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Tyre Technology For eFFecTive producTion
Multiplex Extrusion Lines
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in pArTnerShip WiTh induSTry
KraussMaei is a premium partner
or the plastics and rubber processing industries
worldwide
Electrical / electronicsMedical / pharmaceuticalConstructionWhite goodsAutomotive
Whatever you aim to achieve in plastics or rubber
processing, KraussMaei is your partner. We are
the only company with intensive expertise across
the three main engineering felds. And we have a
strong track record in integrating this expertise to
develop new processes and systems.
ra f a a
Our Injection Moulding Technology Division
supplies machines and systems or standard and
special applications, very large machines and ully
automated solutions. Our main markets are in the
automotive, packaging, electrical, electronics, medi-
cal technology and consumer goods industries.
Our Reaction Process Machinery Division supplies
machines and complete systems or processing
polyurethanes and other reactive materials.
Completing our product portolio, Tooling
Technologies supplies oam moulds, cutters and
routers. Our customer base is wide, with a ocus
on the automotive, construction and white
appliances industries.
Our Extrusion Technology Division supplies
machinery and systems or compounding, or pipe,
prole and sheet extrusion, physical oaming, and
the production o technical rubbers and inter-
mediates or tire production. Machinery rom the
companys range rom single extruders to
complete extrusion lines is used in many
industries, including chemicals, pharmaceuticals,
automotive, construction, urniture and packaging.
p f pasts
We are the people or plastics. We are your
partners rom the rst exploratory discussion,
through development to commissioning, servicingand operating your system, and nal disposal. At all
times, you are assured o outstanding competence
in planning and engineering, as well as reliable and
ast spare parts, service and support.
A a f stms
We put our expertise to work or your success.
With machine ranges engineered or modularity,
we can deliver application-specifc solutions
based on our wide range o standard modules and
specially engineered solutions. This strategy oers
customers technical and cost advantages.
cs t stms a t w
As an international company, KraussMaei has a
presence in all the major markets or the plastics
and rubber processing industries and employs over
3,000 people worldwide. Our sales and service
network keeps us close to all our customers around
the world.
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Packaging
Combining excellent product quality with
maximum production output Multiplex
extrusion lines
As an expert partner for the tyre manufacturing
industry; KraussMaffei Berstorff delivers complete
leading-edge systems for the production of tyre
components. Our goal is to offer the made-to-measure
solutions you need to succeed in todays fast moving
competition.
In our product portolio you fnd Multiplex extrusion
lines with the highest output-rates in the market.
Proven engineering power, unrivalled technological
expertise, numerous patented developments and
active participation in the production processes of
the tyre manufacturers testify to the innovative
character of our machinery and made us what we
are today: the world leader in this technology.
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Seite Multiplex Extrusion Lines
MulTiplex exTruSion lineS
High technology, high quality, high output
The automotive vehicle tyre is a high-perormance
precision unit. The requirements o saety, com-
ort, economy and environmental compatibility
demand a high level o quality in every single tyre
component.
For the manuacturer, this means the application o
technologies, which combine excellent quality with
high output.
KraussMaei Berstors response to this challenge
is the delivery o complete high-tech extrusion lines
or the production o tyre components.
Our know-how matured over decades, our own
patented developments and our active participationin the innovative processes o the tyre manuacturers
all go to make us an expert partner or the industry.
The demands and expectations o our customers
are met with closely-targeted advice, highly-develo-
ped project management methods, computer-aided
component design and state-o-the-art manuactu-
ring and application-specic commissioning.
Our Technical Centres oer practical pre-contract
support with production-scale machinery and labo-
ratories with inspection and testing acilities. Trials
are conducted under real conditions to secure the
basis or each investment. The result is customer
satisaction right rom the outset.
High-tech extrusion lines with the highest output
rates conrm our position as the world leader in
this technology as all the signicant manuacturersproduce their tyres on KraussMaei Berstor
machinery.
Tread
Capply
Belt layer 1
Belt layer 2
Sidewall
Bead
Tread compound
Undertread
compound
Sidewall
compound
Rim cushion
Carcass
Innerliner
Apex
Bead wire
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Preline Seite
MulTiplex uniTS For pre-ASSeMbly
Pre-assembly: precision in detail
Pre-assembly defnes the level o the production
technology. This is because pre-assembly of
passenger car and truck tyres utilises al l the
reserves o rationalisation, whilst simultaneously
raisng the tyre component quality to a high level.
