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Techniques – Markets – Trends Volume 9 – 2/2015

Always perfectly staged:

WITTMANN auxiliary equipment

Quarterly magazine of WITTMANN Kunststoffgeräte GmbH and WITTMANN BATTENFELD GmbH. Appears to meet the informa- tional demands of staff and customers. Editorial office: WITTMANN Kunststoffgeräte GmbH, Lichtblaustrasse 10, 1220 Vienna;tel. +43-1 250 39-204, fax +43-1 250 39-439; [email protected]; http://www.wittmann-group.comIssue 3/2015 of “WITTMANN innovations” will appear at the beginning of the third quarter 2015.

WITTMANN innovations (Volume 9 – 2/2015)

Articles that appeared in WITTMANN innovations so far

Automation• Productionandqualitycontrolinmedi-

calengineering1/2007• Thehandlingoflargestructuralfoamparts2/2007• ThenewR8robotcontrol3/2007• High-end:Theproductionofseatadjustmentrods1/2008• Driveengineeringforrobots1/2008• Automatingtheproductionoftrans-ponderpins2/2008• Automatedremotecontrolkeys3/2008• AutomationatCarclo,UK4/2008• Theflexibleautomationcell1/2009• ThecultivationofgrowthwithWITT-MANNrobots2/2009• 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,Switzerland:Qualitythroughautomation3/2012• Zero-rejectproduction4/2012• SmallestpartsatJENOPTIK2/2013• TheSchrambergautomation3/2013• TheBusch-Jaegerautomation1/2014• AutomatingIn-MoldDecoration2/2014• AutomationatPortEriePlastics3/2014• AutomatingSTARPLASTIK4/2014• JonesPlasticandWITTMANN1/2015

Conveying/Drying/Entire Systems• CentralsystematBOSCH1/2007• Qualitycontrolofdryers1/2007• Kromberg&Schubert'ssystem2/2007• Costefficientmaterialdrying2/2007• FEEDMAXforthecleanroom3/2007• ThenewDRYMAXED803/2007• Focusonmaterialfeeding1/2008• NetworkcontrolatArge20002/2008• Changingparameterswhenconveying

differentmaterials2/2008• Optimizingaconveyingsystem3/2008• Dryerswithenergyrating3/2008• TheMetchemcentralsystem4/2008• AuxiliariesatDelphiinChina1/2009• LISICOSMETICS'centralsystem2/2009• Perfectplanningofcentralsystemsavoidsdowntime3/2009• TestingenergyclaimsatFKT4/2009• ThenewFEEDMAXB1001/2010• GreinerissavingenergybyusingWITTMANNdryers2/2010• TheA.C.S.conveyingsystem3/2010• FEEDMAXPrimusconveyor4/2010• ThenewDRYMAXAton2/2011• TheBKFconveyingsystem2/2011• WDKunststofftechnikanditscentralsystem4/2011• PETprocessorusesaWITTMANNconveyingsystem1/2012• ThePLASTICOMsystem2/2012• TheNICOMATICsystem3/2012• Savingenergyinmaterialdrying4/2012• TheBespakmaterialhandling2/2013• VisionTechnicalMolding:Prescriptionforefficiency3/2013• WPCinjectionmolding1/2014• NewPollmanncentralsystem2/2014• TheHELLAMexicosystem3/2014• TheProcopisystem,France4/2014• TheSLMmaterialmanagement4/2014• SlovenianproducerreliesontheWITTMANNGroup1/2015

Granulation• 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

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

In-Mold Labeling• IMLstackmoldsystems3/2007• TheWITTMANN2+2stackmold

1/2008• ATMd.o.o.inSerbiagrowswithWITTMANNsystems3/2009• QuadrangularIMLdesignatPLASTIPAKinCanada4/2010• TeaPlastinAlbaniawantstobecometheNumberOneinIML3/2012• EcoPower:fourfoldIML1/2013• IMLasamultifacetedprocess4/2013

News From The Subsidiaries• Australia2/2008, 2/2013• Austria2+3/2008, 1/2010, 3/2011,

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

Temperature Control• Advantagesofpulsedcooling1/2007• Comparingwatertooil2/2007• Thenewtemperaturecontrollersofthe

TEMPROplusCseries3/2007• COOLMAXcoolingunits2/2008• Temperaturecontroller“guarding”injectionmoldingmachines3/2008• TemperaturecontrollerswithDUOcooling4/2008• Variothermaltempering1/2009• TEMPROplusC1802/2009• TEMPROdirectC120[C250]3/2009• WFC:WaterFlowControl4/2009• TEMPROplusC1801/2010• TEMPRO:Universalbenchmark2/2010• BFMOLD®moldcooling3/2010• TEMPROplusD4/2010• Online-thermography1/2011• TemperingandinjectionmoldingatFuchs&Sohn2/2011• TEMPROplusDintheautomotivesector1/2012• Oscilloscopefunction2/2012• Compacttemperaturecontroller4/2012• Qualityassurancethroughtheoptimaltemperingprocess1/2013• TheStarlingerspecialsolution2/2013• NewWITTMANNtemperingandflowcontrolequipment4/2013• TEMPROusesheatwaste1/2014• CleansolutionatDELPHI4/2014• Blumusingaspecialsolution1/2015

Injection Molding• Injectionmoldingonestopshop4/2008• MetalinjectionmoldingatIndo-US

