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“Technology

advances mark the

way forward.”Dr. Dietmar Straub,

KraussMaffei CEO.

EDITORIAL

made by KraussMaffeiPublished by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, 80997 Munich, Germany Phone + 49/89/88 99-0, Fax + 49/89/88 99-2206, www.kraussmaffei.com Responsible: Matthias Andreesen Viegas

PUBLICATION DATA

EDITORIAL | NEWS

Editorial office: mk publishing GmbH, Döllgaststraße 7–9, 86199 Augsburg, Phone +49/821/3 44 57 0, Fax +49/821/3 44 57 19, www.mkpublishing.de Photo credits: Becker Kunststofftechnik, Bikkoplast/Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunst-stofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM

02 MADE BY KRAUSSMAFFEI 1 ¦ 2010

Dear Readers,

Forcing down costs, increasing efficiency and boosting productivity – these

are key concerns right now throughout the plastics industry. It takes new-

generation machines and systems to gain a key competitive edge; technology

advances mark the way forward.

This holds true for KraussMaffei as much as for the rest of our industry. It’s

why we’ve recently invested a substantial amount to boost quality and

productivity in our main production plant in Munich. Our new Surface

Treatment Center opened just a few days ago, replacing our previous paint

shop. All in all, the new facility cost around four million euros – you

couldn’t ask for a stronger sign of our conviction that the economy can and

will recover. Experts tell us that you’d have to look a long way to find the

equal of our new facility anywhere in the world. For example, we now

move parts and modules weighing up to 32 tonnes through the paint line on

an overhead track system synchronized with the rest of the assembly line.

When the system is operating at full capacity, it is handling the equivalent

of the take-off weight of an Airbus. As you see, we never let up in our

pursuit of quality and productivity for our machines and processes. But

your vote is the decisive one – as our customer you have the final say in

whether we’re offering you the right solution at the right time!

If you’re among the customers who currently have no plans for major

investments, we can nonetheless show you affordable options for increasing

the efficiency of your production. Our retrofit packages and upgrades can

significantly improve the productivity and energy efficiency of your installed

machines. You might opt for a higher level of automation with a robot from

our expanded portfolio, or for reduced energy consumption with one of our

efficiency packs. Especially in recent years, KraussMaffei has taken up the

theme of energy efficiency; today “BluePower” stands for the products and

upgrades we offer to help you reduce energy consumption. To add even

more momentum to this strategy, KraussMaffei has now launched the

BluePower Award, which will honour energy- and resource-efficient

production solutions. We’ll be announcing the winners during the world’s

biggest plastics show, the K2010, at the end of October. We’re looking

forward with great interest to your competition entries.

With best regards,

Dr. Dietmar Straub

BluePower is the

concept that bundles

our continuing

endeavours to

promote the

development

of energy- and

resource-efficient

production

solutions. As part

of this effort, KraussMaffei has now launched

the BluePower Award inviting entries from all

the innovative plastics processors among our

customers.

We’re looking for new developments that deliver

a significant increase in energy- and resource-

efficiency. They can be anything from individual

applications and processes to complete concepts

– and they can come from any area of the plastics

processing industry. We’re especially interested in

processes that make sustainable use of synergies

through intelligent combinations of different

technologies, such as injection moulding, reaction

moulding and extrusion. The entries will be

evaluated and the winner selected by an independent

jury panel made up of high-ranking representatives

from science and industry. KraussMaffei employees

will not be eligible to vote on this panel. The winner

of the BluePower Award 2010 will be announced on

October 28, during the world’s biggest plastics show,

the K2010 in Düsseldorf, Germany. Closing date for

entries, which must be in writing, is May 31, 2010.

More information and details of how to enter are

contained in a questionnaire that you can request by

email. p

KraussMaffei sets up a prize for efficiency!

BLUEPOWER AWARD 2010

CONTACT

Dr. Reinhard SchiffersPredevelopment/EnergyPhone +49/89/[email protected]

KraussMaffei Berstorff is now offering complete

systems for continuous production of PU-

insulated pipes. One, or two, plastic media pipes

is encapsulated in an insulating polyurethane

layer plus a protective polyethylene sheath.

The insulated pipes can transport either hot or

cold media. With this single-vendor production

solution, the company, a world leader in

plastics and rubber processing machinery,

once again demonstrates its multitechnology

competence – in this case in pipe extrusion and PU processing – built on

many decades of engineering excellence. This unique know-how enables

us to develop complete production solutions by skilfully integrating

modules from different technologies. p

NEWS

Events through to autumn 2010

TRADE SHOWS

19. – 22.04. Chinaplas Shanghai, China

19. – 23.04. Expoplast Algiers, Algeria

11. – 14.05. RusChem Moscow, Russia

11. – 15.05. Technics Belgrade, Serbia

13. – 16.05. Plastex Cairo, Egypt

25. – 28.05. Plastpol Kielce, Poland

26. – 28.05. PU China Shenzhen, China

14. – 16.09. Composites Essen, Europe Germany

27.10. – 03.11. K 2010 Düsseldorf, Germany

COVER

03

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Perfectly paired off:pipe plus insulation

Bavarian Economics Minister

Martin Zeil (right) and

Dr. Dietmar Straub,

KraussMaffei CEO, at the

opening of the new Surface

Treatment Center.