KraussMaei Berstor machines are designed in
concept to meet the special demands o the manu-
acture o semi-fnished components. Duplex,
Triplex and Quadroplex extrusion sets guarantee
precise combination o the dierent components,
totally ree o air inclusions. The end result is
always more than the sum o the individual parts
here is component technology in perection,
allowing signicant rationalisation by reducing
the number o working stages on the tyre buildingmachines.
Extrusion Passenger TruckExtrusion Passenger TruckHead Product car tyres tyresHead Product car tyres tyres
DuplexDuplex Sidewall + rim strip Cap + base
2-component apex
TriplexTriplex Cap, base, wings Cap, base, cushion Black sidewall, rim strip, shoulder pad
QuadroplexQuadroplex Cap, base, wings, cushion
2 x cap, base, wings White sidewall, rim strip, shoulder pad Cap CushionWings Base
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MulTiplex lineS
Quality and perormance
without compromise
All tyre makers are seeking ever-tighter manu-
acturing tolerances, whilst throughput rates are
steadily rising.
KraussMaei Berstor extrusion lines are concei-
ved or high product quality and maximum output
and are equipped with extruders o dierent types
(GE-SC or GE-KS) and sizes.
The modular design makes or rapid recongura-
tion to suit the mode o operation Mono, Duplex,
Triplex or Quadroplex.
KraussMaei Berstor Multiplex extrusion sets are
designed in a piggy-back arrangement to achieve
the highest product quality through symmetrical
material fow in the head. In addition, the compact
design makes or real space savings. A urther
eature to satisy the quality requirements is the
special design o the fow channels in the extrusion
head. These ensure a very gentle, even material
transer rom the round section at the extruder
outlet to the rectangular fat orm o the prole. In
addition, the changes in direction o the material
fow in the fow channel are kept to a minimum.
All stages o the process are controled by a monito-
ring system, thus ensuring operational security.
Throughput rates o up to 10,000 kg/h or about
30,000 passenger car treads per day are achieved
with these modern extrusion lines.
Flow channels in the Multiplex extrusion head
Pre-assembly o a
Multiplex extrusion set
Multiplex Lines
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Preline Seite
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MulTiplex exTruSion heAdS And ToolS
Versatile and efcient:
systemised head operation
The range o dierent tyres dictates the require-
ments or changing the compound, dimensions
and programs run on any production line, whilst
the extrusion head determines the quality and
eciency o the tyre production.
Multiplex extrusion heads rom KraussMaei
Berstor represent the state o the art with
working widths up to 850 mm or up to 2 treads
in one production pass
locking orces up to 10,000 kN
connection o up to our extruders o dierent
types and sizes
To achieve rapid change times or dierent prole
dimensions, KraussMaei Berstor have two
solutions:
Casset te changer unit on the operator side,
consisting o a housing and a vertical sliding unit
on either cassette. One housing is in production,
whilst the other is in the preparation position.
Double wedge comb to shorten change o the
nal die without changing the splice bar. While
the outer wedge comb is opened, the inner one
holds the housing and splice bar closed against
the head.
This minimises scrap and allows rapid restart o
production.
The upper and lower parts o the head can be ope-
ned separately to acilitate cleaning when changing
the compound and to accelerate the changeover.
Multiplex extrusion heads and tools
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Easy to clean: extrusion head in opened position Multiplex extrusion head with cassette changer unit
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Width
measurement
Accelerator roller train
with blow-o jets
Cutting machine skive
Multiplex
extrusion set
Take-o roller train
with marking unit
Continuous length
weighing scale
and width scanner
Prole
scanner
MulTiplex coMpleTe lineS
System technology at a stroke
The better the individual process stages t together,
the more secure is the fow o the production.
KraussMaei Berstor designs complete line con-
cepts to attain perect interplay o all components
under changing parameters.
Based on our wide experience, we bring together
all elements o the production line into a systemised
technological solution. From the eed units to the
wind-ups everything rom one single source.
Each part mates with the next and every compo-
nent o the line can be matched to the process-tech-
nical requirements o compound and dimensional
changes or changes rom cut piece to wind-up
operation. The interace-ree conguration o the
machinery ensures constant product quality at
maximum capacity utilisation.
