Cosmetic Tube Technology
Asiamold 2013 closes with exceptional praise
The world of injection moulding was the guest of BOY
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Weathering Testing - The Track to Faster Results
Mold-Masters Accelerates its Automotive Molding
Cosmetic Tube Technology
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High Expectations Exceeded at K 2013
Soul & Solutions for Your Success
35 Empresas Polar, Venezuela, doubles output
Vol.1 No. 2 | November-Decmber 2013 | New Delhi, India
Annual subscription: US$100 Managing Editor Sarvjit Associate Editor & Public Relations Director Reny Joint Editors Vishwapreet Amrita Advisor Rajiv Sanghavi Production Rakesh Marketing & Communications Surinder Circulation Surekha Design, Art & Web Development Diamond Infomedia Correspondents Germany - Sandra UK - Mike Steele Australia - Andy McCourt Netherlands - Alex & Lilly China - Ying / Adrian Indonesia - Upi Thailand - Amy For advertising, subscribing or to submit a press release, contact us: info@plasticsandrubberreview.com
Successful Trade and Innovations Show The rubber industry is delighted at the success of the trade and innovation show. Its own “Rubber Street”, over 400 exhibitors with rubber / TPE
Head Office: Plastics & Rubber Review D-182, PR House, Anand Vihar, 110092 New Delhi - India. Tel : +91 11 22141542 / 4309 4482 Fax: +91 11 22160635
coatings: from the perspective of rubber processing firms the K trade fair
Published, printed, & owned by S. Singh, on behalf of Milinia Inc. at
remains a central international hub for meeting upstream suppliers. After
D-182, Anand Vihar, 110092, New Delhi, India and printed at
a comparatively subdued trade fair year in 2010 the K trade fair has now regained its previous strength and has even reinforced its position. Therefore, the K fair once again lived up to its reputation as the leading fair in the sector.
Technical Press, D-182/C, Anand Vihar, 110092, New Delhi, India. Views expressed in this magazine are of the contributors, authors and companies and not necessarily of the publisher and/or editors’ and they do not take any responsibility for the errors and/or accuracy of the information published in this publication. No part or design of this magazine can be reproduced without prior permission of the publisher, who reserves the right to use the information published in this magazine in any manner whatsoever.
Plastics & Rubber Review | November-December 2013 | 3
W E A T H E R I N G
High Irradiance Weathering Testing - The Track to Faster Results Atlas Material Testing Technology, the global leader in weathering technology and services, presents state-of-the-art research and the latest industry knowledge on high irradiance weathering testing. “Significant reduction of testing time is a key challenge in weathering. With instruments capable of high irradiance testing, like Atlas’ Ci5000 HE Weather-Ometer®, Xenotest® Alpha+, the brand new Xenotest® 440, and our Solar Environmental Chambers, we offer unique ways of reducing test times to our customers,” said Andreas Riedl, Director of Atlas Global Consulting. Recently, Atlas launched www.high-irradiance.atlas-mts.com, a site devoted specifically to the topic of high irradiance testing providing visitors the ability to easily contact Atlas to receive further information including a brochure, case studies and articles on the topic. “What drives our efforts is our strong desire to provide our customers with as much information as possible and assist them in defining the best solutions for their testing needs,” said Sandra Schneider, Global Marketing and Client Education Manager at Atlas. For more information about Atlas weathering testing equipment and services, including high irradiance testing options for laboratory and outdoor weathering, visit Atlas online at www.high-irradiance.atlas-mts.com or contact atlas.info@ametek.com.
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oday, only companies that can quickly introduce superior products to the market are able to survive a globally competitive environment. Accelerated and accurate weathering testing is a critical component in product development for any material expected to withstand the damaging effects of sunlight, heat, and moisture. Weathering testing at higher irradiance levels than the normally applied “1-sun” can produce degradation results in a much shorter period of time. Currently, many basic laboratory weathering standards allow up to 3-sun testing. The benefits of high irradiance testing are obvious: • Shorter test times • Larger sample turnover • Lower testing costs • Faster time to market • Earlier failure detection • Reduced risk of extrapolation
4 | November-December 2013 | Plastics & Rubber Review
About Atlas Material Testing Technology – www. atlas-mts.com Atlas is a recognized leader in material testing, offering a complete line of instruments and services for accelerated and natural weathering. In addition, the Atlas Consulting Group helps clients from various industries, including photovoltaics, coatings, plastics, textiles, automotive and cosmetics develop the best weathering processes for their products. Atlas is a unit of AMETEK Measurement & Calibration Technologies, a division within AMETEK’s Electronic Instruments Group, a recognized leader in advanced monitoring, testing, calibrating and display instruments. AMETEK, Inc. is a global leader in electronic instruments and electromechanical devices. Atlas Material Testing Technology is ISO 17025 and ISO 9001:2008 registered. Atlas products are designed and manufactured to conform to international, national and industry standard test methods including ISO, ASTM, DIN, JIS and numerous others.
AUTOMOTIVE|MOULDING
Mold-Masters Accelerates its Automotive Molding Offerings with Expansion of the Fusion G2 Line. Mold-Masters, the leading supplier of hot runners and process control solutions, exhibited its new Fusion G2 F7000 Nozzle among other updates and improvements to the Fusion G2 line up at the recently held K 2013 show in Germany. Mold-Master showcased the new Fusion G2 F7000 nozzle as part of their already impressive automotive offerings. The F7000 nozzle is equipped with new heater technology and is sure to impress automotive and large part molders. “Mold-Masters is committed to continued growth and innovation with respect to our automotive and large part product line up. There are some exciting developments featured here at K and some more to follow in the coming year.” said Enrique Moya, Global Automotive Market Manager. The new F7000 series offers nozzles up to 1,000 mm long as well as new gating styles. The Fusion G2 product line now has field replaceable heaters allowing for easy service and most importantly less downtime. Continuing with the theme of ease of serviceability, the wire channels have been completely redesigned. The new protection offers increased durability and wire organization but doesn’t compromise the ease of access for service with fully removable covers.
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Cosmetic Tube Technology
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isitors to K-2013 saw the newest 360°seam™ and Inviseam® technologies running on the latest cosmetic tube equipment from PackSys Global as well as RedCube, the latest in digital printing in collaboration with HAPA Swiss Printing Technologies. Living its motto, ‘Creating Packaging Technology’, PackSys Global presented its latest cosmetic tube offerings at K-2013, including the new 360°seam™ technology, the latest development in cost effective Cosmetic Laminate Tube technology. This technology produces cosmetic laminate tubes with 360° printing. The 360°seam technology will run on PackSys Global’s new CT 80, the latest cosmetic tube line from PackSys Global. This line comprises a CTS 80 side-seamer coupled with an LSH header; specifically designed to cost effectively produce small batches of high quality cosmetic laminate tubes. With production of up to 80 cosmetic laminate tubes per minute, the machine is ideal for customers producing small batches, or startup businesses. It has a highly stable, perfectly accurate seaming process which incorporates all the decoration possibilities and advantages of flat printing. The CTS 80 side-seamer is one of PackSys Global’s new family of CTS side-seamers, which also includes the CTS 125, operating at up to 125 tubes per minute. PackSys Global is also demonstrated its renowned Inviseam® technology. Inviseam® technology renders the seam almost invisible, allowing laminate tubes for the cosmetic industry to give the same feel and appearance as extruded tubes.
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For the first time at K-2013, PackSys Global demonstrated the latest in digital printing in collaboration with HAPA Swiss Printing Technologies. RedCube, is a compact UV DOD (drop on demand) inkjet printer for high-end marking, gold winner of the International Forum Packaging Awards in 2011. Besides the technical developments, PackSys Global also be displayed its latest remote customer support solutions; EagleOwl™ and e-Portal. EagleOwl™ is PackSys Global’s remote service solution, allowing customers to receive real-time online assistance. PackSys Global engineers can connect directly to customer equipment over a secure network. The engineers can see the equipment “live”, reconstruct recent events, modify machine parameters, install new software and talk directly to client personnel at the machine. All this enables more accurate and faster customer support. e-Portal is a secure 24-hour online service platform containing the latest updated customer documentation: detailed, illustrated product information, and a direct order inquiry service for spare parts. PackSys Global is a trendsetter
within the cosmetic industry and continues to be the only manufacturer able to offer a complete cosmetic tube line. The portfolio covers tube heading machines, tube capping and finishing machines and decoration machines for extruded plastic tubes. This is backed up by its global network of well-established customer service centers and a highly-qualified, experienced field service network. Services encompass the complete portfolio: equipment installation, training, preventative maintenance, planning services, hotline advice and remote service. PackSys Global designs and builds full lines for manufacturing and decorating laminate and cosmetic tubes, plastic beverage caps, aluminum screw caps, aluminum tubes, and aerosol cans. Its advanced packaging equipment is ideally suited for beverage, cosmetic, pharmaceutical and industrial markets. PackSys Global presented the latest technical developments in its plastic beverage cap portfolio launching its new SPM 35 slitter at the Drinktec exhibition in September. This is the fastest plastic closure TE-band finishing machine on the market.