KraussMaffei has recently completed a future-oriented project in our main

production plant in Munich. Guest of honour at the opening of the new Surface

Treatment Center (STC), on March 5, 2010, was Bavarian Economics Minister

Martin Zeil. The new facility replaces our previous paint shop. In his address,

Martin Zeil commented, “The German plastics machinery sector has been

especially hard hit by the turbulence of the economic crisis. This is why I’m

absolutely delighted with every Bavarian company that has taken the crisis

as a spur to look ahead, modernize and invest. With its new and innovative

paint facility, KraussMaffei is among the leaders in this area too.” Despite the

economic crisis, KraussMaffei invested around four million euros in building and

equipping the STC. As Dr. Dietmar Straub, CEO of KraussMaffei AG, pointed

out, “With the new Surface Treatment Center we’re improving the transparency

of our entire assembly process; it will enable us to work more efficiently and

cut our turnaround times – our customers will benefit significantly.” The STC

was planned and built in a close collaboration between KraussMaffei and

Rippert Anlagentechnik GmbH & Co. KG, from Herzebrock-Clarholz/North

Rhine-Westphalia. Rippert, a systems engineering company with around 300

employees, has almost 40 years’ experience in planning and installing painting

and filtering systems and industrial ventilation units. Complex coating systems

are among its core competences. p

MULTI-MILLION INVESTMENT

New Surface Treatment Center opened

04 MADE BY KRAUSSMAFFEI 1 ¦ 2010

Cleanroom Competence Center in Rosenheim,

opened on January 29, 2010, provides an excellent

environment for researching this field,” emphasizes

Martin Würtele, Manager Predevelopment New

Technologies at KraussMaffei. Under the aegis of

Prof. Peter Karlinger, researchers in Rosenheim

are working on a complex production cell based

on a KraussMaffei all-electric EX 80/380. “Our

cooperation with the university in Rosenheim has

already generated a large number of successful

projects and graduate theses across all three key

technologies – injection moulding, extrusion and

reaction moulding,” says Martin Würtele. Much

of this research is aligned with KraussMaffei’s

“Technology to the Power of Three” strategy. With

the opening of the competence center, Rosenheim

University became part of the PRIMUS Network

for Innovation set up by KraussMaffei (responsible

for the focus area “Life Sciences”).

Focus on energy efficiency

The University of Duisburg-Essen (UDE) is

also a member of the PRIMUS Network. Since

January 15, 2010, there’s been a cooperation

agreement between the university’s Faculty of

KNOW-HOW SHARING DRIVES DEVELOPMENT

Development engineers in mechanical engineering companies are not the only people working on solutions to tough challenges in plastics processing – there’s a lot of academic research going on too. In Germany alone, KraussMaffei supports over 20 universities and other research institutions with machinery and know-how. Life sciences, lightweight structures and energy efficiency are among the key research topics.

One strong trend in

plastics research is

the increased focus on

the life sciences sector

– medical technology,

pharmaceuticals and

cosmetics. There’s

a long-standing

cooperation in

this area between

KraussMaffei and

Munich’s University

of Technology (TU), with ordinarius professor

for medical technology, Prof. Dr. Dr. Erich

Wintermantel. TU researchers and students have

two injection moulding machines, including an

EX 50/55, and a compounder at their disposal for

experiments.

Relatively new, by contrast, is the cooperation

agreement between KraussMaffei and Rosenheim

University of Applied Sciences. It’s also focused

on the life sciences field and especially on

cleanroom technology. “One of the main concerns

in this sector is to develop processes that make

post-mould sterilization unnecessary. The new

FOCUS

Industry and research hand-in-hand

Celebrating another

recent cooperation

agreement: Prof. Dr.

Dieter Schramm and

Prof. Dr. Johannes

Wortberg from the

University of Duisburg-

Essen with Dr. Karlheinz

Bourdon and Georg

Holzinger, from

KraussMaffei (l. to r.).

05

Engineering and KraussMaffei with the specific

goal of improving the energy efficiency of plastics

processing machinery. The strategic cooperation

partner on the university side is the chair of

Engineering and Plastics Machinery headed by

Prof. Dr.-Ing. Johannes Wortberg. The cooperation

partners have agreed on regular information

exchange and supporting engineering students and

researchers. One specific area of cooperation will

be developing and optimizing alternative drive

technologies for plastics processing machinery. The

remit for this project includes energy consumption,

energy recovery, precision and efficiency.

KraussMaffei is mainly concerned with developing

and optimizing components, in particular with the

practical implementation and with application-

related process engineering.

Combined process for function-integrated

lightweight systems

The cooperation between KraussMaffei and the

Institute for Lightweight Structures and Plastics

Technology at Dresden University of Technology,

headed by Prof. Dr. Werner Hufenbach, dates

back to 2008. One important area of research

here is fiber-composite lightweight elements and

the development of new resource-efficient process

chains for manufacturing them. The researchers

in Dresden have at their disposal an innovative

LFI (Long Fiber Injection) system, including a

shuttle mould carrier, supplied by KraussMaffei’s

Reaction Process Machinery division. The research

encompasses multitechnology and multiprocess

solutions.

The Center for Integrative Lightweight

Technologies (ZIL) at the Chemnitz University

of Technology is working in related fields. For

example on the development of a new combined

process for reinforcing plastics with long fiber

materials and fabric intermediates in injection

moulding. These types of lightweight composites

are used in making anything from aircraft to

rolling stock and road vehicles, because their

lighter weight reduces fuel consumption and

carbon dioxide emissions. The ZIL, headed

by Prof. Dr. Lothar Kroll, operates a total

of six KraussMaffei machines, including a

multicomponent spin-platen machine, a RIM

polyurethane system and an IMC injection

moulding compounder. A new addition to the

center’s machine park is a ZE 40 A x 50 D UTXi

twin-screw extruder from KraussMaffei Berstorff

engineered for high-performance compounding

tasks. “Basic research is very important for us

as a mechanical engineering company, because

it paves the way for adapting our extruders

to market requirements and to continuously

developing them,” points out Prof. Dr. Bernd

Poltersdorf, head of Foam, Film and Sheet

Extrusion at KraussMaffei Berstorff. p

FOCUS

CONTACT

Martin WürteleManager PredevelopmentNew Technologies/Process EngineeringPhone +49/89/[email protected]

Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]

Prof. Dr. Bernd PoltersdorfManager Foam, Film and Sheet ExtrusionPhone +49/511/[email protected]

Prof. Dr. Lothar Kroll,

Dr. Wolfgang Kempt and

Dr. Wolfgang Nendel

(from left) of the TU

Chemnitz with the ZE

40 A x 50 D UTXi twin-

screw extruder from

KraussMaffei Berstorff,

Hanover, which offers

new scope for research.