Feed units with
metal detectors
automatic setting o the eed rate
simple service and maintenance
Gauging instruments
continuous weight per meter and weight per piece or
precise weight measurement
width measurement beore and ater the cooling unit
prole scanning or continuous monitoring o the geometry
length measuring units or monitoring the cut prole lengths
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Manual pick-o roller train
cut-piece operation
Reject roller train Cross-cutting unit
Wind-up stations
Spray cooling
Marking units or
printing o coloured stripes
printing o identication codes
imprints o numbers and letters
Cementing station
to increase adhesion o the
splice suraces
Cutting units (Skiver)
fying cut or start/stop cut or cut-piece
operation with the highest cut quality,
length precision and maximum cut rates
per minute, rotary cutting or wind-up
operation
Wind-up operation
cassette winders
spool winders
Cut-piece operation
manual pick-up roller train
automatic booking system
Cooling systems
units or spray or immersion cooling
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conTrol And AuToMATion
Multiplex Extrusion Lines
Planning and construction o the electro-techni-
cal equipment or the extrusion lines are carried
out in modular form to the latest standards.
Customised confgurations can be quickly created
without problems.
The extruder motors are equipped with micropro-
cessor drives, digital actual value access and bus
connector set point provision. This technology
ensures a high degree o repeatability, exact regu-
lation and dynamic screw speed control. All this
has a direct infuence on the quality o the extruded
prole. KraussMaei Berstor developed control
sotware mimimises start-up scrap and keeps the
extruded profle within the prescribed dimensi-
onal and weight tolerances during production.
The system continuously reads the weight and
the dimensions o the prole as well as the screw
speed and the stock pressure and temperature in
WIN CC (Win NT)
11 22
33 44
55
66 7788
99
10101212 1313
1111
1414 1515 1616
1717
1818 1919
2020
2121
2222
2323
each extruder. I the actual process values deviate
rom the set points, the process parameters are
corrected individually or, depending on their
proportion o infuence on the prole components,
o all extruders. Auxiliary drives are equipped
with low-maintenance three-phase standard motors
and vector-controlled requency converters. Non-
contact sensing systems such as CCD cameras and
ultra sonic sensors and special digital dancer-type
regulators provide tension-ree material transport.
Each system is provided with a digital sotware con-
trol, which guarantees optimal speed matching with
its adjacent downstream drive. The PLC automation
units o the individual machines are networked via
TCP/IP with each other and with the visual display.
Operator-riendly visualisation and easy-to-use
recipe management acilitate fexible production
planning, high product quality, minimal start-up
scrap and rapid changeovers.
Control and automation
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Service
Host
Modem
4 Switch
OPC server
6 Main operator panel
7 Operator box head Ethernet TCP/IP
9 Probus DB
Extruder control
Terminal- and
operator-boxes
Feeding or
extruder 4
Feeding or Mini RH
4 Head
Terminal- and
operator-boxes
6 PLC customer
communication
7 Probus DB
AC Drive with
pulse generator
Extruder 4
9 AC drive withpulse generator
Mini Rollerhead
Heating controller
Camera
Scale
AC Vectordrive
with pulse generator
Downstream ...n
roller-heAd lineS
Tandem operation or
maximum precision
Roller-Head technology rom KraussMaei
Berstor combines precision and economy into one:
close-tolerance work or the production o innerliners
and ller strips. The rubber compound is plastied
in the extruder and ed directly to the roll gap o
the two-roll calender via a wide-slot extrusion die.
The calender calibrates the web exactly to the preset
nal thickness. This process avoids the ormation
o a rolling ball in the calender and thus the risk
o air inclusions. The narrowest o tolerances over
the entire web width and optimal homogeneity o
the compound ensure the perect tyre innerliner and
ller strip.
Both proles are doubled with the highest centricity
and absolutely blister-ree.
Roller-Head lines
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Rely on us or a ast and competent response to
all your service needs anywhere in the world.
Whatever you need rom troubleshooting or
training to spares or repairs were on the job.
Were dedicated to supplying service quality on a
par with the outstanding quality o our machines
and systems. We oer ar more than spare parts
and hotlines. Well work with you to choose thebest and most cost-eective solution or your
production. Well help you test new applications
and well plan customized service packages.
