Competence Forum 2018

Thank you for visiting our Competence Forum 2018! On this page we have compiled the highlights of the two days at the Munich plant from injection molding machinery, reaction process machinery and extrusion technology.

Impressions

Gallery

Gallery - 2
Gallery - 3
Gallery - 4
Gallery - 5
Gallery - 6
Gallery - 7
Gallery - 8
Gallery - 9
Gallery - 10
Gallery - 11

Exhibits

iPul system: Pultrusion process

Fiber-reinforced profiles in pultrusion process
  • Higher production speed
  • Enclosed fiber soaking for fastreacting systems in injection box
  • Processing of fast reacting systems
  • Complete solution from a single source, together with our partner network: systems engineering, mold, full process control, and service
Haul-off speed: up to 3 m/min
Metering machine: RimStar Nano 0,6/0,9-PPU
Discharge capacity: 0,5 g/s - 10 g/s
Mixing head: MK ND 7-2
Mold technology: with individual heating zones for final shaping

Wet molding with fiber stack handling

Automated wet molding cell for series production
  • Polyurethane processing in wet molding process
  • Short cycle times
  • No preforming – also in the case of complex geometries
  • Low investment costs with smaller clamping forces compared with HD-RTM
Metering machine: RimStar 8/4 RTM
Discharge capacity: 75 - 130 g/s
Mixing head: MK 10-2K-RTM mit Breitschlitzdüse
Cycle time: ca. 5 min
Material: Polyurethane application on Semi-finished fiber product
Automation: Robot with needle gripper for fiber stack handling and suction gripper for component removal
MX mold carrier: SFT MX-H-25-16-8000-0-0
Clamping area: 2.500 x 1.600 mm
Clamping force: 8.000 kN
Locking forces: 4 hydraulische Differenzialzylinder

PUR Multicolor technology

Fast and flexible from shot to shot
  • Fast dye change: up to four colors using one mixing head
  • Addition of colors in area of component nozzle
  • Excellent coloring of components
  • Processing of liquid and abrasive dyes
  • Precise and proven color metering systems
Metering machine: RimStar 29/29
Discharge capacity: Up to approx. 400 g/s, depending on mixing ratio
Mixing head: MK 10/15-ULK-2K+4
Pump color metering: FD color metering system
Piston color metering: CD color metering system, for abrasive colors
Foam mold: KraussMaffei

Structural Component Spraying (SCS) Mixing head

Flat-circular spray changeover for efficient spraying process
  • Quick nozzle changeover from flat to circular jet in seconds
  • Two spray geometries with one mixing head
  • Reduced investment thanks to one metering machine with tow spray methods
  • Improved cycle times thanks to fast changeover
  • Reduced material consumption
  • Patented changeover at mixing head
Discharge capacity: 30 - 200 g/s
Mixing ratio: 1:1 - 1:2
Spray adapter: Flat-circular jet spray nozzle changeover
Flat jet nozzle: Spraying width max. 1,000 mm, Discharge capacity 60 - 130 g/s
Circular jet nozzle: Spraying width max. 120 - 150 mm, Discharge capacity 30 - 70 g/s
Glass metering: Local addition
Glass cutting length: From 6 mm
Mixing head: MK 10-2K-S

Electrical mold carrier with foam mold

Mold carrier for instrument panel: Efficient in individual and series production
  • Intelligent operating concept for simple handling and high level of flexibility
  • Dynamic and low maintenance thanks to electric drives
  • Excellent ergonomics
  • Short cycle times
  • Low energy consumption
  • Standardized modular design for quick assembly and commissioning
Width: 3.900 mm
Depth: 1.660 mm
Height (closed): 2.490 mm
Clamping force: 400 kN
Long parallel stroke: 1.100 mm
Clamping force stroke: 5 mm
Closing time: < 3 s
Foam mold: KraussMaffei in series operation at the Company Reydel

4-way mold carrier with foam molds

For producing small trim parts
  • Excellent driving dynamics with servo motors
  • Simple mold change
  • Decentralized human machine interface (HMI)
  • Air cushion selectable in proportional technology
  • Choice of reliable Siemens or SEW drives
  • Up to eight vacuum circuits possible
  • Modular pneumatic equiqment
Mold carrier: Four mold places
Clamping force: 34 kN
Closing time: ≤ 3 s
Opening angle: 0° to 90°
Mold cartridge tilting angle: -10° to 30°

