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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 EXTRUSION

“We supply complete

systems exactly tailored

to your requirements with

all system components

engineered to operate

perfectly together.”

Manfred Reichel,

General Manager,

Extrusion Technology.

KEYNOTE

Dear Readers,

KraussMaffei is the only company worldwide to unite

under one roof three technologies of key significance

for the plastics and rubber processing industries

– extrusion and injection and reaction moulding. You,

as our customer, profit in many ways from this bundled

competence. In this issue of our magazine, we offer you

an impressive example of a multitechnology solution

– our new systems for continuous production of pipe

with foamed PU insulation. These systems build on

our engineering know-how and the experience of many

years in the fields of pipe extrusion and PU processing

to deliver successful, integrated production solutions.

They are just one example of our ability to supply

systems exactly tailored to your requirements with all

the components engineered to operate perfectly together

Our engineering expertise in multitechnology solutions is

only one aspect of our holistic approach. In addition to

supplying machines, we support our customers in every

way – right through to planning complete production

plants. Our goal is to ensure you a long-term competitive

advantage in your markets. There is an increasing

awareness, around the world, that the capital cost

of an individual machine must be compared with the

impressive return on investment possible with a complete

system solution. This was emphasized most recently at

the Interplastica 2010 in Moscow, where KraussMaffei

Berstorff achieved considerable success.

Manfred Reichel,

General Manager,

Extrusion Technology

In 2009, KraussMaffei Berstorff, Hanover,

booked its biggest order to date for compounding

machines. The Chinese company AGT

Compounds, previously known mainly for

flame retardants, ordered 50 ZE Basic twin-

screw extruders for a new plant in Changzhou.

AGT will install 44 of these lines to compound

technical polymers in a vast plant with 90,000

sqm production floor and 7,500 sqm laboratory

area. The remaining machines will be deployed

as laboratory machines in product development.

“AGT was especially interested in quality with

a ‘Made in Germany’ label,” explained Claas

Uphoff, Sales Manager China at KraussMaffei

Berstorff. “Thanks to a very high level of

standardization, our ZE Basic carries a very

attractive price tag.” p

50 at onceZE BASIC – BIG ORDER FROM CHINA

AGT Compounds ordered 50 ZE Basic twin-screw

extruders for its new plant in Changzhou, China.

At the Interplastica in Moscow (January 26-

29, 2010), it was obvious that the plastics and

rubber industries are beginning to recover and

that demand for extrusion systems is picking

up. Many intensive discussions with customers

confirmed that KraussMaffei Berstorff is still

the Number 1 in the Russian market. Visitors

to the Interplastica showed strong interest

in a number of topics – polymer processing,

film and sheet production, glassfiber pipe

production, direct extrusion and PU-insulated

pipe. p

Still Number 1INTERPLASTICA 2010

UDI (United for Developed

Industries), the second recent

Egyptian customer, is part of the Lasheen Group,

the regional leader in plastics production. UDI

ordered four PVC pipe extrusion lines from

KraussMaffei Berstorff for the production of

pressure and waste water pipe. “Before awarding

us the contract, UDI made extensive enquiries from

other companies in the Arab-speaking world about

KraussMaffei Berstorff and our competitors,”

reports Albert Brunner, Sales Manager for Egypt.

“In the last analysis, our reputation and our proven

quality were decisive in winning the contract.” p

11

Two important orders from companies in

Egypt illustrate how KraussMaffei Berstorff is

opening up new markets with mature extrusion

technology “Made in Germany”. The large,

Cairo-based Al Amal already operates a

pelletizing system from KraussMaffei Berstorff.

Now the company has placed an order for six

extrusion lines to produce U-PVC, C-PVC and

PP-R pipe. The company aims for very high

quality standards, especially in the area of

C-PVC pipe. So it was logical to turn again to

KraussMaffei Berstorff when the time was ripe

for expansion.

