardiinterviewing the MAFLEX Director Marco Ravazzani Klarenbeek.Page 4

Quality leap through TEMI+

Page 18

News Turkey:Portrait of the Turkish branchof the WITTMANN GroupItaly:Opening of the new buildingof WITTMANN BATTENFELD Italia

Page 17

WITTMANN4.0

MicroPower at YONWOO

BernhardGrabneron the WPR 730 at SANIT: a suc-cess story since 25 years.Page 14

InjectionMolding

Gabriele Hopfon the Korean packaging special-ist ...Page 8

Large parts at aquatherm

... and the German pipeline systems specialist.Page 10

Liquid injection molding (LIM)

The record holder

Reinhard Bauerdescribes the respective WITT-MANN Group solutions.Page 12

FlowControl

WITTMANN innovations – 3/20194

WITTMANN 4.0

MAFLEXwasestablishedinthe1980sandstartedoffasanassemblyandautomation

specialistbeforeengaginginplasticsinjectionmolding.

Inthecourseofthelasttenyears,itsinjectionmoldingbusinesshasgainedmoreandmoresignificance.Today,thecompanyhas25employeesandrunstwoproductionsites,eachwith1,500m²floorspace.Workpro-ceedsinthreeshifts,ifnecessarysevendaysaweek.

MAFLEXisoneofthosesmallerItaliancompaniesmakingactiveuseoftheopportunitiesopenedupbytheItal-iannationalPlan Industria 4.0.Thishasledtoanumberofchangesinordertoimprovethecompany’scompetitiveness.“Ourself-imageasanenterprise–or

ourphilosophy,sotospeak–hasprom-ptedusmoreandmoretodevelopin-toafull-servicesupplier.Firstandforemosttoleadingindustriessuchastheelectronics,automotive,cosmeticsandhouseholdappliancesindustriesaswellascompaniesfromtheirrigationsectorwhich,takentogether,makethelargestcontributiontooursalesfigures.Toalesserextent,thisalsoappliestothepharmaceuticalandtoyindustries,besidesvariousothernichesegments”,saysMarcoRavaz-zaniKlarenbeek,GeneralManagerofMAFLEXinCarbon-ate.“Inordertobesuccessfulhere,wehavethoroughlyinvestigatedtheprocessingmethodsforvariousplasticmaterialsincludingthemosttechnicallydemandingvariet-ies.Wehavearangeofultra-moderninjectionmoldingmachineryatourdisposalwithasmallcleanroomformicroinjectionmolding,andverticalmachinesformulti-compo-

The Italian company MAFLEX in Carbonate, Lombardy, can be regarded as a prime ex-ample of a small or medium-sized business under modern management. MAFLEX has invested in state-of-the-art machinery and an integration solution for its production equipment specially tailored for its needs.Andrea Selva – Nicoletta Boniardi

Interview: Quality leap for a small Italian company

nentinjectionmolding.Inaddition,wehaveassemblylinesforpadprintingandultrasoundwelding,andaworkshopformoldservicingaswell.”

You just mentioned your range of modern machinery. How is it laid out?

Marco Ravazzani Klarenbeek:Weworkwith20injec-tionmoldingmachines,morethanhalfofwhichhavebeen

TEMI+ allocates one page to each machine to visual-ize the production progress and plan-ning data, which are automatically linked to the pro-cess data.


acquiredduringthelastfiveyears.OurincreasinglyclosecooperationwithWITTMANNBATTENFELDhasbe-comeveryimportanttousandgivesussecurity.Weap-preciatethemachinesfromWITTMANNBATTENFELDbecauseoftheirspecialtechnicalfeaturesandlowenergyconsumption.

Allinall,thisisoneofthekeyfactorstoensureourcompetitiveness.WITTMANNBATTENFELDactivelysupportsourstrategyofalwaysacquiringnew,powerfulinjectionmoldingmachinesinordertocontinueonourcourseofconstantgrowth.Forourmostrecentmachinepurchases,wechoseall-electricandhydraulicmodelsfromtheSmartPowerandEcoPowerseries.WiththehelpofthenewUNILOGB8machinecontrolsystem,weareabletocontroltheentireproductioncellineachcase–includingmonitoringofthestatusoftheinjectionmoldingmachineandthatofsomeauxiliaryappliancesintotheproduction

cell.Thegreatbenefithereisthepossibilityforcompre-hensiveintegrationofallappliancesandprocesses.

Integration of different systems … how do you see your approach to Industry 4.0?

M. R. K.:BeforethePlan Industria 4.0andtheopportu-nitiesitofferswereinexistence,wehadnodigitalprocessforcontrollingthevariousstagestheproductsmustpass

throughbefore,duringandafterproduction–allthewayfromworkschedulingandproductiontostorageofthefinishedproducts.Ifthepossibilitiesavailabletodayarefullyutilized,smallcompanies,too,canpresentthemselvesassupplierstolargecompaniesactinginastructuredway.Companieswhichtodayrequiremoreandmorestringentcontrolofthesupplychainandoftheproduct.

Havingseizedthisopportunitymeansthatwearenowabletopresentourselvesonthemarketasoneofthefirstin-dustrialsupplycompaniesactuallyapplyingtheprinciplesofIndustry 4.0.Afterwehadlaidthefoundationwiththeacqui-sitionofthenewmachines,westillhadtotakesomefurtherstepsinor-dertoreachthestageofintegratedproduction.

Hot did you approach the implementation of this project?M. R. K.:Themostrecentlypurchasedinjectionmolding

machinesfromWITTMANNBATTENFELDwerealready

laidoutforintegrationacrosssystems.Thechallengeforuswastoenablethealreadyexistingoldermachinestocommunicatewitheachotherviaacentralcomputersystem.

Atthattime,therelevantpossibilitieswerealreadyavailable,eventhoughnoapplicationscouldbefoundany-wherethatwouldperfectlyfitoursituation.Wecarefullyexaminedalloptionsavailabletousasarelativelysmall>>

WITTMANN 4.0

At MAFLEX, 20 injection molding machines are in-stalled. More than half of these have been acquired in the course of the last five years, which is due to the company’s increasingly close cooperation with WITTMANN BATTENFELD.