MIM4/2008• Costoptimization:EcoPower1/2009• ITassistedservices1/2009• Waterinjectionforall-plasticparts2/2009• TheKronaIndústriaequipment2/2009• Micro-parts:Microsystem503/2009• Multi-componentprocessatwolfcraft4/2009• Processdataacquisition:partnershipwithWilleSystem4/2009• Thenewall-electricEcoPower 4/2009• ThomasDudleyandWITTMANNBATTENFELD1/2010• IMLwithTMXpress1/2010• AIRMOULD®andAQUAMOULD®Mobile1/2010• DesignMoldedPlasticsandtheirmold-ingmachines2/2010• StadelmannreliesonWilleandWITT-MANNBATTENFELD2/2010• ThenewMicroPower3/2010• AQUAMOULD®andprojectileinjec-tiontechnology3/2010• Newbenchmark:MacroPower4/2010• STELLAreliesonWITTMANNBATTENFELDmachines4/2010• TheServoDrivetechnology1/2011• The75thmachineforKrona1/2011• PackagingspecialistTMXpress2/2011• WAVIN(CzechRep.)andWITT-MANNBATTENFELD3/2011• 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

WITTMANN innovations – 2/2015 3

Editorial

DearReader,

WearelookingforwardtoApril22and23withgreatpleasure.Onthesedays,wewouldinviteyoutoagainvisitourmachinemanufacturingplantinKottingbrunn,wheretheMacroPower Days2015willtakeplace.Asthenamealreadyimplies,thespeechesandpresentationsofthiseventwillfocusprimarilyonourMacroPowerseriesoflargemachines.Weareofferingourguestsanopportunitytotakealookatseveninjectionmoldinglineswithclampingforcesrangingfrom400to1,600t,andtogatherinformationaboutadvancedprocesstechnologies.TheothermodelsfromourPowerSerieswillalsobeavailableforviewing.

Well-knownexpertsfromindustry,scientificresearchandteachingwillholdpresentationsonhighlytopicalsub-jectssuchasIndustry 4.0,manufacturingof“organosheets”,injection-moldedintegralfoam,andnumerousotherapplicationsfromvariousbranchesofindustry.Inshort,aprogramawaitsyouwhichcoverstheentirebandwidthofapplicationoptionsforourMacroPowermodels.

Univ.-Prof.FriedrichBleicher,HeadoftheInstituteforProductionTechnologyatTUVienna,willholdtheopeningspeechabout“Industry 4.0fortheplasticsindustry“,dealingwithadevelopmentwhichisvitalfortheCentralEuropeanindustryandforeconomicpolicies.Industry 4.0standsforpoolingalltrendswhichaimtoimplementcomprehensivenetworkingofallinformationandcommunicationtechnolo-giesinanInternetofobjects,servicesanddata.Thefacilitiesforquick,flexibleresponsetocustomers’demands(includ-ingcost-efficientproductionofsmallbatches)willbefurtherimproved,thuspreservingthecompetitivenessofcountrieswithhighwagelevels.

ThecompaniesoftheWITTMANNGrouphavetheuniqueexpertiseattheirdisposaltointegrateallinjectionmoldingcomponents,i.e.thecompleteautomationsystemandfullrangeofperipheralequipment.Thisgivesusadeci-sivecompetitiveadvantageoverothercompaniesoftheinjec-tionmoldingequipmentindustry.Withourintegrationsolu-tioncalledWITTMANN 4.0wearealreadyofferingnowwhatas,forexample,beendescribedbytheFraunhoferInstituteasthegreatestchallengeinconnectionwithIndustry 4.0:thedefinitionofcommunicationstandards,includingguaranteedsafetyofdataandaccess.WithWITTMANN 4.0 wehaveal-readyreachedagoalwhichmanyothersareonlyjuststartingslowlytopursue.WewouldinviteyoutogatherinformationaboutthepotentialofWITTMANN 4.0attheMacroPower DaysoftheWITTMANNGroup!

Yourscordially,MichaelWittmann

Michael Wittmann

ContentAutomation

Effectiveness and cleanness

Thus productivity occurs

Sonny Morneaultvisits Alliance Precision Plastics in Spindale, North Carolina.Page 8

InjectionMolding

Resource saving production

News

Gabriele Hopfon Fushima, a Spanish molder working for the world market …Page 10

Jimmy Teowrites about auto-mation systems at Greenland Plastics in Singapore.Page 4

EntireSystems

Best molding quality

We present: the WITTMANN BATTENFELD QuickLook app.Page 14

We provide insight into WITTMANN Kunststoffgeräte GmbH in Vienna, Austria.Page 15

Terry Liudescribes the Gerresheimer central system in China.Page 6

Conveying

… and on Tielke in Germany, the all-round injec-tion molder and toolmaker.Page 12

Highly integrated workcells

Portrait

WITTMANN innovations – 2/20154

Automation for a smooth process run

OneofthesecretsbehindGreenland’ssuccessisthattheirautomationcomponentshavebeenconsistentlystate-of-art.ThisphilosophyledtotheacquisitionofaWITTMANNW818servorobotwithfullyautomaticdownstreamequip-mentdeliveredfromWITTMANNBATTENFELDSingapore.

A well-established Singapore plastics processor usesautomation systems provided by the local WITTMANN branch –and achieves a remarkable increase in productivity.Jimmy Teo

GreenlandPlastics,locatedinSingapore,isaspecialtyproducerofPVC(Polyvinyl

Chloride),PE(Polyethlene)andABSparts(AcrylonitrileButadieneSty-rene),andalsoprocesseshalogenfree(HF)material.