MAJOR ORDERS FROM EGYPT

NEWS EXTRUSION

Albert Brunner, Sales

Manager Egypt (2nd

from left) and Project

Planner Dominik Prechsl

(front right) with Al Amal

representatives during

acceptance tests for the

pipe extrusion lines.

downstream components. Output is up to five tonnes an

hour. The customer plans to produce rubber belts, up to

2,850 millimeters wide and between 3 and 18 millimeters

thick, as the upper and under layers of conveyor belts. A

special doubling unit can bond two of the rubber belts

to produce one thicker intermediate product. Conveyor

belts of these dimensions are used mainly in mining and

open-cast mining to transport coal and ores. p

In mid-2010, KraussMaffei Berstorff will ship one of

the four biggest roller-head lines installed in recent

years to a conveyor belt manufacturer in Eastern

Europe. The line is 60 meters long and includes a

250-mm-screw-diameter rubber extruder with a wide

slot die (slot width 3050 mm), a 2-roll calender and

ROLLER-HEAD LINE FOR EASTERN EUROPE

A really big one

sales and marketing for this part of the product

range. He also has overall responsibility for the

die engineering, project planning and process

engineering teams and for the pipe TechCenter.

Peter Oswald heads up the Profile Extrusion

product group, with additional responsibility for

project planning, process engineering and the

profile extrusion TechCenter. p

The Munich arm of KraussMaffei’s Extrusion division

has a new sales management team. Now structured

even more clearly by product group, the organization

is closely aligned with customer expectations. Andreas

Kessler is the new General Sales Manager, with overall

responsibility for orders and sales and for the German

and international sales subsidiaries of Munich Extrusion.

He’ll be working closely with Ralf J. Dahl who holds

the same position at the Hanover arm of KraussMaffei

Berstorff. Michael Hofhus has been appointed Product

Manager Pipe Extrusion in Munich, responsible for

MUNICH EXTRUSION

The roller head line can

process up to five tonnes

an hour.

Andreas Kessler Michael Hofhus

“Made in Germany” a success factor

Effective, focused organizational structure

Peter Oswald

MADE BY KRAUSSMAFFEI 1 ¦ 2010

CONTINUOUS FOAM ENCAPSULATION FOR PIPES

KraussMaffei is the only company in the market with expertise in the three major machine technologies for plastics and rubber processing: injection moulding, reaction processing and extrusion. The company’s new systems for the continuous production of pipe with PU insulation are a convincing example of our ability to supply complete multitechnology solutions as a single vendor.

From media pipe to a complete pipe element

The media pipe produced on a conventional

extrusion system is made of HDPE or PE-X, to

suit the application. A barrier layer can also be

applied. Coming off the line, the pipe is wound

onto large steel drums. Alternatively the pipe can

be bought in and then have the insulation layer

added on the second section of the production

system. Here, the pipe is unwound from the

steel drums, centered, heated if necessary, and

fed under tension into a shaping conveyor with

a mixing head dispensing the polyurethane mix

at the inlet throat. The aluminium shaping jaws

limit the foam volume to define the outer diameter

of the insulation layer. A film layer prevents the

polyurethane from adhering to the aluminium

shaping jaws. Once the PU insulation layer has

cured, the pipe leaves the shaping conveyor and

a PE outer sheath is applied using a single-screw

extruder with a sheathing die. This outer sheath

is cooled, and the whole pipe element is hauled

KraussMaffei Berstorff

has the advantage

of many decades of

technology competence

and experience in

pipe extrusion and

PU processing. We are

uniquely positioned to

supply complete systems with

perfectly matched components for continuous

production of pipe with PU insulation. Our

production system has two sections. The first

section is a conventional line that extrudes the

media pipes; in the second section the media pipe

(one or two) is encapsulated in PU insulating

foam and then sheathed in a protective

polyethylene layer. By contrast with some other

systems on the market, KraussMaffei Berstorff

systems are characterized by sharply reduced

wear on all system components, high system

reliability and a high-quality end-product.

New production system concept from a system partner

The PU metering

system ensures that

the components are

homogenously mixed.

12 FOCUS EXTRUSION

Key components of

the system for foam

encapsulation and

sheathing of media pipes

are the unwinder (1) …

… retarder (2), center-

ing and prewarming

station for the media

pipe (3), …

13FOCUS EXTRUSION

off and wound on a drum. The system makes it

possible to integrate anti-diffusion barrier layers,

and also wires to monitor leakage.

No limits on pipe length

Continuous production of insulated pipe, as in

this KraussMaffei Berstorff system, has a number

of important advantages compared with dis-

continuous production. One major advantage

is the relatively high level of automation that

results in lower labour costs. Furthermore,

there are virtually no limits on the length of the

pipe being produced. This is largely due to the

way the mixing head is engineered to eliminate

stoppages for cleaning and mixing-head changes.