06 MADE BY KRAUSSMAFFEI 1 ¦ 2010 FEATURE

– adding up to around 14 in total. “Thanks to our

joint project with Evonik, we can now offer our

customers a far more cost-effective process,” says

Dr. Karlheinz Bourdon, head of KraussMaffei’s

Injection Moulding Machinery division. And Josef

Renkl, R&D Manager for the company’s Reaction

Process Machinery division adds, “Thanks to our

multitechnology know-how – in this case injection

moulding and PU processing – we’ve been able to

develop the process to market readiness. It will

dramatically shorten the process chain. The new

CoverForm process has just four steps: incoming

check, injection moulding and coating in the same

mould, quality control, final assembly. All these

steps are performed in one and the same machine.

The process saves time, costs and production space.

In addition, the surfaces produced in this way are

often more scratch-resistant than those that are

COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK

Display panels in mobile phones, appliances,

consumer electronics and automotive instrument

panels are made of transparent polymers.

The displays must remain transparent despite

exposure to mechanical and chemical impact, for

example, through cleaning agents or handcreams,

otherwise they are not fit for purpose. The

material most used for these applications is

polymethyl methacrylate (PMMA) often known

by the tradename Plexiglass. The PMMA must

be specially coated to protect the surface from

scratches and chemical damage. In conventional

production, this coating is applied in a post-

mould paint process.

A far shorter process chain

A conventional process comprises multiple steps

including quality controls, storage and transport

Joint project in surface treatment technology

Dr. Karlheinz

Bourdon, member of

KraussMaffei’s Board of

Management (left) and

Gregor Hetzke, head of

Performance Polymers

at Evonik, at the opening

of the CoverForm

Competence Center.

The CoverForm process, developed by KraussMaffei, as machine supplier, and Evonik, as material supplier, substantially shortens the process chain for the production of transparent, scratch- and chemical-resistant parts. Processors save transport effort, time and production floor space – in the last analysis they save costs. The quality is often better than can be achieved in a conventional painting process.

COVERFORM PROCESS STEPS Inl ine scratch-resistant coating of PMMA

Inject PMMA

Compression/cooling

Open cavity & inject coating

Compression & heating 100%

Compression & cooling

Compression & start heating

FEATURE 07

conventionally painted. It couldn’t be simpler. This

is how CoverForm works – after injection of the

special PMMA, a mould stroke forms the surface

to be coated. The part cools in the mould. The

cavity is then enlarged slightly, creating a space for

the surface coating layer. This gap is flooded with

a liquid reactive system, ideally matched to the

PMMA material, and the mould closes in a second

compression stroke. The high-performance Dynamic

Temperature Control (DTC) ensures that the

temperature profile in the mould, required for the

different process stages, is exactly repeated in each

cycle. The only post-mould process is UV curing

which takes place immediately after demoulding.

The parts are then ready for assembly.

Competence center

for award-winning process

In November 2009, a CoverForm Competence

Center was opened at the Evonik plant in

Darmstadt – it’s the ideal

place to demonstrate

the new process. The

center was opened by

Gregor Hetzke, head of

Performance Polymers at

Evonik and Dr. Karlheinz

Bourdon. Evonik is using

the new center both for demonstrations and for

further development of reactive systems. Among

the possible candidates are new anti-reflective or

electrically conducting coatings. In addition, the

center is the ideal training environment for the

technicians in Evonik’s worldwide service teams.

despite its relatively short time on the market,

CoverForm has already won an award. At the

Materialica trade show, last autumn in Munich,

it won “Best of” award in the category Surface

and Technology. In its review, the jury noted

that CoverForm is a forward-looking,

market-ready process which is the

result of productive interaction between

materials, engineering expertise and design.

CoverForm is a system solution available

exclusively from the joint partners Evonik

and KraussMaffei. It’s yet another example

of the sustained increase in productivity

that can be achieved by joining up

processing technologies, as advocated by

KraussMaffei’s “Technology to the Power

of Three” strategy. p

KraussMaffei injection

moulding machines are

at the heart of CoverForm

production cells.

CONTACT

Marco GruberManager Application Engineering,Process Development IMMPhone +49/89/[email protected]

Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]

Sven Schröbel, Evonik

Industries, Martin

Eichlseder, KraussMaffei,

and Arne Schmidt, Evonik

Industries (from left),

showing off the “Best of”

award at the Materialica.

Demoulding Final curing (UV curing)

08 MADE BY KRAUSSMAFFEI 1 ¦ 2010FEATURE

LIFE CYCLE SERVICE

Technologies change over time. Part of KraussMaffei’s full-service offering is our commitment to maintaining and upgrading plastics processing machinery over the whole life cycle, so that it is always fit for purpose in fast-changing markets.

Multitechnology processes – such as CoverForm

(see page 6/7), nanoskin (see page 9) or inline

compounding – are an important way forward

for plastics processors. Production cells for these

processes are all based on a KraussMaffei injection

moulding machine. Our customers know they can

count on our many decades of experience with

injection moulding machines, which are one of

our core businesses. Our expertise goes beyond

developing and supplying highly productive ma-

chines; we also have the engineering skills to make

sure they stay that way over long service lives and

in the face of changing products and markets. “A

processor buying a machine today generally has

only the vaguest idea of what he’ll be producing in

five or ten years’ time. He would be well advised

to invest in KraussMaffei machinery, because we

can make sure that his production solution will

grow with his changing applications – even for

decades ahead,” says Josef Hammerschmid from

Service Marketing at KraussMaffei.

Retrofit, overhaul, move

A production cell may undergo many changes over

the years. The experts in our Service teams can

help our customers cope with them all. A pro-

cessor might come to us with a request to adapt

an existing machine for a new application, perhaps

with a MuCell package for physical foaming at low

unit cost. Or he might want to expand into multi-

component moulding. This upgrade can be achieved

relatively simply with a bolt-on unit. Hydraulic and

electric bolt-on units are completely self-sufficient,

so only minor changes, if any, need be made to the

machine.

Combining an upgrade with a planned machine

move saves production time. “We’re professionals in

moving and transporting machines – we do it all the

time,” points out Josef Hammerschmid. “Our com-

mitment to our customers is to move any machine

any distance, on time and within budget. And to see

the job through from start to finish.” Occasionally,

the machines make a detour to the KraussMaffei

plant in Munich for a general overhaul. We also op-

erate a practical trade in used machines. In our skilled

hands machines get a new lease on life. p

CONTACT

Josef HammerschmidService SalesPhone +49/89/[email protected]

Always fit for purpose

KraussMaffei Service

professionals have

the expertise to make

a complete success of

any task, however big.