WITTMANN 4.0

businessandpreciselydefinedthegoalweultimatelywantedtoreach.Ofcoursewewerealsoabletotakeadvan-tageofcertaintaxbenefits,butwewouldcertainlynothavehadtheresourcesavailabletoestablishacompletesmart factory,forwhichitwouldhavebeennecessarytopurchasehighlycomplex,andex-tremelycostlysys-tems.

Afterwehadba-sicallyclarifiedwhichstepsshouldbetaken,wealsocametothecon-clusionthatitwaspos-sibleforustocatchtheexactlyrightmomenttoengageinthedigitizationofprocesses.Thiswassimplyintheair,sotospeak,somethingwhichisre-confirmedagainandagainwhenwetalktocustomers,suppliersandcompetitors.Theyallhaveagreatentrepreneurialspirit,andtheyallwantedtohaveacomebackafterthecrisis–acrisiswhichcausedanevenmorerigorousselectioninthemarket,wheremoreandmorespecializationandservicewerecalledfor.

TheItalianentrepreneurswereactuallycaughtupwithatypeofenthusiasm,moreorlessinspiredbythe“German”approach,understandingdigitizationasthemotordrivingtheeconomyandinnovation.Wedecidedthatthismustbethemomentforustotryitourselves–usingwhatevermeanswehadatourdisposal.

How can this be successful without a company of this size being burdened with excessive costs?

M. R. K.:Thesolutionsofferedbymajorplayersfre-quentlyconsistofMESsystems(MES=ManufacturingExecutionSystem),whichhavehighlycomplextechnicalarchitectureswhichsmallcompaniesfindverydifficulttouse.Suchcompaniessimplydonothavethehumanresourcesattheirdisposalwhichcouldbeexclusivelyde-dicatedtothistypeofsystem.Frommypointofview,smallandmedium-sizedcompaniesneedasoftwarechar-acterizedaboveallbybeingveryeasytolearnandtoapply.Moreover,suchasystemmustnotputthoseatadisadvan-tagewhohavemachinesofdifferentbrandsandvaryingages.Itmustbepossibletoincludeallappliancesintothecorporatenetwork.SowedecidedtocooperatewiththeyoungcompanyICE-flex.

Followingathoroughexaminationofourneeds,ICE-flexdevelopedtheMESsystemoriginallynamedTemiPlast4.0,whichisonthemarkettodayunderthename

ofTEMI+.Thissystemwasdesignedonthebasisofourexperience,andalso

subjectedtoextensivetestinghere.Itisalsoidealforapplica-

tioninothercompaniesofsimilarsizeandstructureandthusaddressesatargetgroupconsistingofnumeroussmallandmedium-sizedcompaniesofourindustry.

Which require-ments had to be met

when the system was implemented?

M. R. K.:Primarilytheneedtohaveasim-

ple,well-organizedsystemwhichisnotinvasive,with

theadvantagesoflowcostsandlowpersonnelrequirements.

Inpractice,ourcustomersdemandamoreandmoredetailedtraceabilityoftheproducts,andTEMI+enablesustomeetthisdemand.

Weareatlastabletoapplyacom-prehensiveoperatingconcept.Thishasmadeusmoreflexibleandenabledustomeetawiderangeofdifferentneeds–evenwhenagivenprojecthasalreadybeenstarted.Wecanmonitorallproduc-tionprocesses,controlthemalsoonweekendsorduringthenightandreceiveallinformationincludingthereportsaboutmachinedowntimesinrealtimeviaremotequery.

Thistoolallowsustoofferourselvesasasuppliertomarketleaders,sincewecanensurethetraceabilityanddocumentationofallnecessaryindicators.Itisnowpos-sibleforustomonitorthemoldchangetimes,derivethenecessaryremedial

actionsfromthealarmgraphs,evenduringongoingpro-duction,andtohavetheconsistencydataofthecycleandbuffertimesatourdisposal–allbasicparametersfortheproductionprocess.

Butjustasimportantisthecutinpaperconsumptionandcontinuousreductioninpaperfiling.Itisourambi-tiontomaketheuseofpapervirtuallydisappearaltogether,aswecanuploadalldrawingsandworkingparametersintothescreencontrolsystemsoftheinjectionmoldingmachines.

Theoperatorcanconfirmthequalityinspectiondirectlyonthemonitor–currentlystillamanualprocess,butoneweareplanningtodigitizecompletely,whichwillenableustokeeptheproductionhistoryalwaysuptodateaswellasverywellorganized.Inshort:wehavethecompletetrace-abilityofallourprocessesatourdisposal,notjustthatofourrawmaterialsandthecorrespondingbatches.•

Andrea SelvaandNicolettaBoniardicontribute to the Italian PLASTIX magazine.

TEMI+ collects both process and quality data directly in each machine, which ensures trouble-free reconciliation of these data.

Marco RavazzaniKlarenbeek:

“Thanks to TEMI+ we are able to ensure complete traceability and offer ourselves as suppliers

to market leaders.”


WITTMANN 4.0

Commercial MES solutions (Manufacturing Execution System) have established themselves successfully in the plastics industry as information and control centers for the production monitoring and planning of injection mol-ding machines. One of the reasons for this success is the availability of the standardized interfaces as Euromap 63 and upcoming OPC-UA based protocols, which ensure a simple connection between machine and MES. Practically all MES solutions, however, stop at the machine level as the lowest communication ayer and thus cover only a small fraction of the process-deter-mining devices in a production hall. One consequence of this re-striction is that it has so far not been pos-sible to achieve com-plete and consistent quality recording and assurance. Especially in times of Industry 4.0, in which the call for the IIoT (Industrial Internet of Things) is growing louder and in view of the increasing demand for quality assurance, product liability and trace-ability of produced parts, this situation is no longer accepted, particularly by the automotive industry, demanding a more comprehen-sive solution.