Longer pipe sections reduce the number of prod-

uction system restarts and also the number of

connections needing to be made when the pipe is

laid. This in turn eliminates the risk of thermal

bridges and leaks, and makes pipe laying far

easier.

Outstanding insulating properties

The standard version of this production system

can be used to produce pipe with an outer

diameter between 20 and 110 millimeters. In

the diameter range 20 to 63 millimeters, the

integrated pipe element usually contains two

pipes (outflow and return). The exterior dia

meter of the pipe element will be between 75

and 180 millimeters, depending on the diameter

of the media pipe(s) and the thickness of the

insulating layer.

Outstanding mixing head performance produces

a PU foam layer with extremely low thermal

conductivity – between 0.02 and 0.03 W/(m x K),

depending on the type of foam and the supplier.

This highly efficient insulation makes these

pipes the ideal solution whenever a significant

temperature differential must be maintained

between the medium flowing through the pipes

and the ambient temperature. In some cases,

the medium being transported is hotter – such

as supply lines for combined heat and power

or geothermal plants, or hot water pipelines

in general. Insulated pipes are also sometimes

required for potable water transport if there is

a risk of the pipes freezing. The second major

application area is the transport of cold or cool

media in warmer ambient temperatures, for

example, in air conditioning or refrigeration

systems, or pipes for transporting liquefied gas.

With the current focus on energy savings, strong

growth in demand can be expected in all these

application areas. p

CONTACT

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

The outer diameter

of the PU foam is

defined by the shaping

conveyor during the

chemical reaction.

… shaping conveyor and mixing

head (4), single-screw extruder with

sheathing tool (5), spray bath for

cooling (6), haul-off (7) and winder (8).

The media pipe is

produced on a conven-

tional line headed by a

single-screw extruder.

The outer PE protective

layer is applied via a

sheathing tool.

MADE BY KRAUSSMAFFEI 1 ¦ 201014 APPLICATION

MATERIAL DEVELOPMENT WITH THE ZE 25 A UTXi LABORATORY EXTRUDER

Headquartered in Pirmasens, Germany, Framas Kunststofftechnik GmbH is a leading global supplier of plastic components for the athletic footwear industry. To promote the development of new materials for increasingly better products, the company is now investing in a KraussMaffei Berstorff ZE 25 A UTXi twin-screw laboratory extruder.

task. In addition, it supplies all data required for

scale-up to a production line and ensures low

operating cost owing to easy maintenance and

highly efficient wear protection.

Measuring melt quality directly

The ZE 25 S UTXi laboratory extruder has a

D/d screw diameter ratio of 1.46 and thus offers

the optimum relation between intake volume

and torque. It achieves screw speeds of up to

1,200 rpm, which make it ideal for high-perfor-

mance compounding. A processing unit length of

42D allows additives to be injected at any point

along the barrel and the melt to be degassed if

necessary. In other words the extruder offers

maximum flexibility. The extruder is fitted with

an Ultra-Glide drive unit that allows the screws

– even when completely filled with melt – to

be pulled out from the rear of the stationary

processing unit, so that the melt quality can be

directly evaluated. p

Framas has long been aware of the correlation be-

tween perfect plastics and maximum comfort and

functionality when it comes to sports shoes. The

company, with offices in Germany, Asia and the

USA, supplies major brands such as adidas, Nike,

Puma and Reebok with plastic components. About

400 single-component and multi-component

injection moulding machines are currently used to

produce mainly lasts, soles and bootlegs for sports

shoes.

The company promotes material development in

close cooperation with Kaiserslautern University

of Applied Sciences. For this purpose, Framas

ordered a ZE 25 A UTXi twin-screw extruder

from KraussMaffei Berstorff and placed it at the

disposal of the university on a loan basis. The

joint development activities are focussed on ma-

terials providing weight reduction combined with

enhanced stability and improved damping proper-

ties. Thanks to the sophisticated equipment, the

laboratory extruder is particularly suited for this

The interaction of

the ultra-functional

materials in sports shoes

provides support for the

athletes.

On track for the perfect plastic

The ZE 25 UTXi

laboratory extruder

is ideal for the

development of new

polymer formulations.

CONTACT

Gerhard SchmittSales Manager Twin-screw ExtrudersGermany, Austria, SwitzerlandPhone +49/511/[email protected]

15 APPLICATION

EXTRUSION LINES FOR BRAZILIAN PIPE PRODUCER

Corr Plastik Industrial Ltda., one of Brazil’s major producers of PVC pipe, has substantially increased production capacity with a new factory in the north east of the country. The extrusion lines for the new plant were supplied by the German extrusion specialist KraussMaffei Berstorff, long-time supply partners for Corr Plastik.