PX 25-55 SilcoSet with sprue picker SPX 10

Compact and high-precision micro-injection molding with LSR
  • Special micro-plasticizing for LSR
  • Maximum precision for miniature components thanks to PX and APC plus
  • Consistent compact design: from the metering unit to the gripper
Clamping force: 250 kN
Screw diameter: 12 mm
SilcoSet technology: Low-maintenance processing of LSR
Automation: Servomotor-controlled sprue picker SPX 10
Sealing ring, 4 cavities
Shot weight: 0,6 g
Material: Liquid silicone Silastic RBL-9200-50
Cycle time: ca. 12 sec.
  • ACH solution GmbH
  • AVR Tech Innovations GmbH
  • GWK Gesellschaft für Wärme und Kältetechnik mbH
  • DOW SILICONES DEUTSCHLAND GMBH
  • MiniMix ACH solution GmbH

PX 320-2000 In-Mold Decoration with industrial robot IR 60 R1610

Flexibility meets maximum output for decorated functional component
  • Additional back injection of printed electronic IML
  • PX with 3,200 kN clamping force
  • IMD turnkey automation concept with UV curing, burr cleaning and more
  • Twofold film feed unit with independetn film positioning
Clamping force: 3.200 kN
Screw diameter: 60 mm
Conveyor: Incl. integrated UV curing
Industrial robot: Incl. laser cutting and flake removal
HMI display
Cycle time: ca. 43 sec.
Shot weight: 136 g
Material: PMMA ZK5BR, Dekorfolie mit Einzelbild, Dekorfolie mit Anti-Glare-Effekt
  • LEONHARD KURZ Stiftung & Co. KG
  • Evonik Performance Materials GmbH
  • motan-colortronic gmbh
  • HB-THERM GmbH
  • Datronik Laser & Automation Solutions GmbH & Co. KG

MX 1600-12000 with linear robot LRX 500

Lightweight, paintable components in a single step
  • Weight reduction of 15 % thanks to glass hollow balls compound from 3M
  • Cascade injection molding with maximum precision thanks to FlexFlow hotrunner control
  • APC plus for repeatable mold filling
  • MX series: Powerful, versatile, durable
Clamping force: 16.000 kN
Screw diameter: 120 mm HPS
APC plus: Adaptive process control for excellent mold filling
Spoiler

Partner: Inglass S.p.A., 3M Deutschland GmbH, A. Schulman GmbH, motan-colortronic gmbh, SINGLE Temperiertechnik GmbH, HRS Inglass S.p.A. FlexFlow, integriert in MC6-Steuerung

Cycle time: Approx. 48 s
Material: Polyfort PPC MGB6 H1
Shot weight: 1.100 g

GX 650-4300 FiberForm with industrial robot IR 600 R2030 F/K and IR 900 R3700 S/K

FiberForm: Lightweight construction in large-scale production

Partners: KINGFA motan-colortronic gmbh SINGLE Temperiertechnik GmbH

  • Short cycles thanks to decoupled process steps
  • Synchronous and homogenous heating thanks to intelligent oven control
  • Transparent processes thanks to higher-level process control
Anwendung: Querträger
Material: GFPP-L40 DMBK005 KE-SX020 BK
Schussgewicht: 1.015 g
Clamping force: 6.500 kN
Screw diameter: 90 mm
Infrared heating station: Homogenous heating with integrated heating zone control
Automation concept: FiberForm, concept 3, optimized, standardized concept based on component size

CX 160-750 Direct processing procedure

Material mixing directly on the injection molding machine
  • Tailored material properties
  • Define or adjust recipes yourself
  • Massively reduce material costs
  • Material cost savings of exhibit part: “ejotherm VT 2G combination washer” approx. € 0.35 / kg
Clamping force: 1.600 kN
Screw diameter SGM: 50 mm
Screw diameter (Single screw extruder): 30 mm
ejotherm VT 2G Kombiteller

Partners:EJOT HOLDING GmbH & Co. KG, LANXESS Deutschland GmbH, 3B-the fibreglass company, Exipnos GmbH, motan-colortronic gmbh, gwk Gesellschaft Wärme Kältetechnik mbH

Material: B40F (PA6) 47.0 %, DS1125 10N (glass fiber) 50.0 %, Flow medium 1.0 %, Masterbatch Blue 0.3 %, UV stabilization 0.5 %
Shot weight: 100 g
Cycle time: Approx. 20 sec