LIFE CYCLE

SERVICE FROM

KRAUSSMAFFEI

• Plasticizing units

• Refurbishing

• Functionality upgrades

Moving machinery •

Technology upgrades •

Consulting and advice •

Bolt-on units are a

fast, sure route into

multicomponent

moulding.

Teleservice •

• Robots, handling systems, automation

09FEATURE

NANOSKIN PROCESS

Integrated multitechnology processes are often the answer to the challenge of producing polymer parts with durable, functional surfaces at a competitive cost. The new CoverForm process (see page 6/7) is an example of this type of integrated process. Another new process – nanoskin – is approaching market readiness. Again teaming injection moulding with PU processing, the nanoskin process is being developed by KraussMaffei and a number of project partners.

Functionalizing materials by generating a finely

structured surface – a nanostructure – is among the

dominant trends in process engineering. There are

well-known examples of nanostructures with useful

properties in nature, like the self-cleaning leaves of

the lotus flower or the anti-reflective surface layer

of moths’ eyes. The quest is on to develop a process

for transferring the moth’s-eye effect to transparent

polymer parts so as to make them inherently anti-

reflective – in other words to eliminate the need

for a post-mould anti-reflective coating. The part

would also need to be resistant to mechanical and

chemical damage. Possible applications include

covers for dashboard instruments and displays.

The nanoskin process supplies the answer.

Injection moulding and RIM

The nanoskin project partners set themselves

the task of developing a cost-effective technical

solution for a one-step multicomponent moulding

process which would combine thermoplastic and

chemically crosslinking polymer materials. The

core of the part can be produced in a conventional

injection moulding process. Only the nanostruc-

ture surface is generated in a parallel RIM process,

using a chemically crosslinking polymer which also

guarantees the necessary mechanical and chemical

resistance. The nanoskin research and development

project received funding from the German Federal

Ministry of Economics

and Technology as part

of the government’s

InnoNet concept, which

aims to promote and

support networks for

innovation. It was carried

out with organizational

and technical support

from the project sponsor,

the VDI/VDE. “Now,

well ahead of the planned

project end in autumn

2010, we can already say

that KraussMaffei and

our partners are writing

the first chapter of a suc-

cess story. Together we

have taken the nanoskin

process to a point where we’ll be able to offer it to

our customers for concrete production applications,”

says Martin Eichlseder, who is leading KraussMaffei’s

contribution to the nanoskin project. p

CONTACT

Martin EichlsederProcess DevelopmentSystems & SolutionsPhone +49/89/[email protected]

Finely structured

The nanoskin process

generates transparent

parts with finely

structured surfaces.

NANOSKIN PARTNERS

• Plasmatreat GmbH and Fraunhofer IWM:

Regenerative hybrid layer systems and process-

integrated atmospheric plasma treatment

• Hochschule Heilbronn: Process integration

• Mast Kunststoffe GmbH & Co KG:

Durable, functional components, tested under

production conditions

• FHR Anlagenbau GmbH:

Mould coating and surface structuring

• Krallmann Holding & Verwaltungs GmbH:

Moulds with highest precision and rigidity

• RÜHL PUROMER GmbH and KraussMaffei:

Tough, transparent polyurethane systems

for surface functionalization and technology

development – flow moulding

MADE BY KRAUSSMAFFEI 1 ¦ 201010 KEYNOTE | NEWS REACTION

“Working

together to

add value!”Frank Peters,

General Manager,

Reaction Process Machinery.

KEYNOTE

Dear Readers,

Two important strategic responses to difficult economic times

are to optimize production processes and to open up new

business areas. KraussMaffei can support you here. As a

worldwide premium partner for the plastics and rubber

processing industries, we offer highly productive solutions that

deliver maximum efficiency and return on investment. Our

engineers deliver complete custom solutions by combining

modules from the wide KraussMaffei product portfolio and

pooling their special expertise in the different process

technologies and automation. Our solutions combine the

advantages of series production machines with the benefits of

application-specific technology. Typical examples are our

special machine for producing drug delivery systems, or our

mobile RimStar system for SPS sandwich plate systems. We

developed custom production solutions for both these

applications, supporting our customers’ drive to optimize their

production processes and reinforce their market success. As

with all our products and services, these customers can rely on

our competence as a system supplier capable of delivering the

quality and know-how they need.

We’ve also optimized our service and product portfolio, for

example, by adding to our WinCap series of mould carriers, by

improving our foam moulds, and with a revised price structure

for our EcoStar series. Together with our innovative engineering

and ultra-efficient production solutions, these improvements are

part of our drive to offer you real added value – the best basis

for our common success.

With best regards,

Frank Peters,

General Manager,

Reaction Process Machinery

Benefits for customers

MANUFACTURING METERING PUMPS IN-HOUSE

KraussMaffei’s Reaction Process Machinery division

has long pursued a policy of offering complete

production solutions as a single vendor. Key to

the success of this policy is our ability to apply

our experience and know-how to continuously

improve individual system components. Now we’ve

taken a further step in this direction by moving the

manufacture of metering pumps in-house. “This

change will give us the opportunity to align our

products even more closely with the needs of our

customers,” emphasizes Wolfgang Frehsdorf, Business

Area Manager in the Reaction Process Machinery

division. “In particular, we’ll be able to better adapt

our pumps to the specific processing requirements of

current and future plastic monomers.” In addition,

KraussMaffei made pumps will have longer service

lives – and deliver a better return on investment.

In future, the EcoStar, RimStar Compact, RimStar

Modular, MiniDos and our hybrid machines will all

be fitted with KraussMaffei metering pumps. From

April 2010, we’ll be producing pumps rated for

16 to 40 litres a minute. During the year, we plan to

add more pump sizes to our portfolio. p

CONTACT

Siegfried EidenmüllerManager Precision PartsAssembly and Service RPMPhone +49/89/[email protected]

KraussMaffei is now

manufacturing metering pumps in-house.