New standardised hot runner manifold concept
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ASCO is presenting a completely revised hot
melt channel deflections and as
metrical nozzle configuration on a
runner concept for the first time at K2013. This
plugs on the manifold bars. This
square, with a maximum distance
offers a very wide range of options for the
guarantees a leak-free manifold
of 315 mm possible for the nozzle
layout of a hot runner system, despite the dif-
and optimum passage of the melt
spacing.
ferent, standardised outside dimensions of the
through the deflection, while
manifold blocks.
ensuring that the molten polymer is
Hot runner systems based on the
subject to only minimal shear.
new, standardised manifold con-
Not only can the hole distances for the nozzles be freely selected within the pre-defined limits
The H4000/... manifold concept
– HASCO also tailors the flow channel cross-
takes in a series of manifold geom-
sections in the manifolds to the application in
etries. Simple deflector manifolds
question. The H4000/... manifold concept is
are supplied for nozzle spacings
combined with the nozzle series in HASCO’s
from 35 mm to 440 mm. Natu-
current nozzle range to provide high-quality hot
rally balanced manifolds for 2 or 4
runner systems that meet the most stringent of
nozzles arranged in a row can simi-
requirements for injection moulding production.
larly be supplied with a maximum distance of 440 mm between the
The HASCO turn plugs that have been success-
outside nozzles. The cross-shaped
fully used for many years are employed for the
manifolds are designed for a sym-
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cept H4000/... offer an outstanding price to performance ratio. They are also the answer to tightly scheduled mould projects, since they can be supplied within just a few working days. Our specialist advisers and application engineers will be pleased to assist you in selecting the right hot runner system for your application.
S H O W | R E P O R T
High Expectations Exceeded at K 2013 • Many Pioneering Innovations prompting a Remarkable Number • Exhibitors anticipate Strong Post-Fair Business
worth millions. Chairman of the Exhibitors’ Advisory Board for K 2013 Ulrich Reifenhäuser was extremely pleased with the results: “We had not expected visitors’ willingness to invest to be this high! The many innovative products and applications premiered in Düsseldorf met with great interest from trade visitors. And the innovations were not just admired as many, very concrete negotiations were held and contracts were signed. Many customers are extending their capacities and are investing in new technologies to sharpen their global competitive edge. We very confidently anticipate strong postfair business and expect continuing growth in our sector.”
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t was with great expectations that companies from the plastics and rubber industries came to Düsseldorf, to the world’s most important trade fair in their sector, K 2013. The upturn experienced in the sector for months now along with the confidence of its companies to be able to showcase pioneering product innovations for all sections of the value added chain raised justified hopes of a good fair and brisk post-fair business. And these expectations were actually even exceeded over
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the eight days of the trade fair. Exhibitors reported unanimously on numerous concrete project enquiries, intense negotiations with trade visitors from throughout the world and a remarkable number of business deals, some of which were concluded instantaneously and quite a number of which were
This view was echoed throughout all areas of the fair and shared by the over 3,200 exhibiting raw material producers, processors and machinery producers to an equal extent. Exhibitors particularly highlighted the now even wider international spread of visitors and their great specialist expertise plus the fact that a disproportionately high number of top managers had made the journey to Düsseldorf. The some 218,000 trade visitors to K 2013 came from well over 120 countries. Werner Matthias Dornscheidt, President & CEO
S H O W | R E P O R T
of Messe Düsseldorf, delighted along with his team at the excellent response: “Once again it becomes very clear that K is and remains the most important event in the rubber and plastics industry! This is where new technologies are premiered alongside fully matured further developments and this is also where orders are placed for these innovations. Foreign visitors to K 2013, in particular, showed an extremely high willingness to invest and one in two visitors came to Düsseldorf with specific purchasing intentions in mind. Even if the size of delegations from the individual purchasing companies dropped slightly, no firm producing or using plastic goods missed this chance to find out about the innovations of today and the trends of the future at K 2013.” The previous event in 2010 saw 222,486 visitors and 3,094 exhibitors taking part. Results from the visitor survey also underpin this view held by exhibitors that the international flair of visitors has risen once again: 58%, i.e. 126,000 trade visitors, came from abroad. Just under half of all foreign visitors came from overseas – travelling to Düsseldorf from as far away as Angola, Burkina Faso, the Falkland Islands, the Yemen, Malawi, Nepal, New Caledonia, Oman, Peru and Turkmenistan. As expected, the
proportion of trade visitors from Asia accounted for the largest group of foreign visitors – some 30,000 specialists came to the Rhineland from South, East and Central Asia as well as from the Near and Middle East. Visitors from India were once again the largest group here while the number of trade visitors from China, Indonesia, Iran, Japan and Taiwan rose considerably. Also posting a significant plus was the proportion of visitors from North America: some 8,100 visitors were registered from the USA and Canada – 1,300 more than at K 2010. Some 11,000 specialists came from Latin America, i.e. about as many as came three years ago. Forming the largest contingent were experts from Brazil, Mexico, Argentina and Colombia. Another gratifying increase was also noted in the number of visitors from South Africa with some 2,000 hailing from there. Amongst visitors from neighbouring European countries the Netherlands dominated with 8,000 visitors followed by France, Belgium, Great Britain and Italy. There was also a noticeable rise in interest from Poland, the Czech Republic and Hungary. Across all national borders there was a disproportionately high
number of managers amongst trade visitors: about two-thirds came from top or middle management. Well over half played a decisive or co-determining role in their companies’ investment decisions. The proportion of visitors from research, development and design was also considerable.
industry and vehicle construction, packaging as well as electrical and medical engineering through to agriculture. Overall, visitors to K 2013 gave their best grades to the range on show in the 19 halls of the exhibition centre: 96% affirmed that they had fully achieved the goals of their visit.
Solutions for saving resources and energy efficiency dominate many product launches and the sector is marked by a desire to manufacture products in an environmentally friendly yet cost-effective way. Machinery and plant construction, the largest exhibiting sector at K 2013 with some 1,900 exhibitors, was also at the focus of visitor interest: just under two-thirds of all visitors polled said they particularly wished to gather information on the innovations in this sector. For 42% of trade visitors the presentations of raw and ancillary material producers were of prime interest while 22% mainly directed their attention to semi-finished goods and technical components made of rubber and plastic (multiple responses possible). Visitors came from all key user sectors – from the building
Special Show “Kunststoff bewegt – Plastics move the World” Also meeting with great interest amongst trade visitors from throughout the world was the K 2013 special show entitled “Kunststoff bewegt – Plastics move the World”. This show highlighted the contribution made by plastics to a “life in movement”. The aim here was to address the direct contribution of plastics to the varied facets of mobility as well as emotional movement – for instance, by way of art and design. Future-oriented issues revolving around the major themes of population growth, energy needs and climate change were also discussed. The stand opening on 16 October saw Germany’s former Foreign Minister Joschka Fischer discuss the issue of sustainability.
The next K Düsseldorf will be held from 19 to 26 October 2016. Plastics & Rubber Review | November-December 2013 | 13
K 2013 Show Glimpses!
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K 2013 Show Glimpses!
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The Indian Flag Flies High, Rajoo Abilities Receive Global Acclaim At K-2013 Visitors were in awe of the high quality of five layer blown film plant, the live production of the barrier film aided by an aggressive price approach that was unleashed at K. The large team of Rajoo manned the stand and addressed needs of the blown film industry with aplomb.
Unprecedented response, Rajoo Engineers on a high after K-2013! With efforts lauded, products appreciated and approach well understood, visitors to the Rajoo stand took away much more than what they expected. It all began when Peter Krieg, President, Hosokawa Alpine, Germany, the technical collaborators of Rajoo, inaugurated the stand. Visitors were in awe of the high quality of five layer blown film plant, the live production of the barrier film aided by an aggressive price approach that was unleashed at K. The large team of Rajoo manned the stand and addressed needs of the blown film industry with aplomb. 16 | November-December 2013 | Plastics & Rubber Review
The barrier film output rates and quality, machine workmanship, stand aesthetics, very commonly drew a question from the visitors, ‘Is Rajoo a European company?’ … a recognition par excellence. The wide product range and the Rajoo dominance and leadership status in the Indian market had its impact. As regards Blown Film Lines, the three broad solution categories offered – Economical, Balanced and Advanced met every processor’s requirement, coupled with the
luxury of choice. The intensity to do business was evident when it was noticed that Rajoo was the only company at K 2013 constantly producing nylon based barrier films at the stand with its five-layer blown film line. The unique positioning of a ‘One Stop Solution Provider’ turned out to be a processors’ delight, as they believed that this approach would well-address their current concerns. Another aspect being high
prices of European machines coupled with the appreciation of the Euro with respect to domestic currencies. Rajoo, in its own way added another BRIC(K) to BRICS when the machine showcased at K 2013 was sold to Nylopack, Republic of South Africa. ‘We are really happy with the machine which we bought from the K platform and Rajoo will remain as a preferred supplier to Nylopack for future expansions as well’, says Peter Rousouw, Director, Nylopack, RSA. ‘For Rajoo, it is a matter of honour to be supplying our line to a company as eminent as Nylopack and that too from the prestigious K platform which offers wide choices to processors ’, elaborates Khushboo Doshi , Executive Director , Rajoo Engineers Ltd.
At a time when the footfall from the plastic processing industry at K 2013 was apparently lower when compared to last time, the Rajoo stand was larger with an increase in quality visitors by over 30% in a similar comparison.