CX 200-750 HTV with linear robot LRX 150

Continuous excellently controlled processes for HTV applications
  • Excellent, bubble-free metering for HTV applications
  • AZ50 material feeding unit with stuffing pressure control for continuous material supply
  • Precise mold filling with APC plus
Clamping force: 2.000 kN
Screw diameter: 50 mm
Special equipment HTV: SilcoSet technology package
Automation: LRX technology with fixed X-axis and temperature-resistant gripper and conveyor
Sealing mat, 8 cavities

Partners: RICO GROUP GmbH, Wacker Chemie AG, Regloplas AG

Material: Solid silicone Elastosil R plus 4001/40
Shot weight: 72 g
Cycle time: Approx. 78 sec

PX 160-750

Flexible configuration – fast and simple production
  • Higher injection speed for optimal mold filling for thin wall thicknesses
  • Flexible use of molds thanks to larger mold height / opening width
  • Encapsulated drives and electric ejector for ultimate cleanness
Clamping force: 1.600 kN
Screw diameter: 50 mm
Ejector: Encapsulated, electric
Blood vials, 24 cavaties

Partners: FOSTAG Formenbau AG, motan-colortronic gmbh, gwk Gesellschaft Wärme Kältetechnik mbH

Cycle time: Approx. 6,8 s
Material: PET
Shot weight: 115 g

PX 50-180 with sprue picker SPX 10

Flexibility meets cleanliness: The PX for medical technology
  • All-electric machine and servomotor- controlled sprue picker as compact production cell
  • Absolute process stability thanks to ultra-precision PX injection unit and APC plus
  • DataXplorer for documentation, analysis, and tracking of process data
Clamping force: 500 kN
Screw diameter: 30 mm
Sprue removal: Integrated sprue picker SPX 10
Sprue and parts chute: Integrated in machine housing
Cannula, 16 cavities

Partners: Total Petrochemicals & Refining SA/NV, UniformColorCompany

Cycle time: Approx. 14,5 s
Material: PP
Shot weight: 8,2 g

GX 650-8100 Speed with linear robot LRX 350

GX Speed: Short cycles with long strokes
  • Optimized hydraulics for very fast clamping movements
  • High-performance screw for high throughput
  • Film gate nozzle for very fast injection performance
  • Extensive parallel functions
Clamping force: 6.500 kN
Screw diameter: 115 mm
APC plus: Adaptive process control for optimal mold filling for thin-walled products
Raised machine bed: Option for flexible parts transport
Popcorn / Flower pot

Partners: Haidlmair GmbH, Braskem Europe GmbH, UniformColorCompany, motan-colortronic gmbh, gwk Gesellschaft Wärme Kältetechnik mbH

Shot weight: 90 g
Material: PP C7069-100NA
Cycle time: Approx. 10 sec incl. removal

CXZ 160-380/180 Multinject with Kuka Agilus sixx

OptiSys: Development of optical multilayer parts

Partners: FWB Kunststofftechnik GmbH, Kugler GmbH, Hella KGaA Hueck & Co., Fraunhofer-Institut für Werkstoffmechanik

  • Perfect melt treatment by in-house developed plasticizing units
  • Reliable layer injection molding using rotary table technology
  • Dynamic mold temperature control
Application: OptiSys Demonstrator lens 1+1+1
Material: PMMA 8N (PLEXIGLAS®)
Shot weight: 125 g
Clamping force: 1.600 kN
Screw diameter: 35 / 28 mm
Turntable: 3-station (rotating)

CX 300-1400 Direct processing procedure with IR Kuka KR30KS

Long fibers at low costs
  • Monitored cutting of filaments and homogeneous fiber distribution
  • Newly developed screw technology for gentle fiber processing
  • High mechanical component characteristics
  • Material cost savings of € 0.43/kg (exhibit) compared to standard injection molding with long fiber granulate
Clamping force: 3.000 kN
Screw diameter: 55 mm
Test pieces, 1-cavity

Partners: Borealis Polyolefine GmbH, Owens Corning AG, motan-colortronic gmbh, ONI Temperiertechnik Rhytemper GmbH

Material: Borealis PP BJ400 HP
Bonding agent: WG068AE-9501
Glass fiber: Owens Corning SE4850
Fiber content by weight: 30 %
Shot weight: 229 g
Cycle time: Approx. 55 s

New linear LRX small robot

Progressive. Productive. Efficient.

Your customized demolding robot thanks to a wide range of product variants.