Frank Peters, member of

the board of management,

said the expansion

was indicative of two

of KraussMaffei’s great strengths, “On the one

hand, as a technology company with an in-house

mouldmaking operation, we’re big enough to serve

every market segment and specialized niches which

are still growing. And secondly, we are creating future

capacity ready for the time when the economy begins

a strong recovery, rather than the current hesitant

growth.” p

Frank Peters (center),

KraussMaffei RPM General

Manager, Heinz Lunte

(3rd from right), mayor of

Georgsmarienhütte, and

Plant Manager Rainer

Janotta (2nd from left) at the

groundbreaking ceremony.

EXPANDING THE SALES ORGANIZATION IN BENELUX AND AUSTRIA

KraussMaffei has expanded Reaction Process

Machinery activities in Belgium, the Netherlands,

Luxembourg and Austria. In these countries, the

company now offers not only injection moulding

machinery, but also our classic portfolio of Reaction

Machinery products – mixing heads, metering

machines, moulds

and tooling for

polyurethane

processing,

including cutting

and routing

technology. Sales

11 NEWS REACTION

Doubling production space

PRODUCTION PLANT IN GEORGSMARIENHÜTTE

Automotive Component Systems (ACS), a business

area of KraussMaffei, is expanding its production

plant in Harderberg-Georgsmarienhütte/Lower

Saxony from 1,350 to 2,700 square meters. A

symbolic groundbreaking ceremony took place

on February 4, 2010. Construction is due to be

completed by late summer 2010. ACS makes moulds

for polyurethane processing at its Harderberg plant.

Special order from the USA

OVAL CONVEYOR SYSTEM FOR ROYAL TECHNOLOGIES CORPORATION

Our US subsidiary, KraussMaffei Corporation,

recently booked a large order from Royal

Technologies Corporation. This company develops

and manufactures products mainly for the

automotive industry, but also for consumer goods

and office furniture. We supplied Royal Technologies

Corporation with a turnkey oval conveyor system,

with 26 stations and a four-component duplex mixing

head, to produce seat cushions from PU foam. The

conveyor system was modified to guarantee extremely fast mould

changing – a roller system that was integrated that allows just the

mould itself to be changed via a special screw mechanism. This

system ensures that mould changing

is extremely fast and completely

unproblematic; the customer is

spared the necessity of exchanging

the complete cassette with the mould

carrier as in a conventional system. p

CONTACT

Steffen BauerArea Sales ManagerPhone +49/89/[email protected]

More service, more performance

NEW ADDRESS

KraussMaffei BeneluxMinervum 7408NL- 4817 ZG BredaPhone +31/76 57 22 522Fax +31/76 58 75 686

Manager Johan Van Der Schueren

is now reponsible for RPM

customers in Belgium and

Luxembourg, while Mark

Verveer, Managing Director of the

KraussMaffei branch in Breda,

looks after customers in the

Netherlands. Austrian customers

can rely on Area Sales Manager

Wolfgang Rößler. By expanding

the Reaction Process Machinery division’s presence in these countries,

KraussMaffei has reinforced its status as system supplier – providing local

service and support, and complete system solutions. p

CONTACT

Mark VerveerManaging Director NetherlandsPhone +31/6 50 50 59 [email protected]

Johan Van Der SchuerenSales Manager Belgium & LuxembourgPhone +32/54 32 23 26johan.vanderschueren@ kraussmaffei.com

Wolfgang RößlerArea Sales ManagerPhone +49/89/[email protected]

12 MADE BY KRAUSSMAFFEI 1 ¦ 2010FOCUS REACTION

systems, individual foam moulds or extending and

upgrading existing lines,” explains Gianmario

Bossi, sales manager for white goods. “We can

supply customized concepts, for every manufacturer

and product specification – including high-end foam

moulds, optimally engineered for the manufacturing

process.” In addition to production systems for

white goods, the KraussMaffei Italiana product

portfolio also includes production systems for

panels and sandwich panels for the construction

industry. When we supply a system, our highest

priorities, from the planning phase onwards, are

efficient processes, a compact design and a very

high level of automation. Once the concept has

been accepted, we build, ship and commission the

system. Our comprehensive service and support is

available to our customers at every stage and our

after-sales service is unsurpassed.

RotoStar: designed for success

As a rule, KraussMaffei Italiana supplies the

dry side components of a system, with the other

components being engineered in Munich. One

example is the RotoStar drum unit for foam

filling and processing doors. This is a provenly

successful system, it consists of a base frame in

which the drum with the water-heated mould

carriers revolves. A hydraulic control system makes

it possible to adjust the acceleration and braking

phases and to ensure the drum revolves at

a uniform speed. “RotoStar systems can

be fitted with varying numbers of mould

carriers, depending on production

and process requirements,” explains

Andrew Garnett, Area Sales Manager at

KraussMaffei. “Short cycle times, highest

Within the worldwide KraussMaffei group,

KraussMaffei Italiana in Abbiategrasso is the

competence center for white goods and insulation

technology. The company’s core business is

production systems for foam filling refrigerator

doors and cabinets – for both household and

commercial refrigerators. Foam moulds and

thermoforming tools for these applications are

part of the product spectrum. The materials

used in all applications are heavy-duty PU rigid

foam systems capable of guaranteeing excellent

thermal insulation even in relatively thin layers.

“KraussMaffei combines the know-how and

the technology for high-performance

solutions for the white goods

sector – whether customers

want complete

refrigerator foaming

FOAM SYSTEMS FOR REFRIGERATORS AND INSULATION TECHNOLOGY

Competence in white goodsKraussMaffei Italiana is a competence center for PU systems for white goods and insulation technology. The innovative insulation solutions and high-performance systems for foam filling refrigerator doors and cabinets developed in our competence center in Abbiategrasso are already in operation around the world.

The RotoStar drum unit

is a reliable solution for

foam filling and finishing

doors.

13FOCUS REACTION

product quality and absolutely reliable control of

the process make the RotoStar the system most

frequently chosen worldwide for foam-filling

refrigerator doors.”