Together with its MES partner company ICE-flex, WITTMANN is now presenting for the first time in the industry the MES package TEMI+, which can uniquely cover both injection molding machines and auxiliaries around the machine. Therefore, a full and complete data acquisition and evaluation of the quality parameters of all devices involved in the production of a part is possible for a MES standard product. So far, this would have been feasible only with the help of extensive and expensive programming efforts without taking advantage of the new communication standards available on new equipment.

The most obvious feature of this novel functionality is the extension of the main view of the TEMI+ dashboard to include the auxiliaries, which are part of a WITT-MANN 4.0 work cell. It is practical that the peripherals

automatically log in and out of the WITTMANN 4.0 work cell in the sense of “Plug & Produce”. Thus, the MES solu-tion TEMI+ is always informed about the composition of a work cell and can adjust the display on the screen accordingly and without user interaction.

Another benefit of WITTMANN’s “Plug & Produce” for TEMI+ is the ability to easily and completely identify

which devices belong to a work cell. The WITTMANN 4.0 router placed in front of the work cell as a gateway, au-tomatically groups all the devices in the work cell and represents the work cell with a single IP address to the outside. Thus, the devices within a WITTMANN 4.0 work cell including the injection molding machine are acces-sible for the MES program via this one access point as a fundamental condi-tion for data consis-tency. After the mold change and thus the possible changing of the composition of a work cell, a correct data acquisition will

again be possible from the now pooled together devices in the work cell automatically and without programming efforts. Previous MES systems could not guarantee data consistency.

The access of TEMI+ to the individual devices is implemented via standard protocols. For example, the E63 or E77 protocols are used for communication with the injection molding machines and the protocols E82 or OPC UA for connected auxiliaries.

The perfect interaction of the MES solution TEMI+ with WITTMANN 4.0 offers users completely new pos-sibilities for seamless quality assurance with correct data records. The MES solution TEMI+ is suitable and de-signed for the connection of injection molding machines of all manufacturers. However, a secure and complete data collection independent of user settings and thus possible operator errors will only be possible with the connection to a WITTMANN 4.0 work cell.

WITTMANN 4.0 with TEMI+:Tracing of Q-parameters – the right way


Injection Molding

YONWOO,basedinIncheon,Korea,wasestab-lishedin1983.Today,thefamily-ownedcompanywithacurrentworkforceof1,500employeesranks

amongtheworld’sleadingmanufacturersofcosmeticspackagingwithahightechnologicalstandard.YONWOOowesitssuccesslargelytocontinuousfurtherdevelop-mentofitsproductsandstrictqualitycontrol.

Thecompany’sproductrangeincludesalltypesofcosmeticscontainers,suchascreamjarsandtubes,make-upcontainers,oilpumps,sprays,foamingdevicesandmuchmore.OneofitsmainproductlinesisarangeofdosingpumpswhichYONWOOdevelopedin1990.YONWOOwasthefirstmanufacturerofdosingpumpsinKorea.

ThesepumpswerepreviouslyimportedfromJapanforthecosmeticsindustryinKorea.MostofthesepumpsworkwiththeAirlesstechnologydevelopedbytheKoreancom-panyYONWOO.

Thistechnologyenablesahighlyaccurate,consistentreleaseoftherequireddosingvolumewitheachpumpingprocess.Theportfolioofthesepumpsincludespumpswithdosingvolumesof0.08,0.15,0.2,0.3,0.5and1ml.

YONWOOsellsabout50%ofitsproductsinKorea,theremainderisexported.ItsmainexportmarketsareEuropeandtheUSA.Thecompany’scustomerbasein-cludesgroupssuchasL’Oréal,P&GandEstéeLauder.

YONWOO orders twelveMicroPower machines

Tomakethesmallindividualcomponentsofthepumps,suchassealingcaps,checkvalves,pistoncylindersandhousings,YONWOOhaddecidedtoreplaceconven-tionalinjectionmoldingmachineswithMicroPowerma-chinesfromWITTMANNBATTENFELD.ThecompanyorderedatotaloftwelveMicroPowermachinesfromWITTMANNBATTENFELD,ofwhichsixarealreadyupandrunningsince2017.

Theseareusedtomakepartsforpumpswithdos-ingvolumesof0.15and0.2ml.TheprojecttoreplaceconventionalinjectionmoldingmachineswithmachinesfromtheMicroPowerseriesstartedinDecember2016withWITTMANNBATTENFELDpresentingafirstmoldlayoutincooperationwiththeErnstWittnercompany.ThislayoutwasthenfurtheroptimizedbyYONWOOin

YONWOO, the largest manufacturer of packag-ing for the cosmetics industry in Korea, is re- placing conventional injection molding ma-chines with machines of the MicroPower series from WITTMANN BATTENFELD, which are spe-cially designed for micro injection molding.Gabriele Hopf

MicroPower replaces conventionalinjection molding at YONWOO

MicroPower machines with UNILOG B8 control system at YONWOO in Incheon, Korea.

Typical products from YONWOO.

(Photo: YONWOO)

Martin Philipp- Pichler, MicroPower Product Manager, WITTMANN BATTENFELD, Chong Geun Kim, Managing Director WITTMANN BATTENFELD Korea, Roland Pechtl, Project Manager Asia, WITTMANN BATTENFELD, Kim Hong Suk, YONWOO Deputy Project Leader Incheon, Korea (from the left).


Injection Molding

closecollaborationwithWITTMANNBATTENFELD.Next,afirstmoldwasconstructedandtestedsuccessfullyinMay2017atWITTMANNBATTENFELDinKotting-brunn,inthepresenceofYONWOOstaffmembers.Thiswasthestartingsignalforthefirstsixmachines.TheyweredeliveredinDecember2017.

A challenging application

ThesixMicroPowermachinesreplacedtwoconven-tionalinjectionmoldingmachinesonwhichpartshadpreviouslybeenproducedwitha64-cavitymoldwithinacycletimeof14seconds.Thankstotheircompactde-sign,thesixMicroPowermachinestakeupnomorespacethanthetwomachinestheyhadreplaced.