Corr Plastik doubles production capacity

Corr Plastik has

built and equipped

a new plant for pipe

production near

Maceió.

Ever since its founding 17 years ago, Brazilian

pipe and fittings producer Corr Plastik has

used extrusion lines supplied by KraussMaffei

Berstorff. Certified to ISO 9001/2000, the

company aims to supply premium quality

products. Testing products in an in-house

quality lab is one of the measures it takes to

achieve this goal. In the intervening years, the

company has grown rapidly, it is now doubling

pipe production capacity, and once again

installing extrusion lines from KraussMaffei

Berstorff.

The new Corr Plastik site near Maceió, the

capital of Alagoas state, covers an area of

60,000 square meters. In a first construction

phase, the company has built a 7,500 square

meter plant to produce water, sewage, irrigation

and drainage pipes. In late 2009, KraussMaffei

Berstorff shipped four pipe extrusion lines for

the new plant. Two of the lines were double-

strand lines headed by KMD 75-36/R twin-

screw extruders from KraussMaffei Berstorff’s

Performance series. The other two were single-

strand lines with KMD 90-36/R Performance

twin-screw extruders.

Five new extrusion lines

The lines are configured to produce pipe with an

outer diameter of 20 to 250 millimeters. Together,

the four lines can produce up to 2,800 tonnes PVC

pipe a month. A fifth line, also headed by a KMD

90-36/R Performance extruder, began producing

corrugated pipe in January 2010. This new line

boosts total production volume at Corr Plastik’s new

plant to 3,100 tonnes a month. Together with the

output from the main plant in Cabreúva in São Paulo

state, Corr Plastik now has a production capacity

of 6,000 tonnes a month. This has catapulted the

company, which employs 330 people, into the ranks

of the three largest pipe producers in Brazil. p

CONTACT

Bruno SommerExtrusionPhone +55/11 4612 [email protected]

The four new pipe

extrusion lines at Corr

Plastik can produce up

to 2,800 t of PVC pipe a

month.

MADE BY KRAUSSMAFFEI 1 ¦ 201016 APPLICATION

The profile

extrusion line

at Sauermann

is headed by

a single-

screw ex-

truder.

The core business of Sauermann Franz Spritzguß-

technik e.K., based in Schrobenhausen north of

Munich, is the production of components for

commercial vehicles. The company’s product

portfolio of truck

components

includes plastic

tanks, containers

and mudguards.

Sauermann has

long sourced its

injection moulding

machinery from

KraussMaffei and

currently operates

several machines

from this manufac-

turer in its prod-

uction processes.

Trust in reliability

“Throughout their long service

lives, these injection moulding

machines have proved to be very

reliable, high performance machines

and the customer is very satisfied,”

comments Peter Oswald, head of the

Profile Extrusion team at KraussMaffei

Berstorff. “The strong relationship of trust

built up between Sauermann and

KraussMaffei was a decisive factor in the

company’s decision to turn to KraussMaffei

Berstorff when it needed a profile extrusion

line in order to add technical profiles to its

product range. The new line, supplied

complete by KraussMaffei Berstorff, is

headed by a KME 60-36 B/R single-screw

extruder. A typical representative of

KraussMaffei Berstorff’s single-screw

extruder range, this extruder has an extra-

long processing unit. The extra length

delivers three big benefits: higher output,

more homogenous melt and lower melt

temperature. In other words, the KME 60-

36 B/R supplies the profile die with the melt

quality essential for a quality product.

Sauermann is using the line to produce PO

anti-splash guards and their fixing profiles

for trucks, as well as side rail covers. p

TECHNICAL PROFILE EXTRUSION LINE FOR AUTOMOTIVE COMPONENTS SUPPLIER

Automotive components supplier Sauermann Franz Spritzgußtechnik e.K. has long produced a large number of parts for commercial vehicles on KraussMaffei injection moulding machines. Now the company, located in Schrobenhausen, Germany, has added technical profiles to its product range. As a satisfied KraussMaffei customer, the company turned to KraussMaffei Berstorff to supply the necessary profile extrusion line.

The full spectrum of machine technologies from a single contract partner

Sauermann has

added tech-

nical profiles

to its product

spectrum.