GreenlandoperatestwoproductionplantsinSoutheastAsia,oneproduc-tionplantinSingapore,andtheotheroneinMalaysia.Thehighlycom-petitivecompanyiswellpositionedtomeetanyneedsandexpectationsofitscustomers.

Inthefirstinstance,GreenlandPlasticsishighlyspecializedintheextrusionindustry,especiallyintheextrusionofpipes,industrialhoses,cabletrunkingandprofiles,renderingOEMservicesforcustomrequirements.Withalmost40yearsofextrusionandinjectionprocessexperience,Greenlandiswidelyknownandhighlyrespectedforexcellentqualityandabsolutereliability.

The highest degree of accuracy … over and over again

Automation

Jimmy Teo, Man-aging Director of WITTMANN BATTENFELD Singapore and Chia Mui King, Managing Direc-tor of Greenland Plastics Singapore. The handshake marked the seal-ing of a further automation project, allocated to WITTMANN BATTENFELD Singapore.

Hexagon screw nuts that are inserted into the mold, and finished molded parts, manufactured at Greenland Plastics (S) Pte. Ltd. in Singapore.


Afterthehexagonscrewnuts,producedatGreen-land,havebeenorientedbymeansofacustomizedbowlfeeder,theW818robotreliablypicksandplacestheinsertsintothemold,workingwithabsoluteprecisionandrepeatedaccuracy.Thankstoitsprocessconsis-tency,theWITTMANNautomationsolutionincreasesproductivitythroughasignificantreductionofcycletimes,anditcontributestoimprovingthehighqual-itystandards.Theautomationprocesscanbeoperatedwithoutanyinterruptionforverylongperiods,perhapsevenforyears.

ChiaMuiKing,GreenlandManagingDirectorcom-mentsonthis:“ThankstotheWITTMANNrobot,wehaveachievedasignificantreductionofthemoldopeningtimesthatapproximatelymountupto70to80%.Wehaveincreasedourproductivity;weproducedmoregoodsandworkedoffmoreservicesusingthesameamountoflaborandcapital.Forus,itisnotreallyabout

cuttingcosts,butsimplyabout‘doingthingsright’and‘doingtherightthings’toachievemaximumefficiencyandvalue.”

Service and responsiveness

“WerecognizeandappreciatetheservicedepartmentofWITTMANNBATTENFELDSingaporeasextremelycooperativeandknowledgeable.Theyalwaysrespondimmediately,andthisisthereasonwhywehavechosenWITTMANNBATTENFELDSingaporeasourpreferred

automationpartner.Additionally,ourtechnicaldepart-menthasbenefittedsomuchfromtheircustomizedtrainingprogram,”saysChiaMuiKing.Movingforwardandachievinghigherproductivitythroughautomation,GreenlandPlasticshasmadeanagreementwithWITT-MANNBATTENFELDSingaporetoundertaketheirfutureautomationprojectswiththem.•

Automation

Jimmy Teois ManagingDirector of WITT-MANN BATTEN-FELD (Singapore) Pte. Ltd.

Greenland custom-ized end-of-arm tooling (EOAT), designed by WITT-MANN BATTEN-FELD Singapore.


Conveying

ThecompanyinDongguanwasfoundedin2006,andtheplasticproducts,plasticcontainersandmoldsitismanufacturingareexportedtoEurope,

theAmericasandothercountries.Theirtechnicalex-pertiseranksamongthoseoftheworld’sleadingplasticsprocessors.

TheproductionsiteiscertifiedtoENISO13485:2012+AC:2012andISO9001:2008.Thesitehasatotalareaof10,700m²and1,800m²ofproductionarea,600m²ofwhicharedesignatedforcleanroomproductiontoISOclass8,and1,100m²arecon-trolledareasinaccor-dancewithISOclass9.

Alltheproductsaredesigned,moldedandassembledaccordingtotheGMPstandard(GoodManufacturingPractice).Atpresent,theGerresheimerDongguansiteistheonlyplasticsprocessingfacilityoftheGerresheimerGroupinAsia.

The Dongguan injection workshop

Thecompany’sinjectionmoldingworkshopisinstalledonthegroundfloor,whilethecentralcontrolroomandtherawmaterialbinsarelocatedonthe2ndfloor.ThecentralsystemwasdeliveredbyWITTMANNBATTEN-

Gerresheimer Medical Plastic Systems DongguanCo. Ltd. near Hong Kong, is a subsidiary of theGerman Gerresheimer Group, using a centraldrying and conveying system from WITTMANN.Terry Liu

The central drying and conveying system at Gerresheimer in China

WITTMANN FEED-MAX material loader, mounted on an injection molding machine.

FELDChina.AtGerresheimerDongguan,thefollowingtypesofmaterialareconveyed:PC+ABS,POM,ABS+PTE,POM+PTFE+Silicon.Duetotheparticularityoftheproducts,therequirementsforthecentralconveyingsystemareveryhigh.

Themaintargetsweretogetdust-freeoperationasfaraspossible,toallowonlythelowestamountofmoistureafterhavingdriedtherawmaterial,andtopreventre-moisturization.

Abovethat,thesystemhadtooperatewithoutinter-ruption.WITTMANN’scentralsystemcompletelymetthestandardsrequiredfortheproductionofmedicalparts.

Features of the central system

TheWITTMANNdryingandconveyingsystemcomeswithmanyadvantages.Thedryersallowforadewpointofupto-60°C.