The Rajoo showcase at K 2016 is expected to be much larger than this ‘K’, a clear signal of the impact that Rajoo Engineers made at K 2013! With the success of this prestigious show, Rajoo pays another tribute to its Mentor and Founder, Mr. Chandrakant N. Doshi.
About Rajoo Based in Rajkot, Rajoo Engineers Limited, having made a modest beginning in 1986, has today emerged as an undisputed global player in blown film and sheet extrusion lines. Owing to its focused efforts in blown film, sheet extrusion lines and thermoformers, the Company
With a significant momentum gained at K 2013, Rajoo lost no time in aligning with a German partner M/s Maschinenbau Heilsbronn, one of the last small machine manufacturers in the German segment. This company, offers to German speaking Europe, an optimal and highly efficient range of machinery for blown film and sheet lines. With this relationship, spare parts and services for Rajoo machines will be provided by the local sales and service centres. The customer will have the advantage of an efficient ‘German-speaking Service’ now at an optimum price/performance ratio.
enjoys premium market position in this segment. Being a technology driven Company, product innovations, adaptation, world-class quality, state-of-the-art workmanship, increased energy efficiency and high levels of sophistication and automation have become the hallmark of Rajoo products during all these years, positioning the Company’s products on a global platform, competing with the established world leaders. With representations in many countries of the world and customers in over 53 countries, the Company’s exports have multiplied after its debut in the international market in 1990. (www.rajoo.com)
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K 2013 Show Glimpses!
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S H O W | R E P O R T
Asiamold 2013 closes with exceptional praise from industry players than 30 solid business leads by the second day. There’s a great deal of customers for us in China and Asiamold provides a great venue to meet them.”
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oncurrent fringe events promoted emerging innovations in mould making technology Asiamold, the Guangzhou International Mould & Die Exhibition, successfully concluded its seventh edition with one of the show’s most diverse collection of mould and die suppliers to date. Held from 24 – 26 September at Poly World Trade Centre Expo in Guangzhou, the show hosted 350 firms from 13 countries and regions, who utilised 20,000 sqm of exhibition space to showcase their latest assortment of products and solutions. Manufacturing firms represented a large portion of visitors to the show, with production specialities including automobiles, electronics, home appliances, aeroplanes and associated components, ship building, telecommunications,
consumer goods and medical devices. In total, 17,289 professionals visited the three-day event, as well as more than 60 visitor delegations from companies such as Adidas, BYD, Osram and Toyota, reaffirming the importance of Asiamold to the region’s growth. Mr Louis Leung, Deputy General Manager, Guangzhou Guangya Messe Frankfurt Ltd commented: “I am very pleased with the overall participation figures for exhibitors and visitors this year. Asiamold continues to prove its place as the annual destination for industry players to see all the latest trends in mould and die technology. The industry touches on so many important sectors in the regional and global economy. From my interaction with exhibitors and visitors, the 2013 show has served as a great tool in growing their businesses and making key
industry contacts.” Exhibitors at Asiamold were filled with praise for the show’s ability to connect them with their target audience. Whether they were selling moulds and dies or their ability to manufacture items such as plastic-injected goods or 3D-printed prototypes, the fair gave exhibitors the chance to promote their brands as well as educate customers on their unique benefits. Mr Akihiro Chiba, Section Manager for Takara Tool & Die Co Ltd, a first time exhibitor said: “We came to the show to expand our customer base for our injection mould and inserted mould products. Electronic manufacturers are our main customers, and we service some of the biggest names in Japan. The show has been very fruitful for us. We received more
Mr Jason Ma, Deputy General Manager, Shanghai Union Technology Co Ltd added: “We are a 3D printing company that works with DSM in providing prototyping services to a range of manufacturing businesses. It is our second time exhibiting at Asiamold. We came back because we received a great deal of business leads from our last participation. Our main goal was brand awareness, as the concept of outsourcing prototyping services is still fairly new with buyers of moulds and dies. Thanks to the support of DSM, we have been able communicate our sectors unique selling point as well as promote the benefits our company can offer. Asiamold was a great show for us to be a part of.” Fellow exhibitor, Ka Shui Manufactory Co Ltd, joined the show for a second year due to the high number of business leads their participation provided last year. Mr Nick Chen, Marketing Supervisor for the company noted: “This year our main goal is to export our die-cast and plastic-injected products to overseas car, camera, computer and telephone manufacturers. We are very satisfied with the performance of the 2013 show. We gained several great leads from just the first day and there were some fantastic discussions from visitors. I am sure we will rejoin the fair again in the future.” Visitors shared equal praise for the show’s ability to meet their sourcing needs as well as present new solutions that could help
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S H O W | R E P O R T
all the experts who are gathered at this occasion.” Mr Elvis Pang of Orion Technology Co Ltd in Shenzhen, an attendee commented: “I was very impressed by the level of topics discussed at the show’s fringe event’s this year. I attended several forums, and was able to learn that 3D printing technology, which is the area my company specialises in, is quickly gaining a lot of attention from mould manufacturers and buyers. I visit Asiamold every year, and I am looking forward to the next edition.”
grow their businesses. Mr Peer Christensen, Engineering Manager, Lego Company Ltd shared: “I came to Asiamold for the first time this year to source dies and moulds for our business. We currently produce our toys across Europe and North America, but will be opening up our first factory in China next year to grow our business in Asia. It is a good show with lots of variety. I’m sure I will continue to visit Asiamold as our production business grows in the country.” Another prominent visitor, Mr David Lu, Manager of Tooling for Footwear at Adidas Sourcing Limited commented: “I came to the show with my colleagues to look for the latest technologies and solutions to improve mould production in highquality footwear. We were surprised to have found some professional suppliers offering quality materials at a low cost. The show seems to have recruited more exhibitors specialised in 3D printing this year. We’ve had discussions with these firms and are glad to learn more about this fast-growing technology.”
Concurrent fringe events promoted emerging innovations in mould making technology Over the course of the three-day exhibition, a series of seminars and forums where held on emerging technologies and solutions in mould and die development. Through Messe Frankfurt’s Agora platform and the Third Asiamold Global Mold Making Technology Innovation Summit, 15 industry experts held discussions on topics ranging from 3D scan technology and its application for mould design to flexible manufacturing technology in mould production. Speakers and attendees shared equal praise for the insightful information made available. Mr Victor Clement, Member of the ISO 14006:2011 standard drafting group expressed: “I was invited to Asiamold to speak about my firm’s current standard in green development for mould and die products. The ISO 14006 standard is growing in popularity with Chinese mould and die-cast product makers, as they seek to enter European and American markets. I am very
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impressed with the quality of the show as well as the high level of knowledge on industry trends displayed by visitors. We had some great discussions from attendees.” Fellow speaker, Mr Ma Jie, Founder of Tianjin Vision Sensitive Technology Co Ltd said: “My company specialises in 3D scanning and is expanding the application into the moulding industry. Asiamold is an important trading hub and influential platform where I can introduce our technology and services. I am delighted to have exchanged ideas and thoughts with
Asiamold is organised by Guangzhou Guangya Messe Frankfurt in cooperation with EuroMold, the Hong Kong Federation of Innovative Technologies and Manufacturing Industries Limited and Guangzhou Die & Mould Industry Association. The show is also a part of an alliance with member shows in Africa (AfriMold), Asia (INTERMOLD Japan, INTERMOLD Korea), Europe (Euromold, RosMould) and the Americas (AmeriMold). The next edition of Asiamold will take place from 15 – 17 September 2014 at the China import and Export Fair Complex in Guangzhou. For more information, visit www. asiamold-china.com, or email asiamold@china. messefrankfurt.com
ASIA|MOLD|2013
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ASIA|MOLD|2013
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T E C H N O L O G Y
“Soul & Solutions for Your Success”
“Soul & Solutions for Your Success”– true to this motto DESMA presented itself more successfully than ever at the K 2013. In addition to the highlights like the two DESMA injection moulding machines of the S3 series, DESMA also had innovations on display such as the multiple-axis hydraulics ServoGear and for the first time the EcoSilence temperature-control units. A new technology of DESMA which enables to save as much as 50 % of energy depending on article and production cycle as well as on the interaction with the DESMA EnergyControl software. Hefty material saving potential is provided by DESMA with the innovative cold runner systems. In addition to the patented FlowControl cold runner block, which won the Product Award of the German Rubber Society in 2006, the ITM-pot ZeroWaste was given this Award as well in 2012. Out of the vision K 2010, DESMA was able to offer the forward-looking MoVis system for process automation at this year’s K show. This is a highly efficient mould surface scanner to optimize the service life of moulds.
The ease of optimizing and controlling machine processes is shown by DESMA with the extended Propter system. A service feature which is provided for a defined period and for certain needs e.g. when launching new articles or optimizing existing processes. Jointly with RheinChemie, DESMA, moreover, exhibited the BlendIn method: an innovative concept for the continuous production of rubber compounds. The DESMA e-training was given its premiere in Düsseldorf and also the
first edition of the DESMA compendium „Basics for elastomer injection moulding“ was presented to the public. Thus, DESMA not only offers the classical range of courses, but also provides the customers with possibilities of having access to tailored know-how. DESMA sets the focus on „Performance – Productivity – Profitability“. This is not only confirmed by the strong visitor turnout, but also by the large number of generated leads. To sum it up: the K 2013 was really a great success for DESMA!