Whatismore,incontrasttoconventionalmachines,theMicroPowermachineswiththeirsmalldimensionscouldbetransportedeasilytotheseventhfloor,wheretheynowstandrightnexttotheassemblyareaforthepumps.Inthisway,itbecamepossibletooptimizetrans-portdistancesandtosavevaluablespaceinthehallonthegroundfloor.

Themoldsnowinusehave12cavities.ParticularlypositiveforYONWOOistheweightconstancyofonly2mgfromoneparttothenext.Thiscouldnotbeachievedreliablywiththe64-cavitymold.Inthisway,itnotonlybecamepossibletoconsiderablyreducetheproductionandmaintenancecostsforthemolds,buthandlingandqualityinspectionofthepartshasalso

becomemucheasier.Thecycletimeisnowonly8seconds,andthescrapratehasbeenreducedtoaminimum.Thankstothecostsav-ingsrealizedtogetherwithsignificantlyhigherproductivity,theinvest-mentintheMicroPowermachineshaspaidoffwithinlessthanayear.

Perfect satisfaction

Followingthispositivedevelopment,YONWOOdecidedtoordermoremachines.ThenextsixMicroPowermachinesweredeliveredbetweenNovember2018andthefirstquarterof2019.Themachinesare

equippedwitharotarydisk.Asaspecialhighlight,itshouldbemen-tionedthattheinjectionvolume,whichis4cm³fortheMicroPowerasstandard,couldbeincreasedto6cm³forthefirsttimeinoneofthema-chines.

SeongHoKim,TeamLeaderM&ITechnicalCenteratYONWOO,showedhimselfimpressedbytheshortresponsetimesanduncompli-cated,goodcooperationwithWITT-MANNBATTENFELD.–Inthemeantime,YONWOOhasorderedthe13thMicroPower.•

View of a sealing cap.

Quality inspection of sealing caps.

Machine accep- tance at WITT-MANN BATTEN-FELD in Kotting-brunn. Roland Pechtl, Seong Ho Kim, Team Leader M&I Technical Center at YONWOO, Martin Hirschenauer, WITT- MANN BATTEN-FELD Applica- tion Technology MicroPower, Chong Geun Kim (from the left).


Injection Molding

Theaquathermcompany,foundedbyGerhardRosenbergin1973andbasedinAttendorn,NorthRhine-Westphalia,isthegloballyleading

manufacturerofplasticpipelinesystemsmadeofpoly-propyleneforplantengineeringandbuildingservices.Theowner-managedcompanyemploysmorethan600associatesatatotalofsevenfacilitiesinGermany,Italy,theUK,theUSAandCanada.ProductiontakesplaceexclusivelyatthetwoGermanplantsinAttendornandRadeberg.90%oftheproductsareexportedworldwide.

aquathermproducessome41millionmoldedpartsannuallywithpipediametersrangingfrom16to630mm.Theproductrangeincludesmorethan17,000differentarticles,whichareusedinsingle-familyhousesand

Since the end of 2018, the pipeline specialist aquatherm has beenproducing its large molded parts with diameters ranging from 90to 250 mm fully automatically with a machine from WITTMANNBATTENFELD’s MacroPower series. With 10,000 kN clamping forceand a 9 kg maximum shot weight, the MacroPower 1000/16800 isthe second largest injection molding machine installed at aquatherm.Gabriele Hopf

WITTMANN BATTENFELD machine producing large parts at aquatherm

From left to right: aquatherm Man-aging Directors Christof, Maik and Dirk Rosenberg.

MacroPower 1000/16800 at aquatherm.Photos: aquatherm


apartmentbuildings,hotels,publicbuildings,indus-trialplants,healthcareandsocialservicesinstitutions,sportsandleisurefacilitiesandships.Examplesarepipelinesfordrinkingwaterandsanitaryinstalla-tions,heatingsystems,distributorpipelines,underfloor,wallandceilingheatersandwaterrecycling.Thepipelinesystemsmanufacturedbyaquathermservetotransportwater,compressedair,liquidfoodstuffsandaggressivemediasuchasacids,alkalisandvarnishes,whichoftenrequireextremelyhighresistancetochemicals.Apartfromthehighqualityofitsproducts,aquathermisalsoconcernedaboutenvironmentallyfriendlyandenergy-efficientproductionofitsfittingsandpipelines.

aquatherm uses the MacroPower

AtitstwofacilitiesinGermany,aquathermcon-stantlyworksonoptimizingitsprocessesandincreas-ingitscapacities.In2018,anewhallwith4,750m²floorspaceforinjectionmoldingwasopened,whichwasbuiltaccordingtolateststandardsofenergyefficiencyandprotectionoftheenvironment.Thecompany’srangeofmachinerywasalsoextendedbyaddingalargemachinefromWITTMANNBATTEN-FELD.

ThismachineisaMacroPower1000/16800with10,000kNclampingforceandamaximumshotweightof9kg,equippedwithaW843prorobotfromWITT-MANNandacustomizedautomationsystem.Thismachineproduceslargemoldedpartswithdiametersrangingfrom90to250mm.ThemachinecomeswiththemodernUNILOGB8controlsystembasedonWindows™10IoT,whichstandsoutbyitseasyopera-tion.Theelectricallyactuatedsafetygateontheopera-torsideprovidesadditionalcomfort.A2,000mmopeningstrokeallowstheinsertionoflargemolds.

Moreover,themachinedeliveredtoaquathermfullymeetsthehighstandardssetbythecompany’smanagementintermsofenergyefficiency,cleannessandlownoiselevel.

Themachineisequippedwithamodernservo-hy-draulicdrivewhichoffershighdynamismandrunsverysmoothly.Furthermore,theenergylossintheWITTMANNrobotfromthemodernproserieshasbeensignificantlyreducedbyenlargingtheenergystorageunitintegratedintheservomodules.Duetotherobotseries’optimizedenergychain,thesoundemissionswerealsoconsiderablyreduced.