TheWITTMANNSILMAXdryinghoppersandFEEDMAXmaterialloadersaremadeofadvancedinsu-latedstainlesssteel.Thesystemcomeswithadustfilter,ensuringalargelydust-freeconveyingoftherawmaterial.WITTMANN’suniquetemperaturecontrolledcounter-


flowregenerationavoidshumidambientairwithinthedryinghopper,thuspreventingthere-moisturizationofthematerial.

Thedryerisequippedwithmolecularsievedesiccantbedstoensureaconstantandstableflowofdryair.OneofthespecialrequirementsfortheGerresheimersystemwastheinstallationofanalternatepumptomaintainasteadymaterialthroughput.

Thispumpmatchesperfectlywiththecentralconvey-ingsystemanditislaidoutforfastsetupifnecessary.ThespecialWITTMANNSmartFlowfunctionregu-latesthedryinghopperairquantity,usingthematerialthroughputasareferencevalue.

Therefore,onlytheairquantitythatisactuallyneededforthedryingprocessinthespecificdryinghopperhastobeheated.Asaresult,itispossibletosaveupto80%oftheenergycostassociatedwiththedryingprocess.

TheentiresolutionisequippedwiththeWITTMANNM7.2networkcontrolsystem,allowingforvisualizationofalltheconditionsona15"touchscreen,includingaschematicpresentationofthematerialflow.

TheM7.2controlsystemmakessurethatthedifferentmaterialsareconveyedtotherightprocessingmachines.Itoffersanintuitiveanduser-friendlyinterface,anditiseasytooperate,showinganyandalldataofthecompletedryingandconveyingprocess–thefunctioningoftheFEEDMAXandDRYMAXdevicesrespectively.

UsingtheM7.2,theoperatorisgettingaccesstocommandsanderrormessagesoftheprevious100daysandisabletodiagnosethesystemandtoexecutearapid

troubleshoot.Inshort,thetotalityofthedryingandconveyingequipmentfromtheWITTMANN“one-stopshop”ledtoimpressiveenergysav-ingsat,toaconsiderableincreaseinproductivity,andhelpedreducethescraprate.

Inadditiontoallthis,theWITTMANNGrouppro-videsahighlyqualifiedhot-linehelpser-vice24hoursaday.

ThehighqualityofallWITTMANNandWITT-MANNBATTEN-FELDpro-ducts(aux-iliaryequip-mentontheonehand,andinjec-tionmoldingmachinesontheother)andthe

comprehensiveandthoughtfulafter-salesservicearethereasonswhysomanyplasticsprocessorsrelyonad-vancedauxiliaryequipmentoftheWITTMANNGroup–everywhereintheworld.•

Conveying

Terry Liuis Deputy General Manager of WITT-MANN BATTEN-FELD (Shanghai) Co., Ltd. in China.

The picture is showing a WITT-wwMANN central material drying and conveying system including a DRYMAX battery dryer, 6 SILMAX material hoppers with FEEDMAX loaders, 2 filter stations, and a coupling station.

Xiaoqiang Zhang, Technical Service Engineer of WITT-MANN BATTEN-FELD China.


Entire Systems

AlliancePrecisionPlastics,headquarteredinRochester,NY,isacustominjectionmolding,molddesign,moldbuilding,and

contractassemblycompany.Whatbeganasalocaltoolmakingshopin

1953hasgrownintoapowerfulproductionmoldingcompany,withover90injectionmold-ingmachinesspreadoverfourmainlocationsintheUSandMexico.ThemostrecentlocationcametoAllianceinearly2012viatheacquisi-tionofcertainassetsofMoldingDynamics,Inc.,locatedinSpindale,NC.Withthisacquisitioncametheawardofamajornewprojectbyalead-ingappliancemanufacturer,andaresultingneedforanewlineofmoldingmachinesandauxilia-riestosupportit.“WehadastrongcustomerbaseintheSouth-

easternUS,andsawtheSpindalefacilityasagreatfitforustobetterservicethatregionforbothnewandexistingcustomers,”saysJoeWilliams,VicePresidentofOperationsatAlliance.“Itwasanincrediblysmoothacquisitionandcombinationofcorporatecultures.ThetransactionbroughttoAl-liancethechancetohireanumberoftalentedandhard-workingpeopleinNorthCarolinatojoinourteam.ThatcombinationhasallowedAlliancetoexpandboththeirbusinessopportunitiesandtheirphysicalplant.”

OneofthoseopportunitieswastobidonalargenewprojectbeingofferedbyanexistingSpindalecustomer.Toaccommodatethenewworkcells,AlliancealsoneededtoexpandtheirSpindalefacility.

Asaresult,AlliancePrecisionPlasticsbeganconstructionona17,500sq.ft.additiontotheexistingplant.Thenewspaceisprimarilyforwarehouseuse,leavingmoreroomontheexistingfloorforthenewworkcells.

ThisadditionwasstartedinJuly2014andincludes5dockdoorsformoreefficientshippingandloading,aswellasincreasedcapacity.Itwascompletedandmovedintobytheendof2014.