CONTACT

Peter OswaldManager Profile ExtrusionPhone +49/89/[email protected]

17FEATURE

FIRST MODULAR PRODUCTION SYSTEM FOR TIRE INNER LINERS

Thanks to their modular engineering, the plug-in production lines which KraussMaffei Berstorff offers manufacturers of tire components are ready for operation within a very short time of arrival at the customer’s plant. All essential line components, such as the extruder, control system, calender and winding stations, are shipped fully-wired, mounted on base frames. They undergo extensive testing at KraussMaffei Berstorff’s Hanover headquarters prior to shipment.

Fast production start-up

Tubeless tires have an inner liner, an impermeable

layer of rubber that prevents air from escaping,

instead of the old inner tube. A production

system for inner liners typically consists

of several separate components, including

extruder, control system, calender and winding

stations. KraussMaffei Berstorff has developed

a sophisticated modular concept to supply

these components as a complete package. In

this building block system, once the individual

modules are connected up, they are ready to go.

The individual components, eg, the GE 150 KS

rubber processing extruder with slot die, the

control unit, the whole roll system and the four

winding and unwinding stations, are assembled

and mounted on separate base frames with all the

supply lines and cables in the factory in Hanover.

For shipment, the connections are unplugged, the

winder trestles disassembled to fit the container

and the entire system is transported in oversea

containers to the customer’s premises. The

customer only has to provide the power and water

connections.

Increased operational reliability

thanks to early fault detection

The modular concept makes it possible to

carry out installation, pre-commissioning

and the software components check in the

manufacturer’s works. This sharply reduces

the personnel and time required for on-site

installation. In addition, operational reliability

is increased as potential interface problems are

detected at an early stage and can be eliminated

rapidly and at low cost. Furthermore, the future

operating and maintenance technicians can be

trained in Hanover during equipment pre-

commissioning. A major benefit of the modular

concept is drastically reduced total cost,

because the use of standardized modules results

in lower engineering expenses. In addition,

shipping complete transport units helps to

cut the costs for disassembly,

packaging and reassembly. p CONTACT

Harald HepkeDivisional Manager Rubber TechnologyPhone +49/511/[email protected]

Cooling system and

receiver conveyor.

The full spectrum of machine technologies from a single contract partner

Unwinders and

conveyors, part of the

modular inner-liner

production line.

MADE BY KRAUSSMAFFEI 1 ¦ 201018 FEATURE

NEW KMD 43 K/P FOR LOWER OUTPUT APPLICATIONS

KraussMaffei Berstorff has extended its new range of conical profile extruders with the lower-output KMD 43 K/P. The new extruder is a typical member of the conical series – reliable, flexible, low maintenance, compact and with an excellent price/performance ratio.

of materials. The air-cooled barrel and an AC

motor in the standard versions help to keep

maintenance effort extremely low and make the

KMD 43 K/P a very adaptable machine.

Despite the longer processing unit, the KMD 43

K/P is a very compact machine; overall length

has even been reduced slightly. The new design

and the flexible positioning of the drive unit

make it easy to configure a number of space-

saving coextrusion concepts, such as piggyback

configurations. Even the standard version of

the KMD 43 K/P, with its compact switching

cabinet and the option of a swivel control panel,

is extremely narrow. This is a strong advantage

in engineering coextrusion solutions. The

advanced C5 controller with its sophisticated

control, monitoring and feedback systems

supports a stable and reliable production

process. And finally, the new extruder, like the

whole conical series, has an excellent price/

performance ratio. p

One of the hallmarks

of KraussMaffei

Berstorff’s conical

extruder range is very

good plasticizing

and homogenization

performance. The new

KMD 43 K/P delivers

this performance

thanks to a redesign

of the conventional

conical screw from

the feed to the

compression zones.

Heat transfer in these zones has

also been significantly improved. The result is

optimal temperature homogeneity across the PVC

powder. The extra length of the screw’s preheating

zone contributes to an very stable process and

optimal melt homogeneity.

Flexible, compact and hardworking

The drive unit has been optimized to increase

specific throughput without increasing screw

speed. The result is output up to 100 kg per

hour. The extruder is targeted at profile extrusion

applications with lower output requirements.

Flexible temperature control, self-regulating

internal temperature balancing and hardened

screw surfaces make it possible to process a range

The ideal addition to the conical extruder series

The KMD 43 K/P conical

twin-screw extruder

adds a lower output

machine to KraussMaffei

Berstorff’s conical

extruder series.