An overall positive experience

Boththemanagementteamandthemachineopera-torsarefullysatisfiedwiththenewMacroPowerafterithasnowbeenusedinproductionforseveralmonths.MaikRosenberg,oneofaquatherm’sthreeManagingDirectors,comments:“Inadditiontoitsmodestenergyconsumptionandlownoiselevel,themachinerecommendsitselfbyitshighoperatingcomfort.Itscompactdesign–andconsequentlysmallfootprint–isanothergreatbenefitoftheMacroPower.”•

Injection Molding

Fitting with brass threading.

Gabriele Hopfis the Marketing Manager of WITT-MANN BATTEN-FELD in Kotting-brunn, Lower Austria.

MacroPower 1000/16800 with its customized au-tomation system.

Parts removal and depositing with WITTMANN W843 pro robot.

Bushings on the conveyor belt.


Injection Molding

At the Fakuma 2018, the latest version of liquid silicone injection molding technology from WITTMANN BATTENFELD had its premiere at the Momentive Performance Materials show booth, and what is more, in combination with a highly compact production cell based on a servo-hydraulic machine from the SmartPower series. The most important innovations are a revised screw tech-nology and the integration of the LSR* dosing pump into the machine’s control system via OPC-UA communication. [*LSR = Liquid Silicone Rubber]

Reinhard Bauer

“Smart power” for Liquid Injection Molding (LIM)

At the Fakuma 2018, WITTMANN BATTENFELD presented its latest-generation machine technol-ogy for liquid silicone injection molding. The pic-ture shows a pot holder, produced at the show booth of the Momentive Performance Mate-rials company.

Foto: R. Bauer

Picture left:SmartPower 90/350 working cell with integrat-ed 2-component dosing/mixing de-vice, temperature controllers and parts removal/depositing equip-ment.Picture right:WITTMANN hand-ling equipment for highly elastic parts.


LiquidsiliconeinjectionmoldinghasbeenanintegralpartoftheWITTMANNBATTENFELDrangeofmachineryandtechnologyformanyyears.Thema-

chinesareoperatingsuccessfullyatnumerouswell-knownprocessors.“ThemarketrequirementsarethedrivingforcebehindthecontinuousfurtherdevelopmentofLIMprocesstechnology”,emphasizesWolfgangRoth,ApplicationTech-nologyManageratWITTMANNBATTENFELD.Andhecontinues:“ThelatestversionpresentedattheFakuma2018includesnotonlyupdatesinthemechanicaldesign,butalsotheintegrationofcommunicationinterfacesbetweenthemachineandtheauxiliarycomponentsaccordingtotheIndustry 4.0standard.Apracticalexampleisthenowexistingfacilitytoconnecteveryliquidsiliconedosingandconveyingsystemcommonlyavailableonthemarketwiththemachine’scontrolsystemviaanOPC-UAinterface.”

TheworkcellwithaSmartPower90ondisplayattheboothofMomentivePerformanceMaterialsattheFakuma2018produceda255cm²potholderwithahoneycombstructureonbothsides,madefromSilopren.Duringthesimula-tionphase,thepartsgeometrywaslaidoutforeven,clamping-force-optimizedcavityfillingbySIGMAEngineeringwiththehelpoftheirvirtualmoldingsoft-ware.ThemoldmakerEmdeMouldTecdesignedtheactualproductiontoolonthebasisofthissimulation.Feedingofthe2-componentliquidsiliconematerialwaseffectedviaaMaxiMix2GdosingpumpfromACHSolution.

Virtual design of LSR applications

Thepotholderisacomplexpartwithashotweightof83g,a135mmflowpathlengthandamaximumwallthicknessof1mmovermostofitsarea.Evenfillingofthecavitywith-outaprematurestartofcuringisthereforeadecisivequalityfactorforthispart.Thisiswhythenumberandoptimalpo-sitioningofthecoldrunnernozzleswerecalculatedfirstbyavirtualDoE(DesignofExperiments)system.BycheckingthefillingandgeometryscenarioswiththeSIGMASOFT®virtualmoldingsoftware,itwaspossibletoascertaintherightinjectionconceptunderstatictemperatureconditions.Inadditiontothegeometries,thecalculationofthisconceptwasalsobasedonthesteelgradesusedforthecavitiesandthecoldrunner,aswellastakingintoaccounttheposition-ingandoutputoftheheatingcartridges.

Efficiency gains through several improvements

Inthelatestversion,theplasticizingunit,thecoreoftheLIMprocesstechnologyinsidetheinjectionmoldingmachine,hasbeenrevisedinaconsiderablenumberofde-tails.Forexample,thedesignoftheshaftsealattheendoftheshaftinfrontofthescrewcouplinghasbeenoptimizedtoreducetheriskofliquidsiliconeleakingouttowardsthescrewdrive.Anotherinnovationisthemeticulouslayoutofthecheckvalve,combiningalargerflowcross-sectionwithafasterandmorepreciseclosingmechanism.Thishasledtoasignificantimprovementinshotweightprecision

comparedtothepredecessorversion.Themulti-zoneliquidtemperaturecontrolsystemofthebarrelandthepneumaticneedleshut-offnozzlewereleftunchanged.

Compact mold/machine nozzle assembly

Anadditionalspecialfeatureofthetradefairdemonstra-tionwastheextremelycompactassemblycombiningthemachine’snozzlewiththecold-runnerinjectionsystemandthemold.

Forinstance,thecoldrunnerfromEmdeMouldTecwasfasteneddirectlyontothemachine’snozzleandthenguidedthroughthemachine’splaten.Thistypeofdesignnotonlyofferscompactmolddimensions,butalsominimizesthecontactbetweentheinevitably“cold”gatingsystemandthe“hot”mold.

Footprint minimization through integration

ThecomprehensiveinjectionmoldingequipmentrangeoftheWITTMANNGroup,includingmaterialshandling,temperaturecontrol,robottechnologyaswellasinjectionmoldingmachines,providesthebasisofexpertiseforcon-centratingsystemcomponentstocreatespace-savingpro-ductioncells.ThesystemdemonstratedattheFakumawasonesuchexample,wherethedosingunit,thecolorantfeedsystemaswellasthefinishedpartsremovalanddepositingequipmentwerepackedtogetherinaminimumofspace.