A new work cell

Uponwinningtheprojectandplanningtheexpansion,Alliancewentoutlookingfortheequipmentnecessarytobuildthenewworkcellsnecessarytosupportit.Thenewprojectwasacomplexonethatrequiredmachinesthatof-

After winning a bid for a complex new molding project, Alliance Precision Plastics needed additional new equip-ment that was customizable, easy to integrate, and quickly delivered. By pro-viding one-stop shopping, WITTMANN BATTENFELD was able to meet all of their needs and meet them faster than the competition.Sonny Morneault

Alliance Precision Plastics: Workcell integration, automation and service


Entire Systems

feredflexibility,customization,andafastturnaround,andworkingwithWITTMANNBATTENFELDmadesense.“WehadworkedwithWITTMANNBATTENFELDbeforeonacustomspoolautomationprojectbackafewyearsagoandwehadsomegreatfeedbackfromouremployeesontheeaseofuseandqualityoftheWITTMANNrobots,”

Small picture above: View of injection molding machines from WITTMANN BATTENFELD at the Alliance Preci-sion Plastics plant in Spindale, NC, USA.Picture left (from left to right): Joe Minor (WITT-MANN BATTEN-FELD IMM Region-al Sales Manager), Joseph Williams (Vice President of Operations for Alliance Preci-sion Plastics), Joe Varone (Regional Sales Manager of WITTMANN BATTENFELD Robots and Auto-mation), Dave Wyscarver (WITT- MANN BATTEN-FELD Regional Sales Rep).

saysAlanKearns,GeneralManageratAlliance’sSpindalefacility.“WehaveagreatrelationshipwithWITTMANNBATTENFELD’ssalesrepsintheareaandtheypitchedusaturnkeylinewitheverythingweneeded.Wehadacustomerandothermoldershighlyrecommendthemtous.Theintegrationoftheworkcell,thesinglesourcing,andthefast

Sonny Morneaultis National Sales Manager of WITTMANN BATTENFELD, Inc. in Torrington, CT, USA.

deliverytimewereallbigsellingpointsforusthatWITT-MANNBATTENFELDcouldachieve,sowepulledthetrig-ger.”Asaresult,Alliancepurchasedseveninjectionmoldingmachines(aTM500,2HM150s,2HM90s,anHM65,andanHMMC300two-shotmachine),4robots(2W833sand2W831s),5granulators(4SJMinor2sandanML33),

3dryers(2DRYMAXAtonF70-200-Msand1DRYMAXE30-70-M),3loaders(3FEEDMAXS3Primuses),2pickers(W702s),5TCUs(TEMPRObasicC200s)andasilo.

Withallofthisequipmentcomingfromasinglesource,Alliancehadallofitdeliveredtotheminthreemonthstime,somethingthatwasimportanttothemwiththeirneedtogetthenewprojectunderwayassoonaspossible.Themachinesandrobotswereintuitivetoprogramandsetup,aswellasbackedbyWITTMANNBATTENFELD’sstel-larcustomerserviceandsupportteam.Theeaseofintegrationwaskeyfortheproject,withalloftherobots,materialhandlingsystemsandinjectionmoldingmachinescommunicatingandworkingtogetherseamlessly.TheplantpersonnelatAlli-ancepraisethesimplicityofthecontrollersandthecontrolsystems,andappreciatetheconsistencyofthemacrosstheentireworkcell.“Asgoodastheequipmenthasbeen,theser-

vicehasbeenanevenbiggeraddedvalueforus,”saysKearns.“Theyhaveknowledgeable,helpfulsalesrepresentativesandindependentserviceprovidersthatarebasedrightinourbackyard,whichmakesourliveseasierandhelpsourequip-mentrunevenbetter.”

A custom solution

Oneofthenewmachinesneededtomoldachal-lengingpartfortheapplianceindustrythatrequiredacustombuild.Theapplicationwasatthecruxoftheworkcell,andwasnecessarytomoldthebasecomponentofthefinishedcomplexappliancepart.AllianceworkedcloselywiththeengineersatWITT-MANNBATTENFELDandtheybuiltacustomtwo-shotmachineprovidingthesolutionthatwasneededattheworkcell'sfrontend.“WereallyleanedonWITTMANNBATTEN-

FELDforhelpwiththetwoshotmachine.”saysKearns.“Themoldsizerequiredabigmachineandtheshotsizesdemandedsomethingdifferent.Whatweendedupwithwasanearlycompletelycustommachinethatfitourapplicationperfectlyandpro-videduswiththesolutionweneeded.”

“WehavethoroughlyenjoyedworkingwithAlliancehereinSpindale,”saysJoeVarone,Re-gionalSalesManager–RobotsatWITTMANNBATTENFELD.“JoeMinor(RegionalSalesMan-

ager–MoldingMachines),DaveWyscarver(RegionalSalesRepresentative)andmyselfhavebeenheremanytimesandknowthecaliberofcompanytheyare.We’reproudtohaveafullWITTMANNBATTENFELDworkcellupandrunningintheirfacilityandexcitedforthemtoreapthebenefitsourequipmenthastooffer.”•


Injection Molding

Fushima, a well-known maker of toothbrushes and many other personal hygiene products located on the north coast of Spain, has been relying for many years on injection molding machines from WITTMANN BATTENFELD.Gabriele Hopf

Top-quality toothbrushes with WITTMANN BATTENFELD injection molding machines

Installation of the EcoPower ma-chines at Fushima.

– Fushima has 14 BATTENFELD machines installed on its production floor located in Guarnizo in the North of Spain.

Photos: Fushima


manualtoothbrushes.About40%ofthecompany’ssalesarerealizedoutsideofSpain.Fushimatoothbrushescanbefoundin55countriesworldwide.