CONTACT

Peter OswaldManager Profile ExtrusionPhone +49/89/[email protected]

The new KMD 43 K/P is

an extremely compact

machine.

19FEATURE

The ZE-UTX twin-screw extruder series from

KraussMaffei Berstorff, Hanover, has several

hallmarks that make it ideal for processing natural-

fiber-reinforced polymers. These include intensive

material and heat exchange, a narrow dwell time

window, effective degassing and speed-independent

throughput. Building on our vast experience, we

have systematically developed this series and made

a wealth of minor improvements to produce an

extruder which is perfect for processing undried

natural fibers. The deep-cut screw flights of this

R model, which has a D/d of 1.74, have plenty of

volume and thus help ensure that the water vapour

released during processing is reliably removed.

Economical and simple

When combined with the special, 6D barrel

elements, natural fibers containing up to 12%

moisture can be effectively degassed and processed.

The benefits of processing undried materials include

low operating costs, which come from eliminating

expensive pre-drying processes, and simplified

handling without the risk of dust explosion.

Patented KraussMaffei Berstorff dual-process screw

elements ensure that the natural fibers are gently

incorporated during extrusion. Neither high shear

rates nor temperature peaks occur that would

thermally damage the natural fibers. Nevertheless,

the special mixing elements provide the desired

level of homogenization and dispersion, and thus

ensure that the end products have comparable

mechanical properties. Finally, low housing-

wall temperatures are important in natural-fiber

Extruded natural-fiber-

reinforced plastics can

incorporate any of a

wide range of natural

fibers.

compounding for preventing

local overheating of the

melt. To this end, the

company has developed

a heat-treatment

process for the

figure-8 bore of the

housing elements. This

process has reduced

the distance between

the cooling holes and

the process chamber,

thereby guaranteeing

very effective cooling

performance. The natural

fiber compounds are converted particularly

economically and gently into the film, profile

or panel end product direct by attaching the

shaping die and the downstream equipment to

the twin-screw extruder itself. KraussMaffei

Berstorff supplies a melt pump for this

constellation that ensures pulsation-free melt

flow at the end of the extruder, combined with

constant pressure. p

The R model of the ZE-UTX twin-screw extruder series from KraussMaffei Berstorff is the perfect extruder for extremely cost-effective compounding of natural-fiber-reinforced plastics. What makes it ideal is the large free volume, special mixing elements and locally variable barrel heating.

The perfect extruder

CONTACT

Lars DarneddeProcess EngineerRenewable Raw MaterialsPhone +49/511/[email protected]

The R model from the

ZE-UTX twin-screw

extruder series makes

light work of natural

fibers with up to 12%

moisture content.

EXTRUSION OF NATURAL-FIBER-REINFORCED PLASTICS

Anz_EX_ZEBasic_DE.indd 1 09.02.2010 14:28:25 UhrAnz_EX_ZEBasic_DE.indd 1 09.02.2010 14:28:25 Uhr

ZE Basic twin-screw extrudersSimply good for compounding

INJECTION MOULDING

REACTION PROCESSING

EXTRUSION

The ZE Basic series of twin-screw extruders is the simplest

solution on offer from KraussMaffei Berstorff for any basic

compounding task – like plastifying, or filling and reinforcing.

Available in 6 sizes, from 26 – 77 mm screw diameter, the ZE Basic

series covers an output range from 5 kg/h to 2.7 t/h. These rugged

machines can be relied on to operate dependably and economically

over their entire service lives. By standardizing many components,

KraussMaffei Berstorff is able to offer you our proven quality

at a budget price.

Anz_EX_ZEBasic_GB.indd 1 09.12.2009 13:39:45 Uhr

ZE Basic twin-screw extrudersSimply good for compounding

INJECTION MOULDING

REACTION PROCESSING

EXTRUSION

The ZE Basic series of twin-screw extruders is the simplest

solution on offer from KraussMaffei Berstorff for any basic

compounding task – like plastifying, or filling and reinforcing.

Available in 6 sizes, from 26 – 77 mm screw diameter, the ZE Basic

series covers an output range from 5 kg/h to 2.7 t/h. These rugged

machines can be relied on to operate dependably and economically

over their entire service lives. By standardizing many components,

KraussMaffei Berstorff is able to offer you our proven quality

at a budget price.

Anz_EX_ZEBasic_GB.indd 1 09.12.2009 13:39:45 Uhr

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