A s
Our service oering is broad. Well congure your
system, install and commission it, train your sta,
plan measures to minimize your downtime risk and
maximize productivity, and carry out maintenance,
repairs and upgrades. Youll nd us ast, reliable
and competent. Our hotline is manned by highly-
trained and experienced service technicians.
I necessary, well get a technician to you quickly.
Remote diagnosis, interacing directly with your
machines control system, can be a practical
alternative. Spares or all important wear parts are
available at short notice. Were continuously
expanding our service network to speed up spare
parts shipment. Talk to us about the right service
solution or your business.
cstm tas a tt tst a
The Extrusion Division operates a test lab in Ger-
many and USA tted with the latest machinery and
equipment. We can run trials and ne-tune pro-
cesses on your behal. We can work with you to test
and evaluate processes, machines and equipment in
order to identiy the best approach or a particular
project. Our highly-qualied application engineers
are there to help you.
Ta wt as tt
Courses are held in our lab and training centre,
or, optionally, on your premises. We oer
clearly-structured basic and advanced training in
operation, process control and maintenance or
KraussMaei extrusion systems. On request, well
plan and hold special courses on topics o your
choice. All participants spend a high proportion
o their training working hands-on with original
KraussMaei Berstor machines. A well-structured
training program produces skilled operators and
technicians, which will positively impact your up-
time and productivity.
Service WorldWide
Service, support and spare parts when you
need them, where you need them
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Krauss Maei Italiana S.r.l.
Rezzato, Italy
Phone: +39 030 2590707
Fax: +39 030 2592369
Email: [email protected]
BKM Servicegesellschaft OOO
KraussMaei Berstor
Moscow, Russia
Phone: +7 495 9377554
Fax: +7 495 6265745
Email: [email protected]
Krauss Maei Corporation
Florence, USA
Phone: +1 859 2834376
Fax: +1 859 2830290
Email: [email protected]
Krauss Maei Mexico
Mexico City, Mexico
Phone: +5281 15211604
Fax: +5255 53081727
Email: [email protected]
Krauss Maei do Brasil Ltda
So Paulo, Brazil
Phone: +55 11 56412273
Fax: +55 11 56419337
Email: [email protected]
KraussMaei Co., Ltd.
Shanghai, China
Phone: +86 21 58682662
Fax: +86 21 58681173
Email: [email protected]
Krauss Maei Asia Pacifc Pte. Ltd.
Singapore
Phone: +65 65 535828
Fax: +65 64 550419
Email: [email protected]
Contacting us by postContacting us by post
I you need to contact any o our
international service or spare parts teams
by post, use this address:
cstm Scstm S
KraussMaffei Berstorff GmbHKraussMaffei Berstorff GmbH
An der Breiten Wiese 3-5An der Breiten Wiese 3-5
30625 Hannover30625 Hannover
GermanyGermany
Worldwide hotlineWorldwide hotline
numbersnumbers KraussMaeiBerstor GmbH
Hannover, Germany
Customer Service
Phone: +49 511
5702-533
Email: service-ext.
ha@kraussmaffei.
com
Phone rubber
technology: +49 172
511 9620
Phone plastics
technology: +49 172
511 9621
Phone service
hotline: +49 172 511
9623
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KraussMaffei is a premium partner for the plastics and rubber processing
industries worldwide. KraussMaffei machines and systems are used wherever
plastics and rubber are converted into products. As a knowledge-driven
technology company, we build on many decades of experience and a strong
commitment to research and development.
KassMaff bstff gmh
An der Breiten Wiese 3-5 30625 Hannover
Phone +49 511 5702-0 Fax +49 511 5619-16
www.kraussmaffei.com
As an expert partner or the tyre manuacturing
industry; KraussMaei Berstor delivers complete
leading-edge systems or the production o tyrecomponents. Our goal is to oer the made-to-
measure solutions you need to succeed in todays
ast moving competition. In our product portolio
you fnd Multiplex extrusion lines with the highest
output-rates in the market. Proven engineering
power, numerous patented developments and active
participation in the innovative processes o the tyre
manuacturers testiy to the innovative character
o our machinery and made us what we are today:
the world leader in this technology.
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