Fushima’ssuccessisbasedonhighqualitystandardsandinnovation.TheDINISO9001certifiedcompanyregardsoutstandingachievementsinresearchanddevelopmentasoneofitsmainstrengths.“Alothaschangedinthetooth-brushsectoroverthelastdecades,”saysRaúlCimiano,ManagingDirectorofFushima.“Whiletoothbrushesweremadeofjustonematerialinthepast,today’shigh-qualitytoothbrushesconsistofseveraldifferentmaterials.Thisequallyappliestoothertypesofbrushes.”Agreatvarietyofmaterialsareusedintoothbrushproduction,including,forinstance,polypropylene,TPE,polyethylene,polystyrene,andABS.AccordingtoCimiano,itisalsoaspecialchal-lengetocreateaproductwhichdistinguishesitselffromothersonthemarketandisprofitableatthesametime.Tothisend,Fushimahasseveraldepartmentsengagedintest-ingnewmaterials,creatingnewprocesses,etc.

Fushima relies on WITTMANN BATTENFELD

Toliveuptoitsphilosophyofofferingitscustomersworld-classserviceandthebestpossibleproductstoendcustomers,Fushimaalsoneedsthebestpossibleproduc-tionequipmentthatisexistingonthemarket.Intheareaofinjectionmoldingmachineryandprocesstechnologies,FushimahasreliedonBATTENFELDmachinesformanyyears.

“BATTENFELDmachinesarereliable.Wehavehardlyanydowntimesorproductionfaults,”saysRaúlCimiano.Whatismore,WITTMANNBATTENFELD’sexcellentcustomerserviceandafter-salessupportisalsoappreciatedhere.Atotalof14BATTENFELDmachinesarecurrentlyinstalledatFushima,withclampingforcesrangingfrom50to180t.Untilmostrecently,thecompanyusedmainlyhydraulicmachines.

In2014,Fushimainvestedintwomachinesfromtheall-electricEcoPowerseries,eachwith180tclampingforce,andanEcoPower110.RaúlCimianoisimpressedbythecleanness,thelowsoundlevel,andespeciallybytheenergyefficiencyofthesemachines:“Wehavemea-suredenergysavingsofupto40%comparedtoconven-tionalmachines.”•

Injection Molding

Fushima,basedinGuarnizo,Cantabria,hasmadeanameforitselfasamanufactureroftoothbrushesandhairbrushesfarbeyonditsnationalborders.The

company,foundedbyLaureanoSalcinesGómezin1945,hasmorethan100employeesand,today,itrealizes11millionEurosinannualsales.Ona13,000m²productionfloor,72millionpiecesaremanufactured.Apartfromtoothbrushesandhairbrushes,theyalsomolddentalcareproductssuchasflossandinterdentalbrushes,aswellascosmeticbrushes,make-upmirrors,manicureutensils,barrettesandmore.Fushima’smainproductlineistoothbrushes,particularly

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

From left to right: Daniel Lopez Virto, Fushima; Ignacio Puyuelo and Damian Hernandez, WITTMANN BATTENFELD Spain; Raúl Cimiano, Managing Director of Fushima; Loic Rolin, WITTMANN BATTENFELD Spain; Georg Tinschert, Man-aging Director of WITTMANN BATTENFELD. In the background the EcoPower 110 that Fushima has bought most recently. The pic-ture was taken in Barcelona at the Equiplast 2014.

Pictures left:High-quality den-tal products and brushes made by Fushima.

Photos: Fushima


Injection Molding

InJune2014,AntonTielkeGmbHcel-ebratedits75thanniversary.ThecompanywasestablishedbyAntonTielkein1939,

beginningwiththeproductionofhardwarecomponentsmadeofironandothermetals,primarilyforcustomersfromtheautomotiveandaircraftindustries.Thefamily-ownedenterprisewithaworkforceof25employeeshasnowbeensuccessfullyengagedinplas-ticsprocessingformorethan50years,mak-ingplasticpartsfromallcommonlyavailablethermoplasticresinsandthermoplasticelastomers,withpartweightsrangingfrom0.1to1,400g.Tielke’smaincustomerbaseincludesheatingandsanitaryinstallation,electricalgoodsandbuildingconstructionindustries,butalsoafewselectautomotivecustomers.ItsmainmarketisGermanyandneighboringforeigncountries.

Inadditiontocustomizedproductsmadetocustomers’specifications,thecompanymanufacturesquiteasizeableproductrangeofitsown.Forexample,itproducescapsandstopperstocoversensitivedrillingsandtubesandtoprotectthreadingagainstmoisture,dust,soilinganddamage.Thesepartsareextremelyresistanttoacids,alkali,alcohol,grease,solventsandheat.Tielkealsomakesthedi-rectgreenTMbrandplantsystem,acombinationofplantcon-tainerswithbreathable,water-permeablepotcovers,whichareprimarilyusedfornurseryandhedgeplantsorhigh-stemtrees,and–equippedwithanintegratedwatertank–astransportcontainersandstandsforChristmastrees.

A conscientious all-rounder

Tielkeofferseverythingfromasinglesource,fromprototypingtoseriesproduction.Italsooperatesitsownmold-makingshop.Highqualitystandardsand,aboveall,closenesstocustomersarevital,long-termsuccessfactors

Anton Tielke GmbH & Co. KG in Attendorn, North Rhine-Westphalia, Germany, is firmly committed to protecting the environment and saving resources in manufacturing its products. This is why the first all-electric machine from WITT-MANN BATTENFELD’s EcoPower series, which was delivered at the beginning of June, is greatly appreciated, in particular for its energy efficiency and cleanness.Gabriele Hopf

Resource-saving production at Tielke using WITTMANN BATTENFELD equipment

From left to right: Dipl.-Ing. Ingo Rüggeberg, Man-aging Partner and Ralf Dingerkus, Authorized Repre-sentative of Anton Tielke GmbH & Co. KG, and Frank Höher, Sales Representative of WITTMANN BATTENFELD, in front of the EcoPower 55/130 delivered in 2014.