Strategies for success in elastomer technology For 40 years DESMA has been a worldwide leading manufacturer of Injection Moulding machines for Rubber and Silicone. Apart from classical Vertical and Horizontal machines with Clamping Forces ranging from 250 kN up to 40,000 kN, Rotary table/ Stator and C-frame machines as well as Compression Presses are also produced. Breakthrough developments of the past years were the Innovative BENCHMARK clamping system for Vertical machines, the Patented FIFO-Injection system “A” and Cold Runner Block with hydraulic needle-shaped shut-off technology, ITM and the DESFLEX-system to minimise flash. DESMA is the world leader in Turnkey production systems and therefore has own effective Mould Design and Construction Centre. Due to a best-equipped technical rubber centre, optimum conditions for an efficient process development and customised trainings are given. Together with you we are engineering the best production solution. With our plant in India , USA and China we are rightly placed to cater the changing needs of Global Markets. Give us a try!
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W O R L D | N E W S
Cooper Tire shareholders approve sale to Apollo Tyres
GN THERMOFORMING EQUIPMENT PRESENTING THE LATEST GENERATION OF GN760 THERMOFORMERS
Cooper Tire and Rubber Co said its shareholders approved its sale to India’s Apollo Tyres , bringing the tire makers one step closer to completing their $2.5 billion deal. About 96 per cent of the shares that were voted at a shareholder meeting on Monday were in favor of the merger. The company said about 78 per cent of Cooper’s outstanding common shares were voted at the shareholder meet.
Michelin launches XZY3 HD tyre for commercial vehicles French tyre maker Michelin today announced the launch of its ‘XZY3 HD’, for commercial vehicle industry. XZY3 HD tyre, which aimed at improving mileage, fuel saving and safety, was unveiled at the three-day International Commercial Vehicle Fair here, Michelin said in a release. The new tyre would cater to the growing needs of fleet owners from multiple commercial vehicle segments and the tyre would deliver superior performance on Indian roads, the release said. Michelin XZY3 HD, which offers a reinforced bead design with more bead wires designed to better cope with heavy payloads, also helped in equal distribution of weight, reducing stress spots around the tyre which enabled longevity, it claimed.
GN Thermoforming Equipment Co. is a leader in roll-fed, in-mold-cut thermoforming machines, is featuring its second-generation GN760 Model, plug-assist, 60-zone, radiant heat machine. The machine boasts energy saving electronic regeneration, automatic chain-rail tensioning to reduce sag, twin servo motors and a rotary-driven toggle. The GN760 has a 30-inch by 21-inch (762 Millimeter by 533mm) forming area and is designed to be able to handle sheets up to 32 inches wide, in thicknesses varying fro, 0.001 to 0.5 inch (0.25 to 1.5mm). “We do in-mold cutting using common-edge knives,” an industry innovation that allows closer placement of individual items produced from straight or blended materials, said GN Thermoforming Marketing Manager, Mr. Jerome Romkey. Those materials include PET, High impact Polystyrene, Polypropylene, Polylactic Acid, PVC and Polyethylene/PET laminate. The GN760’s electrical consumption, compared with competitors’ equipment, is 35-50 percent lower, saving customers as much as $9,000 (about 6,300 Euros) per year, according to the company. The efficiencies have been realised by servo-driven plugging, transport, stripping and stacking. Those advances, according to GN, are integrated to improve high-speed de-nesting and stacking performance. GN currently owns the zone in radiant-heat thermoforming machines, with a 95 percent market share. The GN760 can also produce in an hour as many as 36,000 lids for takeout coffee cups and cold drinks. “As long as it’s ‘makeable’, we can make it,” Mr. Romkey said in a recent interview at the company’s headquarters in Chester. For More Details please contact: Satellite Plastic Industries, 2A2, Court Chambers, 35, New Marine Lines Mumbai 400 020 Phone: 022-22006477, 66346816; Fax: 022-22006556 Email : rajiv.satellite@gmail.com; Website: www.gnplastics.com
26 | November-December 2013 | Plastics & Rubber Review
T I R E | I N D U S T R Y
Pirelli have urged Formula One teams to give them the tools to do their job rather than complaining their tyres are not good enough The Italian company was again in the line of fire at the weekend’s Korean Grand Prix, with Ferrari’s Fernando Alonso and Red Bull’s Mark Webber complaining about how quickly the tyres wore out. The Italian company was again in the line of fire at the weekend’s Korean Grand Prix, with Ferrari’s Fernando Alonso and Red Bull’s Mark Webber complaining about how quickly the tyres wore out. McLaren’s Sergio Perez suffered an explosive delamination of his front right tyre during the race at Yeongam which left debris strewn across the track and brought out the safety car. The incident was reminiscent, in terms of drama, of the spate of blowouts earlier in the season that triggered safety fears and forced Pirelli to return to last year’s structure with 2013 compounds. Pirelli motorsport head Paul Hembery told reporters on Sunday there were no worries about the Perez incident but there was real concern about how the tyres would behave next year when the rules change significantly and a new V6 turbocharged engine is introduced. A planned tyre test with McLaren in Austin, Texas, before next month’s U.S. Grand Prix was cancelled after objections that it could favour the former champions, who are fighting Force India for fifth place overall.
race at Yeongam was marked by high degradation and heavy stress on the front rights, with drivers talking afterwards about how their tyres were effectively ‘dead’. Asked whether Formula One, which will allow some limited in-season testing next year after banning it previously to save money, was getting what it deserved, Hembery smiled wearily. “To an extent, yes,” he replied. “We’re still talking about trying to sort testing out and we’re in October. I just hope the engine manufacturers for next year have been able to do their work, and as they desire. “Otherwise the conversations we’ll be having might be with them next year - I hope not, for their sake.” Hembery said the new engine was likely to see a dramatic change in the application and delivery of power. Yet there were no plans to test tyres in wet conditions with the new cars before the start of the 2014 season, despite the regular risk of a tropical deluge at the second race in Malaysia. “There are things, as a sport, we need to improve on, which is something that is starting to be recognised. A number of the team principals have said we need to do something differently, and we obviously agree with that,” said Hembery.
Pirelli have done several tests, including a controversial ‘secret’ one with Mercedes in May, with teams providing older cars, but have repeatedly complained that they need to use more representative machinery. “We’re running around in a 2010 car, developing tyres for the 2014 car, which nobody really knows what it’s going to look like,” said Hembery. “Yet every time we even ask to test with a 2011 car we come up against opposition. “Going forward, to do what we need to do, we need to have the ability to test and help everybody - drivers and teams,” added the Briton.”Whilst nobody wants to think they’re going to get an advantage in testing, you can’t carry on going round in circles and decide to do nothing. Something has to change.” DEAD RUBBER Hembery said Pirelli wanted to reduce the amount of ‘marbles’ - small chunks of tyre rubber - that litter the track and increase the mechanical strength of the compound. To do that, they need to test at certain tracks with suitable conditions and also need teams to help them. Sao Paulo’s Interlagos circuit could offer one such opportunity after the season-ender there in November. Another option would be for Pirelli to test in Bahrain in January before two more scheduled pre-season tests there with all the teams in late February and early March. “Ideally at the end of the season we’d like to see some use of these (2013) cars because they’re the best and the quickest we’ve got at the moment,” said Hembery. “It would make sense to use them because for the majority of the teams they’ll be of little relevance anyway.” Sunday’s Plastics & Rubber Review | November-December 2013 | 27
TECHNOLOGY|AT|YOUR|DOOR-STEP
Automatic Pipe Bender BMS 63
The WITTMANN group at the Swiss Plastics in Lucerne
The WITTMANN group at the Swiss Plastics with high-tech injection molding technology and peripheral equipment
The BMS 63 is Sica’s automatic machine for bending and socketing with exceptional rapidity PVC pipes common in electronic and telephonic systems. In particular, this machine can process pipes with a diameter from 16 to 63 mm, with possible final length from 140 to 650 mm. The machine is equipped with a versatile multi-bender and multi-belling system that can bend with a variable angle between 90 and 0° (so, it can also avoid bending) and with bend radius from 1 to 5 times larger than the diameter of the pipe itself. At every end of each bend/pipe, the machine can also socket (through suitable thermoforming process) both solvent cement and O-Ring type (optional) in every desired configuration, such as: •
simple bend
•
bend with single socket end
•
bend with sockets on both ends (double socket)
•
straight unbent pipe with single or double socket
•
In this way, every possible production need can be satisfied.