RimStar: the perfect match

A polyurethane mixing and metering machine

from our RimStar range is the ideal match for

a RotoStar mould carrier system. The small

and compact RimStar machine can be flexibly

configured making it the optimal choice, for

example, for refrigerator production. Hallmarks of

the RimStar are minimal pressure losses, precision

temperature control and improved control systems

thanks to shorter, rheologically-optimized supply

lines between machine components. The machines

are easy to operate and maintain and engineered

for easy access. Add-ons for the RimStar system

– from tanks with integrated agitators to complex

configurations with heat exchangers and circulation

pumps – help to ensure that the PU components are

perfectly conditioned, mixed and metered. This is

important for white goods production as well as in

other sectors.

Worldwide success

Today, KraussMaffei production solutions for

white goods and insulation technology are in

operation around the world. In a joint project,

KraussMaffei Munich, KraussMaffei Italiana and

KraussMaffei Machinery in Shanghai recently

supplied a complete multicomponent system

with 20 stations to manufacture refrigerators in

China. Qingdao Haier Refrigerator China, the

biggest white goods manufacturer in China, is

using the system to produce refrigerators for the

Sanyo Electric, Japan.

Production uses the

Side-by-Side system,

where two mixing heads

foam-fill the refrigerator

elements simultaneously.

“Engineering and

building this system

was a real first for

KraussMaffei, it was the

result of outstanding

teamwork involving

KraussMaffei people in Germany, Italy and China,”

says Gianmario Bossi. “Innovative process know-

how and our grasp of the complex technology

enabled us to supply a complete, highly-customized

solution – and the customer naturally profits from

our comprehensive, local service offering”. We also

shipped systems for white goods and insulation

technology to China and Brazil. Six RimStar

systems with six Pentamix units and 20 mixing

heads went to Maersk Container Industry Qingdao

China. In Brazil, Electrolux do Brasil is operating

two RimStar machines and three RotoStar systems

in the production of refrigerator cabinets while two

more RotoStar systems are foam filling refrigerator

doors. p

RimStar mixing and

metering machines

(below) are ideal for

applications in the white

goods and insulation

sector (left).

CONTACT

Gianmario BossiSales Manager KMIPhone +39/02/[email protected]

Gianmario Bossi,

Sales Manager

for white goods

at KraussMaffei

Italiana.

MADE BY KRAUSSMAFFEI 1 ¦ 201014 APPLICATION

CONTACTSteffen BauerArea Sales ManagerPhone +49/89/[email protected]

RIMSTAR SYSTEMS AT ELELE, BURSA, TURKEY

KraussMaffei’s RimStar range of polyurethane mixing and metering machines includes models capable of meeting every production requirement. Elele, a KraussMaffei customer in Turkey, has recently taken delivery of its third RimStar system. Its delivery marked a special milestone for KraussMaffei, because it brought to 100 the number of mixing and metering machines the company has supplied to processors in Turkey.

Market leader in reaction process

machinery

The machine was shipped directly from

KraussMaffei’s Munich plant to Bursa. The sale was

processed by Alp Chemicals, KraussMaffei’s sales

partner in Turkey, headquartered in Istanbul. Taner

Erbil, responsible for sales at Alp Chemicals, says,

“This machine was the third RimStar to go into

operation at Elele, as part of a capacity expansion.

Elele’s decision to invest in this new machine not

only shows the company’s satisfaction with

KraussMaffei’s machinery and customer care, it is

also a sign that the market for plastics processing

machinery in Turkey is picking up again.” With its

three technology divisions, Injection Moulding

Machinery, Extrusion Technology and Reaction

Process Machinery, KraussMaffei supplies not only

the Turkish automotive industry, but also other

industries, such as construction, home appliances,

medical technology and packaging. By shipping the

100th mixing and metering machine to Turkey,

Reaction Process Machinery has underscored its

claim to be market leader in the region. p

Milestone machine with proportional technology

Emre Yilmaz,

Commercial Manager

at Elele (right) and

Steffen Bauer, Area

Sales Manager at

KraussMaffei.

KraussMaffei’s RimStar machines are engineered as

modular systems. This means they can be flexibly

configured to match application specifications and

customer requirements. One of the customers who

welcomes this approach and who has installed a

total of three RimStar machines is Elele Döseme

Sanayi ve Ticaret, in Turkey. The machine supplied

to Elele at the end of 2009 was a RimStar Compact

40/16. Together with the machine, Elele also

installed a foam robot and an MK 12/18 ULP-2KVV-

G mixing head with proportional technology. As

Steffen Bauer, KraussMaffei Area Sales Manager,

points out, “It’s only our proportional technology

that allows the very fast shot cycles that are essential

if users plan to manufacture different products on

one and the same production system.” Elele is using

this RimStar machine to produce seat squabs for

automotive seating in its production plant in Bursa.

One of Turkey’s major

cities, Bursa is a center

of the country’s

automotive industry

where carmakers and

international

components suppliers

operate production

plants.

APPLICATION 15

PRODUCTION SOLUTION FOR DRUG DELIVERY SYSTEM

KraussMaffei recently developed a production solution for a drug delivery system. The solution consists of a mixing and metering machine together with a sheet mould and a punch with tooling. The innovative, application-specific, integrated solution was developed as a joint project by teams from the KraussMaffei plants in Munich and Viersen, in Germany.

Efficient teamwork on an innovative project

The mixing and

metering machine

is at the heart of the

three-part production

solution.

To develop a highly automated process for the

production of drug delivery systems was exactly

the right challenge for KraussMaffei development

and application engineers. They planned a three-

part production system, consisting of a mixing

and metering machine, a sheet mould and punch

tooling. The mixing and metering machine was built

in Munich, the other two elements were supplied

by Tooling Technologies, KraussMaffei’s subsidiary

in Viersen. Every part of the machinery in contact

with the end product at any stage of the production

process had to be manufactured from a stainless

steel grade approved by the US Food and Drug

Administration (FDA). The hydraulic oil used in the

system had to be certified for conformity with FDA

specifications.

Precision drug delivery

In the mixing and metering machine, the raw

material is melted and dehydrated under vacuum

conditions. It is then mixed with the isocyanate

and a catalyst in the mixing head. “The focus was

on high-precision metering”, explains Andrew

Garnett, Area Sales Manager at KraussMaffei.

“The mixing ratio for the components – which are

both processed at approximately 70 °C – must be

precisely adhered to.”