Picture above:The innovative directgreen™ plant system, consisting of a plant container and a breathable, water-permeable pot cover.Picture right:Prototypes of parts that are used in forest enterprises at young trees to prevent damage caused by game animals.

Photos: Tielke


resourcesaremajorconcernsforthecompany’smajoritystakeholderandManagingPartner,Dipl.-Ing.IngoRügge-berg,andareconsequentlyacentralguidingprincipleofitscorporatephilosophy.Therefore,investmentsinmodern,energy-efficientproductionequipmentaremadeonaregu-

larbasis,too.Anenergyconsultantwascalledin2013

forjointpreparationofaconcepttofurtherimprovethecompany’sbalanceofenergy.“Lastyearwerealizeda10%increaseinsalescomparedtotheprecedingyear,withpowerconsumptionremainingonthesamelevel,”IngoRüggebergexplainsproudly.Andthisiswhytheoutstandingattributesofthenewlyacquiredall-electricEcoPower55fromWITTMANNBATTENFELDaregreatlyap-preciatedatTielke.

Atfirst,IngoRüggebergcouldhardlybelievethatsuchamachineastheall-electricEcoPowercouldoperatewithoutcoolingandalmostwithoutlubricant,sinceitrequiresoilonlyforitstogglesystem.TheEcoPower55/130,equippedwithaTEMPROplusDtemperaturecontrollerfromWITTMANN,cameafterahydrau-licmachinewithaServoPowerdriveandWITTMANNspruepicker,whichhadjustbeendeliveredinthefallofthepreviousyear,andwhosecompactnessandhighenergyefficiencywerewelcomedwithgreatenthusiasmatTielke.

A long lasting partnership

Thecooperationbetweenthetwocom-paniesdatesbacktotheverybeginningofplasticsprocessingatTielke.Tielke’sproductionofthermoplasticsstartedoffwithaBSKM10VPfrom1957,builtattheformerBATTENFELDplantinMeinerz-hagen,Germany.

Today,BATTENFELDmachinesfromthePlusseries,togglemachinesfromtheTMseriesandmachinesfromthehydraulicHMseriesareoperatingattheAttendornfacilityinadditiontotheEcoPower55andHM

110ServoPower,withclampingforcesrangingfrom25to500t.Apartfromthemachines’technicalcapabilities,theirqualityandenergyefficiency,thecostsalsoplayavitalpartforTielke,withthemainemphasisbeingnotsomuchontheacquisitioncosts,butprimarilyonthemachines’totallifecyclecosts.Theavailabilityoftechnicalsupportisthusamajorconsideration.

IngoRüggebergandhislong-standingauthorizedrepre-sentativeRalfDingerkusareparticularlyappreciativeofthepersonalcontacttothecompanyandtheexcellentsupportprovidedbythesalesteam.“Mutualtrustandcontinuityinourpartnershipsarethetopprioritiesforus,”saysIngoRüggeberg.“AndthesefactorsareanabsolutegivenatWITTMANNBATTENFELDinadditiontothehighqualityandtechnologicalmaturityoftheirmachines.”•

Injection Molding

forthecompany,whichhasbeencertifiedaccordingtoDINISO9001.Tielkealsotakesprideinitscertificationasan“energy-conscious”company,implementedbyICGZertifi-zierungGmbHatthebeginningof2014,sincethelong-termprotectionoftheenvironmentandsavingofnatural

Tielke currently has 10 BATTEN-FELD machines (WITTMANN BATTENFELD respectively) on its production floor.

Molds produced at the in-house mold-making shop.

Photo: Tielke

A further example of Tielke’s own products: closure elements, made of plastics.

Photo: Tielke


AstatusrequestoninjectionmoldingmachinesfromWITT-MANNBATTENFELDandonWITTMANNrobotsisnowpossibleviaSmartphoneeasilyandatanytime.

TheWiBa QuickLookappdevelopedforthispurposeiscurrentlyavailablefreeofchargeviatheAppleiOSappstoreandviaGooglePlayasanAndroidapp.

Ineachcase,thenewapplinksupwiththelatestsoftwareversionsofWITTMANNR8.3robotsandWITT-MANNBATTENFELDUNILOGB6controlsystems.Inthisway,theproductiondataandconditionofthemostimportantequipmentthatisoperatinginagivenproductioncellcanbecheckedquicklyandeasilywiththehelpofWiBa QuickLook.

PrerequisitesfortheuseoftheWiBa QuickLookapparethesoftwareversions8.21.00forR8robotcontrolsystemsandV07.2forUNILOGB6machinecontrolsystems.Furthermore,theconnectionofthecontrolsystemstotheWIFIsystemoftheinjectionmoldingplantmustbeensured,sothattherobotsandprocessingmachinescanbereachedbytheapp.Dependingonthemodel,theminimumrequirementfortheSmartphoneitselfistheinstallationofeitheriOS7orAndroid4.