Competence for handling highly flexible parts

TheWITTMANNrobotsandautomationbusinessdivi-sioncoverstheentirebandwidthofhandlingtechnologyformoldedplasticparts.Animportantissueinthisareaistheexperthandlingofflexiblepartswhichcannotbeejected,butmustbeeitherexpressedfromthecavitywithcompres-sedair,orpulledoffbytherobotusingagrippingdevice.AdaptationofthecorrectdemoldingmethodtoaparticularmoldedpartcanbeincludedintheLIMequipmentpackageasanoptionalextra.

Micro to medium-sized dimensions

Themachineryandequipmentpackagesforliquidsili-coneinjectionmoldingareavailablewithinagreatband-width,rangingfrommicropartswithshotvolumesfrom1.2to4cm³uptomedium-sizedmoldedparts.WiththisLSRinjectionunitspeciallydesignedforminimalpartweights,partsweighinglessthan1mgcanbeproducedwithhighprecision.•

Injection Molding

Close-up view of the LIM screw shaft with dual sealing system.

The latest version of the check valve with an enlarged flow cross-section as well as a faster and more precise closing mechanism.

Reinhard Baueris a freelance journalist and communications consultant special-izing in plastics technology.


Flow Control

Walter Lichtenberger, the Temperature Control Technology DivisionManager at WITTMANN in Vienna, has discovered a long-used pieceof control technology at SANIT in Eisenberg near Leipzig/Germany:a WPR 730 installed many years ago and still running today.Bernhard Grabner

WITTMANN flow controller running for a quarter century!

Installation of the WPR 730 on a 650-ton injection molding machine at SANIT in Eisen-berg/Germany.


dingmachinemodelsfromWITTMANNBATTENFELD,aswellasWITTMANNrobots,granulatorsandflowcontrollers.

SANIT uses WITTMANN flow technology

Formorethan40years,WITTMANNhasbeenknownasthenumberoneinthedevelopmentandproductionofwaterdistributionsystems.Alreadyinthe1990s,thecom-panydevelopeditsmodelsWPR730andWMTR720,whichwereabletocontroltheflowquantitiesintheindividualtoolchannelsandtore-adjustthemintheeventofpres-surelossviaaproportionalcontrolvalveinthewaterpipesystem.Theflowmeasurementtechnologywasbasedontheprincipleofameasuringtransformerwithcoilingplacedontheouterpipe.

Thefloat,aferritecoreovermoldedwithplastic,servedtomeasureandmonitortheflowquantities.Thepropor-tionalvalveoftheWPR730wascreatedbyplacingaDCmotorwithplanetarytransmissiongearingontheexistingcontrolvalve.

ThissolutionwasanoriginaldesigncreatedbyWITT-MANN,sinceatthattimenolow-costsolutionssuchasstep-permotorswereyetavailable.Onthewhole,theWPR730wasarevolutionarynewdevelopment,butinthe1990s,thetimewasnotyetreallyripeforsuchadvancedmonitoringsystems.DuringacustomercallatSANIT,aWPR730whichwasstillinoperationcaughttheeyesofWalter

Lichtenberger,DivisionManagerforTemperatureControlatWITTMANN.(Manyyearsago,WalterLichtenbergerhadplayedanimportantparthimselfindevelopingthisflowcontrollermodel.)

TiloWalther,ManageroftheSANITinjectionmoldingplant,confirmedthatthisappliancehadnowbeenfunction-ingtrouble-freefor24years–aWITTMANNflowcontrol-lersolutionwellaheadofitstime.>>

SanitärtechnikEisenbergGmbH(SANIT),locatedinEisenberg/ThuringiaandapartoftheAliaxisGroupsincethe1990s,operatesproductionplantsnotonly

inEisenbergbutalsoinRödentalandWittenberg.SANITisarecognizedspecialistintheareaofsanitarytechnology.Thecompanysuppliesitsproductstonumerousindustrialcustomers,includingleadingsanitaryspecialists,andiswellknownandappreciatedbeyondthebordersofEuropetodayasapartnertotheinternationalsanitaryindustry.

Inlargenumbersofunits,SANITmakesdrainunits,tubediffusersandWCaccessories–fromcisternsandWCseatstocompleteon-wallinstallationsystemsand

systemsolutionsforlevel-accessshowers.TheRödentalfacilityisequippedwithtwofullyautomaticproductionlines,includingassemblyandqualityinspection.

Atotalof124injectionmoldingmachinesarecurrent-lyinoperationatSANIT,71ofwhichareinstalledattheEisenbergplant.ThebusinessrelationsbetweenSANITandtheWITTMANNGrouphavebeenwellestablishedformanyyears.SANITisusingvariousinjectionmol-

Flow Control

The WPR 730 proportional flow controller from WITTMANN.

Picture left:Walter Lichten-berger (left), WITTMANN Division Manager for Temperature Control Technology, and Tilo Walther, Injection Molding Plant Manager at SANIT, discussing business.Picture right:Schematic diagram of the appliance’s func-tionality.


Flow Control

The completely as-sembled polysty-rene cistern.

View into the mold space of the application at the moment of parts removal.

Picture left:Production plant of SANIT in Eisen-berg, Germany.Picture left:View of the compa-ny’s showroom.

WPR 730 application at SANIT

AtSANIT,thisWITTMANNWPR730proportionalflowcontrollerisusedonaninjectionmoldingma-chinewith650tonsclampingforceinconjunctionwithfrequency-controlledpumps.Inanapplicationrunningexclusivelyonthismachine,SANITmanufacturestwotypesof6-literpoly-styrenecisternhousingsandtheirlids.