The KraussMaffei MK 5/8 CCM tandem piston

mixing head is ideal for this task, the catalyst is

added using a micro-volume metering piston. The

polymer sheet – 0.8 to 1.0 millimeters thick – is

then formed in the sheet mould and a punch tool

stamps out the shape of the pessary, the drug

delivery system.

Complete application-specific solution

The three system elements are being integrated

into the final system at the KraussMaffei plant in

Munich. „The ultimate challenge in this project

was to select the correct components and materials

to ensure full compliance with the standards,“

says Andrew Garnett. “The project shows that

KraussMaffei experts from our different locations

and specializations are more than capable

of teaming up efficiently to produce highly

customized, integrated solutions for totally new

application areas.” p

CONTACTAndrew GarnettArea Sales ManagerPhone +49/89/[email protected]

A punch stamps out

the final drug delivery

system.

The polymer sheet –

0.8 to 1.0 millimeter

thick – is formed in the

sheet mould.

MADE BY KRAUSSMAFFEI 1 ¦ 2010

CONTACT

Andrew GarnettArea Sales ManagertPhone +49/89/[email protected]

16 APPLICATION

PU METERING FOR SANDWICH PLATE SYSTEMS (SPS)

The RimStar system that

KraussMaffei recently supplied

to Intelligent Engineering Ltd.

was an unusual one. Intelligent

Engineering specializes in

making and installing sandwich

plate systems (SPS) made of two

metal sheets with a PU core. SPS has

several advantages compared with steel alone

or concrete. These include high stiffness combined

with light weight, soundproofing and vibration

damping properties, and the fact that the plates

can be installed quickly and easily. SPS elements

are used in new construction, but also in repairs,

of ships, oil platforms, conveyor systems, bridges,

stadiums and high-rise buildings. The sandwich

elements are generally fabricated at the site where

they are to be installed.

Demanding product specifications

The RimStar system will be used to mix and

meter polyurethane in various grades to form the

plate cores. Fitted with two 80-litre pumps, it

stands for extremely reliable and stable processes

and premium product quality. Hallmarks of the

RimStar are minimal pressure losses, precision

temperature control and improved control

technology thanks to short rheologically-optimized

supply lines between machine components. The

RimStar’s modular engineering makes for flexible

configuration of customer- and application-specific

machines. Intelligent Engineering specified a number

of unusual features. “The whole system had to fit

into a 20-foot container, have its own drive system

and be fitted with a universal power connection so

as to be able to operate anywhere in the world”,

explained Andrew Garnett, Area Sales Manager

at KraussMaffei. “This RimStar machine was

engineered as an autonomous system, capable of

being simply plugged in to the local power supply

and starting production immediately.” The machine

was mounted on a tracked vehicle sourced from

an Italian manufacturer. It can move under its own

power to wherever the sandwich panels are required,

for example, in a dry dock, or on a bridge.

Strong market potential

This latest RimStar system is the fourth that

KraussMaffei has supplied to Intelligent Engineering;

each machine is engineered and modified to match

specific customer needs. “The outcome is always a

highly effective production solution that is absolutely

right for the job,” sums up Andrew Garnett. “As

a preferred partner of Intelligent Engineering, we

look forward to continuing cooperation and to more

projects in this interesting market.” p

One of the many

applications for sand-

wich plate systems

(SPS) is repairing and

strengthening ships.

KraussMaffei recently shipped a RimStar system installed on a tracked vehicle to Intelligent Engineering Ltd.. The PU mixing and metering machine will be used in the production of the company’s sandwich plate systems (SPS) made of sheet steel with a PU core. The mobile RimStar system fits into a shipping container and has a universal power connection – at the touch of a button, it’s ready to operate anywhere in the world.

Mobile RimStar is ready for action worldwide

Compared with steel

and reinforced con-

crete, the sandwich

plate system (SPS)

delivers notable

engineering and cost

advantages.

The mobile RimStar

machine can be

connected up and

operated anywhere in

the world.

17FEATURE

THE WINCAP ELECTRIC MOULD CARRIER SERIES

Success story with a future

CONTACTErich FriesArea Sales ManagerPhone +49/89/[email protected]

KraussMaffei developed the first electric mould

carriers for automotive applications around

three years ago. Now there are many of them

in operation with customers around the world.

They’re used in encapsulation of car windows

and glass roofs and for backfoaming interior

trim elements and other automotive components.

Our policy of continuous optimization applies

especially to our best-selling models. “The know-

how and experience of our whole division flows

into the ongoing development of our electric

mould carriers,” says Erich Fries, Area Sales

Manager at KraussMaffei. “Then add our strength

in innovative engineering and the outcome is

application-specific mould carrier solutions which

will drive our future success in this area.”

Application-specific performance profile

The standardized, modular engineering of

our WinCap range cuts the time required for

assembly and commissioning. Very easy operation

and excellent ergonomics were high on the

list of development priorities. For example,

programming mould functions in situ using the

OP177B touch panel is a simple task. All mould

carrier movements and mould functions are freely

programmable at the operator console; this adds a

high degree of flexibility to production processes.

High-speed and parallel mould carrier movements

yield shorter cycle times and higher productivity

in almost any application. Even heavy moulds are

moved fast and reliably, thanks to the use of poly-

V-belt with transfer rolls for the lift function.

Customized flexibility

Low maintenance effort is another important

plus-point of the WinCap series – together with the

quieter operation and lower power consumption

associated with electric motors. There is a wide

choice of practical options, including additional

mould functions, extra safety features and a

customer-specific mould-fixing system. Moreover,

WinCap mould carriers can be flexibly adapted to

many different types of plant.

The acid test

The ability of

KraussMaffei’s electric

mould carriers to deliver

the performance required

in the challenging

automotive environment

is underlined by recent

orders from international

automotive components

suppliers. They include

10 mould carriers

shipped to ArvinMeritor

in Slovakia and Germany

and 3 systems for

Webasto in Korea. p

Productivity that’s hard to beat, outstanding ergonomics and practical options – all these have made our WinCap mould carrier series a real success story. At the same time, KraussMaffei is committed to continuous further development of all our mould carriers.