The bending is hydraulic/pneumatic, and it is controlled through specific proportional valves and linear encoder that guarantees absolute precision and repeatability of the process. Every setting is automatically adjusted from the operational panel with the machine in operation, which prevents interruptions, manual changes or dangerous access into the unit. Security, management ease, rapid set-up and format change, minimal level of required maintenance, high productivity per hour and high precision in realizing the characteristics of the desired product, distinguish and confirm the quality and the technology of Sica products. For More Details please contact: Satellite Plastic Industries 2A2, Court Chambers 35, New Marine Lines Mumbai 400 020 Phone: 022-22006477, 66346816 Fax: 022-22006556 Email : rajiv.satellite@gmail.com Website: www.sica-italy.com 28 | November-December 2013 | Plastics & Rubber Review
F
rom 21 to 23 January, the WITTMANN group, represented by BATTENFELD (Schweiz) AG and WITTMANN Kunststofftechnik AG, is presenting state-of-the-art injection molding technology, automation and peripheral equipment to trade visitors at the Swiss Plastics in hall 2, booth B 2041. At this year’s Swiss Plastics, the WITTMANN group is showing its visitors latest injection molding technology as well as automation and peripheral equipment again at a joint booth. In the area of injection molding technology, two allelectric machines from the PowerSeries, which has been successfully established in the market, will be on display. These machines stand out by their extreme energyefficiency, optimal user-friendliness, cleanness and high precision. On an EcoPower 110/350 SE with insider cell, a front panel for a coffee machine will be manufactured, using a singlecavity mold supplied by Wittner, Austria. This is a high-gloss visible part made of PC/ABS. The parts are produced by using the a variothermic process VARIOMOULD and the mold technology BFMOLD® . In this technology the entire space below the cavity is used for heating and cooling. This enables extremely even and, above all, quick cooling of the mold area. Therefore this technology is of interest not only in order to reduce cycle times, but also to prevent warpage and to reduce tension. Moreover, sink marks and joint lines can be prevented with the help of this technology, above all on components with a visible surface or parts with a high-gloss surface. The parts will be removed and placed on a conveyor band by a WITTMANN robot W823.
INJECTION|MOULDING
BOY XS and BOY 55 E on the way to Moscow At the Interplastica in Moscow (January 28-31 2014), BOY will emphasize its capability with compact and energy-efficient injection moulding machines.
The BOY distributor BIM Engineering, which is responsible for the Russian market, will present in hall 3 / booth A 21 a BOY XS and a BOY 55 E with servo-drive. While the BOY 55 E (550 kN clamping force) will produce highly transparent rulers with integrated precision magnifying lenses and circular hole templates, the BOY XS (100 kN clamping force) will be impressive with a footprint of only 0,77 m². “Too much power in a small footprint simply doesn´t work,” comments BOY Export Manager Wolfgang Schmidt. BOY goes smart The compact BOY XS will be equipped with the new Procan ALPHA® 2. The main difference of the new system is the multi-touch capability. Like with modern communication devices, operating functions like scrolling or page changes are now achieved by wiping. Compared with previous foil-touch systems, the new Procan ALPHA ® 2 PCT touch technology guarantees considerably longer-lasting functionality. A recalibration of the screen is no longer required and the touch-surface has been protected against damage with a stable single safety glass cover.
drive systems in terms of efficiency, precision and quietness. In direct comparison with electromechanical drives, BOY scores with its servodrive and precision. The E-Series achieves on multiple levels with its low connected load, lower initial cost and favorable spare part prices as well as reduced wear. This means savings of up to 50 %, higher dynamics and precision. Add the typical BOY compact design and BOY becomes the first choice for many users.
With its BOY 55 E the specialist of injection moulding machines with clamping forces up to 1.000 kN proves its claim to produce energy-efficient machines. The BOY E-Series with the servo-drive has a drive technology that outclasses conventional hydraulic
Company profile Dr. Boy GmbH & Co. KG is one of the leading worldwide manufacturers of injection moulding machines
with clamping forces up to 1,000 kN. The very compact, durable machines work precise, energy-saving and therefore highly economical. BOY continually sets new standards in our industry with innovative concepts and solutions. Since the company was founded in 1968, over 40,000 injection moulding machines have been delivered worldwide. The privately owned company continues to put special emphasis on engineered performance and high-class “made in Germany” workmanship. For further information visit http:// www.dr-boy.de/.
Plastics & Rubber Review | November-December 2013 | 29
T E C H N O L O G Y
Phoenix Contact GmbH & Co. KG
Significant cost savings made possible by modern vacuum technology
P
hoenix Contact GmbH & Co. KG produces around 20,000 different injection-moulded parts for its own manufacture of all types of plug connector at its main plant in Blomberg. The small plastic parts for the plug connectors are manufactured on over 100 injection moulding machines. The supply of each individual injection moulding machine with plastic granulates and the transport of the crushed sink heads to the collection containers is carried out via a centralised vacuum system equipped with Mink claw vacuum pumps from Busch, which offer Phoenix Contact significant advantages in its plastic part manufacturing in
terms of maintenance, operational safety and energy costs. For Phoenix Contact’s plastic part manufacturing, a new operational building was built and the previously decentralised workshop area for injection-moulded parts at the Blomberg site was consolidated and expanded. Head of single plastic part manufacturing Jens Fischer redesigned the manufacturing process and, as
Fig. 1: Partial view of the central vacuum supply with Mink claw vacuum pumps at Phoenix Contact
30 | November-December 2013 | Plastics & Rubber Review
early as the planning stage, it was clear that they would be relying on dry-compressed Mink vacuum technology from Busch for vacuum generation in the pneumatic suction conveyor. This decision was based on the positive experience with a Mink from Busch back in 2004, when Phoenix Contact discovered that the maintenance expenditure was practically zero compared to the conventional oil-lubricated vacuum pumps previously in use. When the manufacturing was incorporated into the new operational building, a new supply system from Digicolor was commissioned to supply material using a central vacuum system (fig. 1). It consists of a total of 28 Mink claw vacuum pumps in two different sizes that feed the material from the octabin or the collection containers via the dryers to the injection moulding machines and return the sink heads crushed directly at the machine to the collection containers. Phoenix Contact processes a great number of compounds from various materials and in many different colours. Accordingly, this complexity is reflected in the suction conveyor system. 85 dryers alone are needed to reduce the residual material moisture prior to injection.
T E C H N O L O G Y
Fig. 2: Section of a Mink claw vacuum pump
possible by Mink claw technology in which two precisely manufactured claw-shaped pistons rotate in opposite directions without touching each other or the housing. In the minimal gaps between the moving parts, air turbulences ensure sealing and therefore the achievement of low end pressure. This construction principle made it possible to create an almost maintenance-free vacuum pump that does without wear parts to the greatest possible extent and thereby keeping all the costs and downtime associated with maintenance to a minimum (fig. 2).
lower. At the same suction
Manfred Nunne can only confirm
nology”.
capacity, a Mink claw vacuum pump can be powered with a motor that is at least one output class lower than other mechanical vacuum pumps (fig. 3). At Phoenix Contact, this is clearly reflected in the annual energy costs: at least 11,000 euros in energy costs are saved every year. Jens Fischer is therefore very happy to report that “We are pleased that we decided in favour of Busch Mink claw tech-
Production is perComparison of the energy costs of conventional oil-lubricated vacuum formed to the greatest pumps and Mink claw vacuum pumps possible extent automatically in three-shift Energy costs Centralised vacuum supply with Centralised vacuum supply with vacuum supply Mink claw vacuum pumps oil lubricated vacuum pumps operation. This means 3 18 Vacuum pumps with each 140 m /h 54 kW 72 kW that the material feed 45 kW 55 kW 10 Vacuum pumps with each 250 m3/h has to be ensured on 99 kW 127 kW all machines around the Total energy demand 5000 h Operating time/year clock. The individual vacuum pumps are in 0,08 €/kWh Electricity rate operation between 70 Total energy costs/year 99 kW x 0,08 € x 5.000 h = 127 kW x 0,08 € x 5.000 h = 39.600 €/a 50.800 €/a and 90 per cent of the Saving of energy costs due to working time and there11.200 €/a Mink claw vacuum pumps fore reach an annual Fig. 3: Comparison of the energy costs of operating time of 5,000 conventional oil-lubricated vacuum pumps and the high degree of availability of to 7,000 hours. Maintenance is limited to changing the Mink claw vacuum pumps in a central vacuum Mink claw vacuum pumps: since gear oil, which Busch as the manufacturer stipulates supply first using such a vacuum generashould be carried out after every 20,000 operatContact tor in 2004 and the continuous ing hours. Under these conditions, this corresponds Busch Headquarter Germany procurement of further pumps up to a change interval of three to four years. Manfred Busch Dienste GmbH, Marketing to the current total of 28 Mink claw Nunne, responsible for the production procedure, Mr. Uli Merkle vacuum pumps, there has never remembers the maintenance work required for the www.buschvacuum.com been a breakdown, despite the oil-lubricated vacuum pumps: an oil change, oil filter uli.merkle@busch.de high operating time. change and internal filter element replacement every year, which was combined with downtime, costs for the oil, its disposal and the replacement of wear parts. Mink claw vacuum pumps compress the air they suck in without any operating fluids and without the moving parts in the compression chamber coming into contact with one another. Unlike with other mechanical vacuum pumps, this results in no wear. This is made
The non-contact working principle of the Mink claw technology has another advantage: it achieves a higher degree of efficiency than other mechanical vacuum pumps. For the operator, this means that power consumption is significantly
Contact India Busch Vacuum India Pvt Ltd. Attn.. Ajit Singh, 103, Sector 5 IMT Manesar, Gurgaon Haryana - 122 050 Phone +91 124 4050091 Fax +91 124 2292103 sales@buschindia.com www.buschindia.com
Plastics & Rubber Review | November-December 2013 | 31
TECHNOLOGY|AT|YOUR|DOOR-STEP
BORGHI ITALY UNVEILS STAR R32
BORGHI STAR R32 is an automatic turret style filling machine with 3 stations and 3 carriages for the production of all kinds of brooms and brushes.