TheWPR730installedhereisfedwithawater-glycolmixtureascoolingmedium,usingacentralcoolingsystemwithanoutput-andmotorspeed-controlledpump.Dependingonthelevelofcapacityutilization,thecoolingaggregate’scontrolsystemrespondsbyautomaticallyincreasingorreducingthepump’smotorspeed,thusadjustingthepressureofthemediuminsidetheWPR730.Tokeeptheactualvaluewithinthesettolerancemargin,theproportionalvalvesoftheWPRmustbebroughtintothecorrectposition.Thisprocessiscarriedoutautomaticallyandre-adjustedasre-quired.Thisapplicationischaracterizedinparticularbynothavingthemoldtemperatureadjustedintheconven-tionalway,thatis,nopre-heatingwithatemperaturecon-

trollergenerallyoperatingwithhighenergyconsumptiontakesplace.Themoldisheatedsufficientlybythein-jectedplasticmeltandtheappropriatehotrunnersystembuiltinonthefixedside.Inthisway,theproductioncanbeinitiatedwitha“cold”start.

However,caremustbetakenthattheheatenergyradiationfromthehotrunnersdoesnotoverheatthemold–socoolingisnecessary.Viaproportionalvalves,coldwaterispumpedthroughthecoolingholesinapreciselycontrolledway.Asensorinthereturnlineofthemoldchannelmeasuresthereturnflowtempera-tureandtransmitsthetemperaturereadingstotheelectronicsystemforfurtherprocessing.TheapplicationrunningatSANITworkswithaninletwatertemperatureof15°Candareturntemperatureof29°C–valuescorrespondingtoacavitywalltem-peratureof40°C.

Ifpressurefluctuationsoccurinthecoolingcircuitorifamoldchannelispartlyblockedthroughsoiling,theproportionallycontrol-ledvalvesoftheWPR730openorcloseinresponseandadjustthem-selvesautomaticallytomaintainthesettemperaturelevel.

Atolerancemargincanbedefi-nedforthatlevel.Ifthetemperature

exceedsorfallsbelowthismargin,analarmsignalwillbeissued.TheWPR730wasalreadyequippedwithaninterfacetocommunicatewiththeinjectionmoldingmachine,whichmadeitsuseextremelycomfortableovertheyears.

SANIT’sInjectionMoldingPlantManagerTiloWaltherandWalterLichtenberger,DivisionManagerofTempera-tureControlTechnologyattheWITTMANNGroup,bothagreeononepoint:flowtechnologywhich,onceinstalled,hasnowbeenrunningwithoutanyincidentsforalmost25years,isnotonlyanexcellenttestimonialforWITTMANN’sR&Dwork,butisalsobreakingrecords.•

BernhardGrabneris Head of Graphic Artwork and Chief Editor at WITT-MANN’s head office in Vienna.


News

TheTurkishbranchoftheWITT-MANNGroupwasestablished

in2006inKadıköy-Istanbul.InApril2009,MuzafferEnginbecametheGen-eralManager.Constantlygrowing,thecompanymovedtoabiggerbuildingin2011inMaltepe-Istanbul,makingfulluseof660m²offloorspace,includ-inga200m²showroomand150m²ofstoragespace.In2018,another150m²wasadded.

Thecompany’slocationisverycon-venientforTurkishcustomers,allow-ingquickandeffectiveservice.Cur-rently,WITTMANNBATTENFELDTurkeyemploys16people,amongthemseventechniciansandthreesalespeople.Thereareplanstofurtherincreasethecompany’smanpoweroverthecourseofthisyear.

WITTMANNBATTENFELDTur-keyprovidescustomizedsolutionsforthemostcomplexautomationsystems,includingtop-entryin-moldlabeling(IML)robotsandspecialEOAT(end-of-armtooling)formanyapplications.

Someapplicationexamplesincludeglassinsertions,bushinginsertionsforwashingmachinedrums,andvariedinsertapplicationsfortheautomotiveindustry.Top-entryIMLrobotsarealsoevenexportedtoEgypt,Lebanon,andsomeAfricancountries.

Alongwithitsgrowingmarketshare,WITTMANNBATTENFELDTurkeyhasextendedthenumberofitssparepartsinstock,thusshorteningresponsetimesandprovidingsolutionstocustomersinnexttonotime.Inanygivenmomentthecompanystocksatleastoneinjectionmoldingmachineandonerobot,aswellasmobiledryers,singlematerialloaders,temperaturecontrollers,andwaterflowregulators.

Highlights of the Turkish market

TheautomotiveindustryisthestrongeststimulusfortheTurkishin-jectionmoldingsector.In2018,Turkeyproducedatotalof1,550,000vehicles.

ThemostimportantfactsabouttheTurkishautomotiveindustryareasfollows.

• Number14intheworld-wideautomotiveproduc-tion.

• Leadingsectorfor11years,18%ofthecountry’sexports.

• LeadingindustryinR&D:107respectivecenters.

• Employs200,000people,globallycompetitive.

• Onevehicleproducedev-ery13seconds.

• Holdsanexportshareof77%,exportingtonearlyev-erycountryintheworld.

• Exportsanewvehicleev-ery18seconds.

Thepackagingandelectricalap-pliancesindustriesarealsostronginTurkey.EspeciallytheTurkishwhite

goodsindustrywhichisaninterna-tionalplayer.TurkeyisinfactthebiggestmanufacturerofwhitegoodsinEurope,andnumbertwointheworld.Thesectorexports75%ofitsproduc-tiontomorethan150countries.

WITTMANNBATTENFELDTur-keyparticipatedinthePlastEurasiaIstanbulinDecember2018,thePlastEurasiabeingthelargestplasticsindus-tryfairinTurkeyandaroundTurkey.Morethan1,000companiesfrom44countriesand50,000professionalvisi-torsattendedtheshow.

Asoneofthebiggestplayersinthemarket,WITTMANNBATTENFELDTurkeypresentedthecompany’sentireproductrange,welcomingguestsandcustomerstoashowboothof279m²floorspace.