Glass roof for an Audi

A5 , foam encapsulated

on a WinCap mould

carrier in a mould

made by KraussMaffei.

Best sellers with

multiple benefits:

our WinCap series

of electric mould

carriers.

MADE BY KRAUSSMAFFEI 1 ¦ 201018 FEATURE

CONTACTRainer JanottaPlant Manager, Automotive Component Systems, GeorgsmarienhüttePhone +49/5401/[email protected]

MORE EFFICIENT, LESS WASTE

KraussMaffei has optimized the foam moulds it supplies for automotive instrument panels. New seal technology now minimizes material consumption and almost completely eliminates trimming and waste. This saves time and money, resulting in more efficient processes and lower manufacturing costs. Instrument panels for the new Peugeot 3008 and 5008 are being made using these innovative moulds.

a joint development by KraussMaffei and

Visteon Systémes Intérieurs, one of the leading

international automotive components suppliers.

One development priority was lower material

consumption. “The new foam moulds with their

innovative seal technology minimize material

consumption. At the same time, the process

becomes more efficient because trimming and

waste are practically eliminated,” explains Rainer

Janotta. “This brings substantial savings in

material costs and in processing time.”

One of the detail changes is in the windscreen

area where the décor film is inserted into the

reinforcing section directly in the mould. Around

the tachometer, the center console and the air

vents, tear-off edges in the décor film eliminate

trimming and disposal of the PUR foam and

reinforcing material. 48 of these optimized foam

moulds are already in operation, 23 more are

currently under construction. Apart from the new

Peugeot models, they’re being used to produce

components for carmakers like BMW, Citroen,

Ford, Renault, Volvo and VW, where they ensure

highest precision and quality, plus lower material

consumption and unit manufacturing costs. p

Automotive Component

Systems (ACS) in

Georgsmarienhütte,

Germany, a

KraussMaffei

subsidiary since 2005,

specializes in tooling

technology, mainly

for the automotive

industry. Of more

than 500 foam moulds

sold to date, over 100

of them have been

for instrument panel

production. Each KraussMaffei production system

is engineered as an exact match for customer

requirements. Customers profit from application-

specific solutions supplied by a single expert

vendor. “Our foam moulds deliver what customers

want,” says Rainer Janotta, plant manager at

Automotive Component Systems, “That’s premium

product quality and vanishingly low reject rates.

But we never stand still – our engineers work

continuously to make foam processes, and the

whole process of making a component, more

efficient and economical.”

Less trimming, shorter cycle times

Currently, one of the best examples of this

continuous-improvement approach are the new

foam moulds for the instrument panels for the

new Peugeot 3008 and 5008. The moulds were

Optimized foam moulds

The instrument

panels of the new

Peugeot 3008

and 5008 models

are made using

KraussMaffei foam

moulds.

The newest foam

moulds practically

eliminate trimming

and waste.

19FEATURE

PREMIUM QUALITY, WIDELY AFFORDABLE

Our EcoStar series of mixing and metering machines has a sure-fire formula for success – modularity, reliability and ease of operation. Following a systematic improvement programme, KraussMaffei has revised the pricing structure for EcoStar machines and is offering them at budget prices. This will attract especially small and medium-sized PU processors in many parts of the world, who are already using EcoStar machines in a wide range of manufacturing processes.

New pricing structure for the EcoStar series

KraussMaffei’s EcoStar mixing and metering

machines meet the highest standards in

polyurethane processing. These are small, high-

performance systems, based on high-quality

components, for high-pressure processing with

transfer and linear mixing heads. A very compact

configuration keeps the supply lines between the

separate machine components very short.

This, in turn, enables temperatures to be precisely

controlled, minimizes pressure losses and makes for

optimal process control. In this way, KraussMaffei

customers can count on a stable process and highest

product quality. The machines are easy to operate

and maintain and they’re specifically engineered for

easy access.

Improved price/performance ratio

Through systematic standardization and reducing

the number of variants, KraussMaffei has been

able to improve the price structure for the series, so

that customers can now benefit from an improved

price/performance ratio for the EcoStar. This makes

powerful, premium-quality PU metering machines

available at budget prices, which should appeal

especially to small and medium-sized PU processors.

The basic EcoStar version includes volume flow

meters, double-walled component tanks, MKE3B

mixing heads, axial piston pumps and the Siemens

control system. This basic version can be upgraded

with function packs to suit product specifications

and production requirements, for example, closed-

loop control, transfer mixing heads, plate heat

exchangers and different-sized outriggers.

Worldwide sales success

Customers around the world have been buying

EcoStar systems. Typical are some of the latest

orders, mainly from small and medium-sized

enterprises, which are using the KraussMaffei

machines to produce a huge range of projects. Three

EcoStar systems recently shipped to processors

in Brazil: two to Piatex Indústrie e Comércio

de Fiberlass Ltda. and one to Frisokar

Equipamentos Plásticos Ltda.. Both

companies are using them to produce

components from flexible, semi-

rigid and integral foam that are

widely used in the automotive

sector. The latest system supplied

to India went to Supreme Treves

PVT. Ltd., which will be using

the EcoStar for backfoaming

carpets. In Iran, by contrast,

the Pishgam company is

using an EcoStar to make seat

squabs for office chairs. p

CONTACTKlaus BangeSales Manager Reaction Process MachineryPhone +49/89/[email protected]

Small, compact and

a power pack: the

EcoStar series is ideal

for small and medium-

sized PU processors.

High-performance PU

mixing and metering:

our EcoStar series

delivers premium

quality at budget

prices.

KraussMaffei Technologies GmbH ··· Phone +49 89 [email protected] ··· www.kraussmaffei.com

What’s your choice for ultralight components that are also ultrastrong? Fibre composites are the answer. Today’s production technology delivers cost-competitive, fi bre-composite products with outstanding mechanical properties and paintable surfaces. To source this technology you need to look no further than KraussMaffei. We offer far more than high-performance production systems. We partner with you all the way to drive the success of your production project. However specialized your product and however demanding the specifi cations, we’ll supply the process for the job – LFI, FCS, RRIM, SRIM, SCS or RTM.

In-depth information and contact details are at www.kraussmaffei.com.

Ultimate performance with machines from KraussMaffei.

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