Red Bull’s Mark Webber launches furious attack on Pirelli as tyre debate starts to wear thin A furious Mark Webber reignited the debate over Pirelli’s fast-degrading tyres on Sunday night, accusing the Italian manufacturer of not caring about drivers in producing tyres that “explode a bit” and fall apart after a handful of laps.
The STAR R32 can produce a wide range of models with different filling angles, such as radial tufted, parallel tufted and radial/parallel tufted brushes. The 5 axes of movement run by brushless servomotors allow this machine to have a versatility level never reached before. The high degree of freedom in filling allows to realize all the different types of brooms and brushes for household industry, including toilet brushes and Swedish type dishwashing brushes.
The Australian was incensed after enduring a puncture caused by debris from the front-right tyre of Sergio Perez’s McLaren, which blew spectacularly as the Mexican was flying down the straight on lap 31 of the Korean Grand Prix on Sunday. Webber was later forced to retire after a collision with Adrian Sutil’s Force India, his misery complete when his Red Bull car caught fire thanks to a burst oil radiator.
The working cycle occurs simultaneously on 3 stations: drilling, filling and loading/off-loading. The machine produces two brushes per cycle that are moved from one station to another by a turret system. The block loading is manually operated.
After returning to the paddock it is understood that Webber went to see Pirelli’s director of motorsport, Paul Hembery, to remonstrate with him over the current formula of racing.
The STAR R32 features an innovative new-design protection panels made by thermo-shaped hard plastic material to increase the accessibility to the working tools. The operator works in absolute safety, due to separation of loading/off-loading station and the drilling/filling.
Drivers currently spend much of their time nursing their tyres to make them last rather than going flat out as Webber would like. There have also been plenty of blowouts this year, most notably at Silverstone where the race was almost called off after some catastrophic high-speed failures. “That is how it is. The drivers aren’t super important – it is what other people want,” said Webber, who is quitting Formula One for sports cars next year. “The tyres are wearing a lot and they also explode a bit. But that is for Pirelli to sort out.
For More Details please contact: Satellite Plastic Industries 2A2, Court Chambers 35, New Marine Lines Mumbai 400 020 Phone: 022-22006477, 66346816 Fax: 022-22006556 Email : rajiv.satellite@gmail.com Website: www.borghi.it
SATELLITE PLASTIC INDUSTRIES is part of the Satellite Group Offering Plastic Processing Machinery since 1984. We have more than 400 installations all over India with a growing number of customers because of their trust in the performance of the machinery that we supply as well as the after sales service that we provide, the goodwill thus created offers unlimited possibilities to keep expanding our activities from time to time.
32 | November-December 2013 | Plastics & Rubber Review
“Pirelli will put the puncture of Perez down to a lock-up but the reason the drivers are locking up is because there’s no tread left.” Hembery hit back, saying that the lock-up was entirely predictable as Perez was 21 laps into a stint on a set of tyres that were only designed to last for 20 laps. He said that the Perez blowout was not linked to the tyre structure issues which had caused the Silverstone failures, Pirelli having switched back to old tyre structures in the wake of the British Grand Prix. “There are two issues here that Mark is conflating,” Hembery told The Telegraph. “Firstly the situation with Sergio’s tyre. It was nothing to do with delaminations earlier in the season. He had a major lock-up and flatspotted. “The other issue about degradation is the same old story. You can have a philosophical difference of opinion – as Michael [Schumacher] had last year – but we are only doing what we were asked to do, which is to create two to three stops per race. If they want tyres to last all race we can do that, too.”
C O M P A N Y | N E W S
New Strategic Orientation of Maplan
Setting the Course for further Growth 2. Strengthening sales and service structure 3. Concentration on core business and Expanding manufacturing 4. and development capabilities.
I
Strengthening Staff In 2013 the management was expanded in order to promote the success of Maplan worldwide even faster and more targeted. The result is a double leadership with Leopold Heidegger as CFO for the entire financial sector and Wolfgang Meyer as CEO on the operative side in sales, development and production. It has invested in specialists in many important fields of the company. New experts in the fields of mechanical design, production management and purchasing have strengthened the Team in Ternitz. n 2012, a change of ownership took place in the Starlinger Group within a family. The Starlinger Group was restructured and thereby since then Maplan GmbH has been owned by the Soulier family that had previously held senior positions within the Starlinger Group. With their experience in machine construction business, this new owner wants to expand Maplan significantly. Starlinger will continue to be a co-partner of Maplan. In 2012, the company achieved a turnover of 36 million euros. The aim was to expand significantly by upgrading sales, service and market presence in many countries in order to operate closer to the customers. These efforts are bearing fruit: In 2013, Maplan has 60 sales and service locations worldwide. New Strategic Orientation The new strategic orientation is basically defined by four strategic approaches: 1. Investing in specialists
Strengthening Core Business With this new team, there is a unique, new strategic orientation with a focus on core business, that is, rubber injection moulding. Maplan stands for commitment to quality and highly practicalityoriented solutions. Maplan will use this reputation and concentrate all our resources in the areas of innovation, reliability and customer service in order to offer our existing clients or the entire rubber injection moulding market energy efficient and optimized Maplan machine concepts even faster and more effectively. Investing in the Structure As already mentioned, in recent years we have done much
preliminary work on the development of new markets. Already in 2013, these investments in the structure start to show first positive effects. The fast-growing markets such as Turkey, India, China, Brazil ... just to name a few, are among the priorities that will be pushed massively. At the same time, Maplan will also intensively modify and expand its traditional “old” priority markets. The goal is to provide an even better service to customers in Europe and USA in the next few years. These markets stand for requirements that are technically demanding and are therefore central to Maplan’s current and future performance in development and innovation. Expansion of Production Capacities Due to vibrant demands worldwide, our capacities so far have been stretched to the limit. Therefore, Maplan will open a new production site which will in the first step roughly double production capacities. This switching of position incidentally allows for an optimization of the entire production process which enables a lean, fast and cost-effective production of machines. The new site will be located in Austria. The expertise of our employees, combined with optimal global processes and today’s global purchasing, will make it possible to produce machines in Austria which are very good technically and competitive in terms of cost. Wolfgang Meyer commented: “Quality Made in Austria is what has made us strong - and this will remain a key factor in the future.”
Plastics & Rubber Review | November-December 2013 | 33
TECHNOLOGY|AT|YOUR|DOOR-STEP
TECHNOPLASTIC PET STRAP LINES
New standardised hot runner manifold concept
TECHNO PLASTIC TIGHT STRAP WINDER is a full electronic winder machine for plastic strapping band designed to wrap all kinds of plastic strapping band made of PET and PP starting from 4mm up to 32mm in width. It allows a simply perfect quality in winding on spools of any size on the market, thanks to its capacity of absorbing the winding temporary phases and a linear winding process due to the uncoupling of the speed ramping in the packaging area. The head winder is equipped with a PLC for memorizing and managing the various “recipes” for winding. Via a 10” touch-screen, the programming and management of the production can be carried out for various parameters: meters of strapping band to wrap, inversion angle, stop angle, kind of winding (2pts, 3pts and 4pts), winding step, gap, and traverse up to 300mm (12”), setting to point zero (traverse starting point), width and thickness of strapping band, progressive tensioning on the spool. The winders appointed to the one ahead can be programmed by using the control panel in a singular way or in a multiple way. Furthermore, all models are equipped with a knot-detection system, pneumatic equalizer input for fast winding in case of new tube, motorized pulley, electronic equalizer, adjustable strapping band guide, complete with roll input, air chuck with radial expansion rack inserts, fast recovery pedal and digital counter.
H
ASCO introduced a completely revised hot runner concept for the first time at K2013. This offers a very wide range of options for the layout of a hot runner system, despite the different, standardised outside dimensions of the manifold blocks. Not only can the hole distances for the nozzles be freely selected within the pre-defined limits – HASCO also tailors the flow channel cross-sections in the manifolds to the application in question. The H4000/... manifold concept is combined with the nozzle series in HASCO’s current nozzle range to provide high-quality hot runner systems that meet the most stringent of requirements for injection moulding production. The HASCO turn plugs that have been successfully used for many years are employed for the melt channel deflections and as plugs on the manifold bars. This guarantees a leak-free manifold and optimum passage of the melt through the deflection, while ensuring that the molten polymer is subject to only minimal shear. The H4000/... manifold concept takes in a series of manifold geometries. Simple deflector manifolds are supplied for nozzle spacings from 35 mm to 440 mm. Naturally balanced manifolds for 2 or 4 nozzles arranged in a row can similarly be supplied with a maximum distance of 440 mm between the outside nozzles. The cross-shaped manifolds are designed for a symmetrical nozzle configuration on a square, with a maximum distance of 315 mm possible for the nozzle spacing.
For More Details please contact: Satellite Plastic Industries 2A2, Court Chambers, 35, New Marine Lines, Mumbai 400 020 Phone: 022-22006477, 66346816, Fax: 022-22006556 Email : rajiv.satellite@gmail.com, Website: www.technoplastic.it 34 | November-December 2013 | Plastics & Rubber Review
Hot runner systems based on the new, standardised manifold concept H4000/... offer an outstanding price to performance ratio. They are also the answer to tightly scheduled mould projects, since they can be supplied within just a few working days. Our specialist advisers and application engineers will be pleased to assist you in selecting the right hot runner system for your application.