Functions of WiBa QuickLook

ThevolumeofinformationwhichQuickLookappuserscanaccesshasbeendeliberatelykeptmanageable.Userscarryingoutacheckwillbe

givenaquick,well-foundedover-viewofthemostimportantcurrentparametersettingsinagivenproduc-tioncell–thosewhichconcerntheinjectionmoldingmachineandanyoneorseveralrobotsinvolved.Toretrievespecialdetailinformationortoadjusttheparametersettingsintheproductionequipment,usersarestillrequiredtogodirectlytotherelevantprocessingmachinesandhandlingdevices.

Asalways,specialcarehasalsobeentakentomakehandlingoftheappextremelyuser-friendly.Color-codedoperatingstatesinthelistsofequipmentgiveaquickoverview.Theclose-upviewsfortheindividualcomponentsprovideaccesstothe

productiondataandalarms(ifany),aswellasuser-definedprogramval-ues.Severalcomponentsofaproduc-tioncellcanbegroupedforascreenview,andthelistsofproductionequipmentcanbesortedmanually.Agridviewisavailableasanalternative,whichprovidestheoptiontosortthecomponentsautomaticallyaccordingtostatus.

TheelaboratedfunctionsoftheWiBa QuickLookappmakeiteasytoaddcomponentsbysimplyenteringtheirIPaddresses.

And,lastbutnotleast,thesettingsofequipmentshownbytheappcanbeveryeasilypassedontothirdpar-tiessimplybyusingtheemailfunctionoftheSmartphone.•

News

The WiBa QuickLook app from WITTMANN BATTENFELDprovides a very simple way to check the status ofinjection molding machines and robots via Smartphone.

Molding machine and robot status requests

– List view; status colors are identical with LED colors of WITTMANN W8 pro appliances; green stands for auto-matic operation, blue for non-automatic operation, red for safety criteria not complied with.

– Overview page on calling up an appliance in the automatic opera-tion mode.

– Addition of a new appliance; entry of IP address.(from left to right)

WiBa QuickLook app, now avail-able free of charge from the Apple app store or from Google Play.


Molding machine and robot status requests WITTMANN Kunststoffgeräte GmbH, Vienna

This picture shows most of the employees of WITTMANN Kunststoffgeräte GmbH. About 320 staff members are currently employed in Vienna.

Portrait

In 1976, WITTMANN Kunststoffgeräte GmbH was established in Vienna.Its corporate history, which now consists of almost 40 years, is characterizedby continuous growth based on the constant pursuit of innovation.

InVienna,WITTMANNKunststoff-geräteGmbHhasdedicateditself

toallaspectsofautomationandalltypesofperipheralequipmentusedinplasticsprocessing.ThecompanyconstitutestheWITTMANNGroup’sprimarydevelopmentandcompetencecenterforbasicrobotmodels,includ-ingalloptionsandspecializedvariants,andalsofortemperaturecontrollers,dryairdryers,materialloadersandgravimetricmeteringdevices.

TheplantinViennaisalsoanimportantproductionplant.HeretherobotseriesW832toW873aremanu-factured,aswellasIMLequipment,thetemperaturecontrollersoftheTEMPROplusDseries,coolingwaterflowcontrollersandvariousinjectionmoldingtechnologyproducts.

TheglobalpresenceoftheWITT-MANNGroup,andespeciallyitsproductionfacilitiesintheUSAandinChina,allowstheVienneseplanttoconcentrateontheEuropeanmarket.Fromhere,thismarketisprimarilysuppliedwithrobots,temperaturecon-trollersandrelevantinjectionmoldingtechnologyproducts,withthelargestproportionofsalestraditionallybeingrealizedinGermany.

A location withdevelopment potential

AmajorindicatoroftheVienneseproductionfacility’spotentialfordevelopmentisthefactthatin2014itrealizedanabsolutelyremarkable13%increaseinsalescomparedtothepreviousyear.

About320employeesareworkingforWITTMANNatpresentinthethreeVienneseplants.InWolkersdorf,notfarfromVienna,yetanothernew

buildingiscurrentlyunderconstruc-tiondestinedfortheMaterialHandlingDepartmentandisexpectedtobereadyforoccupationinthefallofthisyear.

In2015,WITTMANNKunststoff-geräteGmbHwillcelebratethe40thanniversaryofitsfoundation.Itiscertainlyanoccasionforreflectingonthepastsuccessstoryofthiscompany,whichhasultimatelyledtoitbecomingtheonlysupplierofcompleteinjectionmoldingsolutionsworldwide.•

The main building of WITTMANN Kunststoffgeräte GmbH. The Viennese facility simultaneously functions as corpo-rate headquarters of the WITTMANN Group. Here, all information is brought together from the subsidiar-ies and representa-tive offices around the world.

BP00000034 – 1502

WITTMANNBATTENFELD INC.1 Technology Park DriveTorrington, CT 06790USAtel.: +1 860 496 9603fax: +1 860 482 [email protected]

WITTMANN ROBOT(KUNSHAN) CO. LTD.No. 1 Wittmann Rd., DianShanHu TownKunshan City, Jiangsu Province215245 CHINAtel.: +86 512 5748 3388fax: +86 512 5749 [email protected]

WITTMANNKUNSTSTOFFGERÄTE GMBHLichtblaustrasse 101220 ViennaAUSTRIAtel.: +43 1 250 39-0fax: +43 1 259 [email protected]

WITTMANNBATTENFELD GMBHWiener Neustädter Strasse 812542 KottingbrunnAUSTRIATel : +43 2252 404-0Fax: +43 2252 [email protected]

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