DespitethecurrencyfluctuationsinvolvingtheTurkishLira,thePlastEurasia2018experienceturnedouttobeaverysuccessfulevent.•

The Turkish WITTMANN BATTENFELD branch

View of the Plast Eurasia 2018 show booth of WITT-MANN BATTEN-FELD Plastik Makineleri Ltd. Sti., the Turkish subsidiary of the WITTMANN Group.

The Turkish WITT-MANN BATTEN-FELD team at the Plast Eurasia 2018 show booth.

For years now, WITTMANN has been the undisputed Turkish market leader for linear robots. And year by year, WITTMANN BATTENFELD Turkey steadily holds a bigger market share for all of the company’s other product divisions: injection molding machines, water flow regu-lators and temperature controllers, drying and conveying equipment.


Theinaugura-tionsawthe

presenceofDr.WernerWittmannandtheWITT-MANNandWITTMANNBATTENFELDCEOsMichaelWittmannandRainerWeingraber.

TheCerianoLaghettoshow-roomwasequip-pedwithadvancedWITTMANNBATTENFELDsolutions:aServoPower120/525injectionmoldingmachinesetupasaWITTMANN4.0workcell,anEcoPower110/350withExpert-StepForcesystem(allowingforastepwisebuildupoftheclampingforce),averticalVPower160Rwithrotarytable,andaCOMBIMOULDSP240/750H+210S.Thecom-pleterangeofWITTMANNauxiliaryequipmentwasalsopresented.TheinterconnectionofallthemoldingmachineswiththeTEMI+systemmadeforacompleteexpositionofallthecurrentWITTMANNGrouptechnologies.

Gratitude for customer loyalty

May9,thefirstdayoftheevent,wasreservedforsomeselectedlong-standingcustomersthathaveshown

theirconstantloyaltyformanyyears–firstlybeingbusinesspartnerswithBATTENFELD,and,asof2008,withtheWITTMANNGroup.AbriefbutcomprehensivepresentationofWITTMANNtechnologiesandtheiradvantageswasfollowedbytheopen-ingceremony.

Dr.WernerWittmannandtheItalianManagingDirectorLucianoArreghinibothcutthroughtherib-bontoofficiallyinauguratethenewpremises.

Thecustomerswereinvitedtovisitthenewshowroom,wheretheyweregivenexplanationsoftheappli-cationsondisplayandtheperfor-manceofthedifferentmachinesandtheauxiliaries.

Theyalsohadtheopportunitytoseethenew,modernofficesandtrainingrooms,thenewtechnicalofficededicatedtoboththe“servicehotline”andthewebservice,andalsothenewautomatedverticalwarehouse.

New premises for the Italian WITTMANN Group subsidiary

News

Boundless joy about the new premises: the enthusiastic Italian WITT-MANN BATTEN-FELD team.

More than 250 guests – including customers, plastics companyrepresentatives and trade media– attended the opening of the newlybuilt WITTMANN BATTENFELD subsidiary in Ceriano Laghetto, Italy.The opening took place on May 9 and 10 and the event’s tagline was “enjoy innovation”. There was much to enjoy in the proceedings.

The new premises of WITTMANN BATTENFELD Italia S.r.l. in Ceriano Laghetto, located in the Lombardy Region in Northern Italy.


Picture left:Dr. Werner Wittmann (left) and Luciano Arreghini, cutting through the ribbon at the opening ceremony.Picture right:Part of the festiv-ity was a concert of classical music in the Villa Erba in Cernobbio at Lake Como.

News

Showroom installation view.

Theeventcontinuedwithcocktails,servedinthemagnificentgardensofVillaErbaatLakeComo,whereacon-certofclassicalmusicwasheld,enti-tled“MusicaljourneybetweenItalyandAustria”,thusmarkingthelongandfruitfulcollaborationbetweentheViennagroupheadquartersandthe

Italianbranch.AgaladinnerwithinthesplendidsettingofVillaErbaconclu-dedtheevening.Inthecourseoftheevening,LucianoArreghinipresentedaframedcommemorativeplaquetoPietroSpinelli,ManageroftheSpivalcompanyinLarciano,Tuscany–inrec-ognitionofhisexceptionalloyaltyand

support.Actually,theSpivalcompanypurchaseditsfirstBATTENFELDinjec-tionmoldingmachinein1959,andthelatestonein2019,whenSpivalboughtatwin-injectionmodelwith160tonsofclampingforce.LucianoArreghiniexpressedhisjoyandpride,inviewofthese60yearsofconstantloyalty.

The open house event

May10wasorganizedasanopenhouseevent–opentoallactualandpotentialcustomers.Herethefocuswasonpresentingthetechnologiesandmachinerythroughlivedemon-strationsintheshowroom.

LucianoArreghinisaidthat“themovetoournewbuildingisanimpor-tantstepforward,dictatedbyorgani-zationalnecessity,and,aboveallbyourdesiretoofferever-greaterefficiencyandserviceswhichareinnovativeandprofessional.Thisisasignificantmo-mentinourhistory.Onewewanttosharewithourlong-standingclients,whohavebeenakeyfactorinourgrowthandwhohavebackeduswiththeirongoingandvaluableloyalty.”

Thenewpremisescoveranareaof1,900m²,including750m²ofofficespaceontwofloors,andanother750m²fortheshowroom,thewarehouse,andtherepairshopfortemperaturecon-trollers,dryersandspruepickers.Thereisatrainingroom,ameetingroomforsome30people,andareceptionroom.Theofficesfeatureglazedwalls,combin-ingtheneedforconfidentialitywithnaturallight,makingtheworkingen-vironmentmorepleasant.Employees’comfortwasapriorityregardingthefurniturethatisarrangedinislandunits–independent,andstillconnected.•

Discussions and exchange of experiences were omnipresent.

BP00000034 – 1903

WITTMANNBATTENFELD INC.1 Technology Park DriveTorrington, CT 06790, USAtel.: +1 860 496 [email protected]

WITTMANN ROBOT(KUNSHAN) CO. LTD.No. 1 Wittmann Rd.DianShanHu TownKunshan City, Jiangsu Province215245 CHINAtel.: +86 512 5748 [email protected]

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