P A C K A G I N G
Empresas Polar, Venezuela, doubles output Sacmi supplies new, complete production line for Sangrìa Caroreña
A
n all-new Made in Sacmi production line has just become operative at Empresas Polar, the longstanding Venezuelan company that has been doing business in the beverage, food and packaging industries for over 70 years. The complete line, now successfully installed and started up at the Bodegas Pomar plant, is designed to produce some 6,900 bottles of Sangrìa Caroreña (PET bottles, 1.75 litres) an hour. The line includes the filler – and relative conveyor belts – manufactured by Sacmi Filling, the new labeller-sealer from Sacmi Verona and, lastly, the bundler and palletizer made by Sacmi Packaging. Sacmi Beverage – the Division that has, for some years now, brought together individual Group excellences to ensure uniformity of output and business logic – is, then, well on the way to achieving its goal of supplying customers with comprehensive ’turnkey’ plant engineering solutions. Thanks to this investment, Empresas Polar has doubled its output capacity on the bottling lines. Moreover, the plant also features a high degree of automation that – with regard to Sangrìa Caroreña alone – will allow the Venezuelan company to boost monthly output from 160,000 to 240,000 bottles. Plastics & Rubber Review | November-December 2013 | 35
INJECTION|MOULDING
CJSC Sumitomo (SHI) Demag Plastics Machinery presents efficient standard injection moulding
CJSC Sumitomo (SHI) Demag Plastics Machinery will present a virtuoso machine from the hydraulic series at the Interplastica in Moscow
T
he Russian subsidiary of the German/Japanese machine builder, Sumitomo (SHI) Demag, will be presenting a hydraulic Systec machine with a consumer application at the Interplastica from 28 - 31 January 2014 in Moscow, in Hall 3 at stand 3C14. A fully hydraulic Systec 210-840 (2,100 kN) will be in operation at the trade show stand of CJSC Sumitomo (SHI) Demag Plastics Machinery, producing the lower portion of a coin dish made from polystyrene (PS). Using the mould from VIKI Vostok OOO, Moscow, the mouldings weighing approx. 98 g are produced in a cycle time of 20 s. An integrated linear robot from Sepro Robotique, La Roche-sur-Yon Cedex/France removes the mouldings from the mould and places them on a conveyor belt. The complete peripherals, comprising a conveyor belt, material transport device and mould cooling, are provided by Moretto S.p.A., Massanzago (PD)/Italy. Sumitomo (SHI) Demag Plastics Machinery GmbH offers the ideal economical solution for a wide range of standard applications in injection moulding processes with its Systec series. The fully regulated, hydraulic multifunction series is available in 19 sizes in the clamping force range from 350 to 20,000 kN.
36 | November-December 2013 | Plastics & Rubber Review
Sumitomo (SHI) Demag offers the Systec series from 350 to 1,200 kN clamping force with a fully hydraulic closing unit; a knuckle-joint closing unit is used from 1,300 to 20,000 kN. active components make full use of the efficiency potential offered by hydraulic machines Various possibilities are also available for increasing efficiency in hydraulic Systec injection moulding machines. For example, the activeCool&Clean filter and oil cooling concept extends the service life of the oil, ensures more precise temperature control, provides for lower wear and lower noise levels, extends the service intervals and thus reduces maintenance costs. What is more, it is possible to use a fully electric metering drive in the knuckle-joint versions available from 1,300 kN
and upward. Dynamic power adjustment of the hydraulic drive by activeDrive provides for further energy savings; this is a combination of a variablespeed electric motor and a highly dynamic regulating pump. CJSC Sumitomo (SHI) Demag Plastics Machinery Interplastica, 28 - 31 January 2014 Krasnaya Presnya Moscow, Russia – Hall 3, stand 3C14 CJSC Sumitomo (SHI) Demag Plastics Machinery Sumitomo (SHI) Demag is represented in Russia and the Commonwealth of Independent States (CIS) by its subsidiary company, CJSC Sumitomo (SHI) Demag Plastics Machinery, based in Moscow. The branch maintains what have traditionally been outstanding business relations with Russian plastics processors. It has
INJECTION|MOULDING
been providing care for its customers not only in terms of sales but also a wide variety of other services for 22 years now. These include not only guidance regarding application technology and project planning but also a round-the-clock hotline and seamless spare parts provision from its Moscow depot. CJSC Sumitomo (SHI) Demag has installed more than 3,200 injection moulding machines in the Russian market since 1990. These successes led to Sumitomo (SHI) Demag rapidly assuming a position as a market leader. Customers with branches and production sites in Russia operating both nationally and also globally have long come to rely on injection moulding technology originating from Schwaig and Wiehe. The CJSC Sumitomo (SHI) Demag Team also manages to gain new customers every year as well. CJSC Sumitomo (SHI) Demag is represented in Moscow with its own central marketing organisation as well as through its own personnel and agents in all the key economic regions such as St. Petersburg, Nizhny Novgorod and Ufa as well as Minsk (Belarus). The activities of the agencies in Kiev (Ukraine) and Tashkent (Uzbekistan) are also managed from Moscow. Dipl.-Ing. Alexander Votinov has been the Manager there since the summer of 2010. Sumitomo (SHI) Demag deals with the demands of the Russian market, which can sometimes be very varied, from its international production sites on a decidedly individual basis. The deployment areas for injection moulding machines as widely spread
throughout Russia as are plastics processing. Manufacturers of plastic packaging, vehicle components, electronic products and devices, hygiene articles, stationery, medical parts and consumer goods rely on standard and special machines from Germany. The machines supplied to Russia are adapted to meet local operating conditions and are all certified according to the Gosudarstvennyj Standard (GOST), the prescribed Russian standard. CJSC Sumitomo (SHI) Demag
addresses the specific needs of individual sectors with focused system solutions. In order to equip imported machines, the branch cooperates with leading European manufacturers of moulds for injection moulding, robots and IML automation technology. This means Russian customers are offered the
full range of peripheral devices - even for complex installations and projects. Sumitomo (SHI) Demag has been in partnership with Sepro Robotique, the largest European manufacturer of removal robots operating independently of injection moulding machine manufacturers, since 2009. Via CJSC Sumitomo (SHI) Demag, Russian customers have access to the respective optimum robot models for solving current automation tasks. A showroom in Moscow is always fitted out with current injection moulding
machines and allows customers to carry out mould tests and mould validations. Training sessions and courses enable operators to become familiar with the machine and operating technology. www.sumitomo-shi-demag.ru www.demag.ru
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S H O W | R E P O R T
The world of injection moulding was the guest of BOY
W
hen he concluded, “the K 2013 exhibition was one of the most successful fairs in the recent past for BOY“, Alfred Schiffer drew a positive balance at the conclusion of the plastic trade fair. During the eight days of the exhibition a multitude of orders could be booked as a result of the many visitors at the open, bright and spaciously designed booth. The BOY exhibition team, which also included a number of worldwide distributors, conducted many promising conversations about pending projects. These will likely lead to machine orders in the near future. New BOYs were impressive With the presentation of six new machine types with a maximum clamping force of 1.000 kN and the newly introduced
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EconPlast, BOY pinpointed the expectations of the fair visitors. Improved efficiency of injection moulding machines was for many users the focus of their visit to the Dusseldorf fair. They found this at BOY, who presented along with the EconPlast units and the servomotor pump drive very good efficiency classifications in their respective clamping force classes. The BOY 60 E and BOY 100 E, which have been presented for the
first time at K 2013, each achieved a Euromap 60.1 classification of 9+. With the development of the EconPlast units, BOY made the melting and processing of plastics more efficient. Therefore, BOY feels once they confirmed their role as a technological pioneer. A BOY handling unit was presented at the fair for the first time. The complete removal automation system, which was CE compliant,
S H O W | R E P O R T
was demonstrated on the BOY 60 E. Now, in addition to injection moulding machines, BOY offers customized automation systems and the required protective housings as a total package. Crowd attractions with flavor Attractive applications like the production of Altbeer glasses on the new BOY 60 E that included a subsequent, local filling station attracted many visitors. The inde-
pendent insertion and over moulding of blanks for hexagonal socket screw keys was impressive as well. Every visitor could produce his own tool kit on the new BOY 25 E VH. This experience – having operated an injection moulding machine themselves – will certainly remain a long time as a positive memory for many visitors. This is especially true for the many young visitors that experienced this hands-on moulding experience. Perhaps many will
soon be entering the exciting field of injection moulding. High-gloss delicacy dishes, which were produced on the new BOY 25 E, were very popular with the fair visitors. The production-related still pre-heated dishes were in great demand. Promising perspective With its successful presence at K 2013 and its newly introduced
machine types, the family-owned company from Neustadt-Fernthal sees itself as best prepared for the future. Even if the energy classifications are still new for many users, time is on the side of BOY because their injection moulding machines are verifiably the most efficient according to Euromap 60.1. For further information visit http:// www.dr-boy.de/.