  • Innovative lightweight design
  • Modular expandability of functions, media and sensors
  • High level of availability thanks to intelligent energy management system
  • Maintenance-friendly design allows optimal access to essential assemblies

PX 80-380 Dynamic Mold Heating with linear robot LRX 50

Efficient production of high-quality component surfaces
  • Inductive, dynamic mold heating, HD Plastics™
  • Maximum energy efficiency thanks to drives with energy recovery
  • Minimal compressed air consumption thanks to linear robot with air-saving function
Clamping force: 800 kN
Screw diameter: 40 mm
Closed lubricant circuit: For cleaner mold area
TV box, hologram demonstrator

Partners: RocTool S.A., SABIC Innovative Plastics, motan-colortronic gmbh, ONI Temperiertechnik, Rhytemper GmbH

Material: PC Lexan 123 R
Shot weight: 36 g
Cycle time: Approx. 32 s

GX 400-2000 with industrial robot IR 600 R2030 F/K

GX and IFW: Fast and efficient production of fitting elbow pipes
  • Space-saving „Smart Ejection“ mold concept with efficient clamping force
  • Complete BluePower package for more energy-efficient production
  • GearX and GuideX for fast and precise clamping movements
Clamping force: 4.000 kN
Screw diameter: 70 mm HPS
Euromap 78 interface: Prototype OPC-UA interface
Automation: Complex removal with 8-part gripper, optimized lightweight design
Fitting with DN 50/45° pipe elbows

Partners: ifw mould tec GmbH, Borealis Polyolefine GmbH, UniformColorCompany, motan-colortronic gmbh, gwk Gesellschaft Wärme Kältetechnik mbH

Shot weight: 364 g
Material: PP BA204E
Cycle time: Approx. 24 sec

GXW 650-4300 ColorForm with industrial robot IR900 R2700

ColorForm: Complete package for perfect high-gloss surfaces
  • Single-step process for painted components in Piano Black without downstream steps
  • Unique, fully integrated PUA / PUR machine
  • MC6 for central control of all process steps
Clamping force: 6.500 kN
Screw diameter: 60 mm
Paint metering and color integration: Reduced footprint by approx. 20 %
Control: Central integrated control of all processes with MC6
Door trim

Partners: WOOSUNG Precision Co. Ltd., Trinseo Netherlands B.V., Rühl Puromer GmbH, motan-colortronic gmbh, HB-THERM GmbH

Material: PC/ABS: PULSE™ AX50 PUR puroclear 2381 IT
Shot weight: 300 / 60 g
Cycle time: Approx. 60 s

CX 80-380 with linear robot LRX 100

Compact, efficient, flexible: The CX series
  • Highly efficient drive concept and state-of-the-art clamping hydraulics
  • Intelligent energy management and BluePower efficiency packages
  • Compact floor space and lots of space for peripheral equipment
Clamping force: 800 kN
Screw diameter: 40 mm
Pump concept: BluePower servo drive
MC6 control options: Graphics analysis package and energy/performance data logging
Set square

Partners: HASCO Hasenclever GmbH + Co KG, Total Petrochemicals & Refining SA/NV, UniformColorCompany, Werner Koch Maschinentechnik GmbH, gwk Gesellschaft Wärme Kältetechnik mbH

Shot weight: 50 g
Material: PS CRYSTAL 1340
Cycle time: Approx. 29 sec

CX 80-380 with linear robot LRX 150

Compact, efficient, flexible: The CX series
  • Highly efficient drive concept and state-of-the-art clamping hydraulics
  • Intelligent energy management and BluePower efficiency packages
  • Compact floor space and lots of space for peripheral equipment
Clamping force: 800 kN
Screw diameter: 40 mm
LRX with full integration: Uniform control via MC6
APC: Adaptive process control with holding-pressure profile
Lid for system box

Partners: Total Petrochemicals & Refining SA/NV, Werner Koch Maschinentechnik GmbH

Shot weight: 31 g
Material: PS CRYSTAL 1340
Cycle time: 28 sec

CX 80-380 with linear robot LRX-S 150

Compact, efficient, flexible: The CX series
  • Highly efficient drive concept and state-of-the-art clamping hydraulics
  • Intelligent energy management and BluePower efficiency packages
  • Compact floor space and lots of space for peripheral equipment
Clamping force: 800 kN
Screw diameter: 40 mm
MC6 control: Graphic analysis package
Additional variable speed pump: Other parallel movements
System box

Partners: Total Petrochemicals & Refining SA/NV, UniformColorCompany, Werner Koch Maschinentechnik GmbH

Shot weight: 80 g
Material: PP
Cycle time: Approx. 30 sec