Plastics & Rubber Review | November-December 2013 | 39
Newly developed MuCell® blow molding process
for automotive plastic parts offers significant weight savings Achieved 32% weight savings and improved thermal and acoustic insulation characteristics with automotive air duct application As a leader in providing lightweighting solutions to the plastics injection molding industry, Trexel, Inc. has extended its MuCell processing solution to blow molded automotive components. In working closely with their OEM and Tier I customers, the company has recognized the need for lightweighting plastic parts beyond the traditional and proven injection molded interior, exterior and under the hood applications. To develop this robust MuCell blow molding process Trexel worked with ABC Group in Toronto Canada, one of the leading providers of blow molded products to the North American automotive industry. Over the last year, engineers from Trexel and ABC Group have been diligently working together on the development of MuCell blow molding. As a result of these efforts the first Mucell blow molding process was achieved with an automotive application. The part is a reinforced 40 | November-December 2013 | Plastics & Rubber Review
Polyethylene air duct with 1.5 – 2mm wall thickness. As a result of the Mucell process the density reduction is 41% of the foamed material, resulting in a 32% net weight saving of the finished part compared to solid. “We are very excited about the results we have achieved so far,“ said Steve Braig, President and CEO of Trexel, Inc. “Commercial development of additional MuCell foamed blow molded parts including design and material optimization should result in higher than 40% weight reduction compared to the solid molded part. These results will be very attractive to OEM and Tier suppliers, and ultimately to car buyers who will enjoy improved
fuel efficiency of their vehicles.” Besides weight savings, there are several highly desirable attributes of foamed versus solid blow molded parts: the microcellular material structure improves thermal insulation and also provides for improved acoustical properties. The MuCell technology, a physical foaming process, also has several advantages over the use of chemical foaming agents: no chemical reaction at narrow processing window, no chemical additive residue in final parts, and most importantly, MuCell foamed parts can be recycled in their original polymer designation; the process does not alter the chemistry of the polymer.
TECHNOLOGY|AT|YOUR|DOOR-STEP
Innovations in the field of plastic pipes Sica presents a wide-ranging innovation in the field of Plastic Pipes. Three “green” initiatives designed to save energy, materials and costs. We can speak directly of a revolution for TRS 160 W cutting machine, because finally it can cut and chamfer without removing material. Yes, you read that correctly: without removing material. This manages to save a considerable quantity of raw material that affects the 80% of the pipe cost, but also to avoid problems of scrap suctioning and recycling. In traditional cutting machines, also in those with knife or tool, chips and dust end up partially between saw mechanisms despite suctioning; for this reason, the necessity of maintenance increases. In contrast, the new TRS 160 W removes the problem with an innovative system (Patent Pending) that guarantees not only a clean and perfectly perpendicular cut with knife but also a precise and well-defined chamfer, maintaining the same productivity and a satisfactory speed; these are requirements for modern extrusion lines. Sica’s saw can cut any PVC, PP and PE plastic material.
MALAYSIA: Supermax plans RM1.3 billion capital expenditure “About 75 % of the land would be used for development, 22 % for infrastructure and 3 % for landscaping, he told analysts, investors and reporters at a briefing. Based on the 30ha available for development, it would use 60 % for the expansion of nitrile medical, surgical and dental examination gloves lines. The remaining 10ha would be carved out into smaller parcels of 0.8ha to 1.2ha for smaller factories built for supporting industries with a gross development value of RM350 million to RM400 million, he said. Asked on how he would market the business park, which it has planned to launch next year, he said: “There would not be many units (10 to 15 units) and we are selling to the supporting industries, of which, most are our long-term business associates and friends. There is already demand before launch. He said the development was still at its initial stage and had yet to firm up with the gross margin for the project, but noted that the selling prices might be higher than projected.
The second important innovative product is the new Multibell 200M belling machine for PVC sewage pipe. This new machine has been completely revised and optimized, maintaining an important productivity per hour that reaches 900 sockets/hour with the flagship version. Maintaining unchanged the quality standards and product reliability, the new machine introduces numerous technical features in view of a greatly reduced price both of machine and equipment. The machine is still completely pneumatic, with the inevitable advantages related to the higher cleanliness and the superior ease of management thanks to the absence of the hydraulic unit.
He also said the profits gained from selling the factories would then be pumped into the capex for the IGMC that would be developed in two phases over nine years.
Sica endeavor always to produce new technologies and innovative products is the Introduction of the Unibell 200 E&P belling machine distinguished by the electromechanical movement of the forming carriage. With this solution the hydraulic movements are eliminated from the machine, bringing many advantages from both functional and environmental points of view. Moreover, with the elimination of hydraulic movements any possible oil leakage into the environment are avoided and ordinary maintenance is reduced. The energy necessary for the forming positioning is used just for the duration of the carriage movement. Moreover, the total absence of hydraulic units brings a significant energy saving, because hydraulic units have a clearly lower total efficiency than this new device. The obvious consequences are: faster return on investment, greater market competitiveness and greater respect for the environment.
With a development period from 2014 to 2018, the total capacity for phase one is 10.85 billion pieces and 4.65 billion pieces for phase two that spans from 2019 to 2022.
With the launch of these machines, we can speak of Sica’s “green” turning point. Along with functionality, productivity and quality at the right price, more attention is paid to the environment, and energy and material savings for a sustainable economy. Environmental conservation and savings for a better world! For More Details please contact: Satellite Plastic Industries 2A2, Court Chambers, 35, New Marine Lines, Mumbai 400 020 Phone: 022-22006477, 66346816 Fax: 022-22006556 Email : rajiv.satellite@gmail.com Website: www.sica-italy.com
Phase 1A of the IGMC, expected to be fully commissioned by the financial year ending 31 Dec 2015 (FY15), would see an additional production of 2.71 billion pieces.
Breaking down the capex, it would spend RM125 million for 2013-2014 and RM164.5 million for 2014-2015. Meanwhile, phase one of Glove City that is also expected to be fully commissioned by FY15, would add 4.1 billion pieces to its nitrile glove production. He said the company would need cash to expand the business in 2014 to 2015 and might look into revising its dividend policy in 2015 to 2016 as its cashflow improved. Commenting on the electricity tariff hike, he said the glove maker would have to spend RM3.5 million extra for its utilities in 2014, which would, in turn, hurt its bottomline by 2.9 %. Thai said the company would explore ways to use electricity more efficiently and that one such way was via renewable energy (RE). He said the company was exploring the usage of RE and urged the Government to further liberalise the green energy sector so that more players could take part in the development of RE. Plastics & Rubber Review | November-December 2013 | 41
Peripheral equipment from WITTMANN
WITTMANN BATTENFELD at the K 2013 K 2013: a complete success for the WITTMANN group
A
t this year’s K show, the WITTMANN group presented its pioneering technologies under the motto of “Power for the Future”. This power attracted great numbers of visitors to the booths in halls 16 and 10 on all eight days, and the fair was a complete success for the WITTMANN group. From the first to the last day of the fair, WITTMANN enjoyed an enormous amount of positive response to its trade fair highlights at both of its booths, resulting in a great number of enquiries and an order vol-
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ume which was just as significant. And this across the board both for injection molding machines and equipment and for automation and peripheral appliances. Georg Tinschert, Managing Director of WITTMANN BATTENFELD, comments: “K 2013 was a complete success for us. Public interest in our machines was overwhelming, above all in our new MacroPower 1500, which scores by its low height and user-friendliness. But the visitors’ attention was also attracted by our highly innovative processes
and manufacturing methods. Of course we are particularly pleased about the great number of orders we were able to secure during this trade fair. For us, the positive result of this fair is a clear indication that we are on the right track with our strategy of giving long-term customer benefit top priority in our product development.” This long-term customer benefit manifests itself in terms of ultimate cost-efficiency and energy-efficiency of the equipment, special user-friendliness, assured quality
T E C H N O L O G Y
of processes and manufacturing methods, and much more. Michael Wittmann, Managing Director of WITTMANN Kunststoffgeräte, also expresses that he is more than satisfied with the results of the fair: “At this K show, we were able to present a great number of novelties to our visitors in all areas of peripheral equipment and automation, and were impressed by the response of interested visitors, which led to a number of spontaneous orders placed at the trade fair for robots and peripheral equipment, too. We can say without reservation that this year’s K show was successful in every respect for the entire WITTMANN group. The highlights in injection molding machinery:
The new MacroPower 1500 The absolute highlight of this year´s product presentation at the K was the MacroPower 1500. With this model, WITTMANN BATTENFELD has extended its portfolio of MacroPower large-scale machines to 6 sizes, ranging from 400 to 1,600 t in clamping force. The machine shown at the K – a MacroPower 1500/8800 – came equipped with ServoPower technology and features maximum energy efficiency and user benefit. The functionality of the machine was shown by producing a ground shaft made of PP (Borealis) in a mold supplied by the Austrian mold maker ifw mould tec. Its 4 outlet apertures for pipes branching off are formed with the help of complex core pull technology.
MacroPower E Hybrid with IML application Another highlight was the MacroPower E 450/2250 Hybrid, consisting of a modern servo-hydraulic 2-platen clamping combined with an all-electric, high-speed injection aggregate. This combination has made it possible to produce a compact large-scale machine with a minimal footprint, which simultaneously offers the ultimate in terms of precision and energy-efficiency at high injection speeds of up to 450 mm/sec This enables the production of high-precision technical plastic parts, as well as packaging components, with an extremely low energy input. The machine was equipped with a WITTMANN W842 HS Top Entry IML unit. On the machine, a high-performance
mold supplied by Abate (Italy) was shown producing a bucket. EcoPower with AIRMOULD® technology Another application which triggered lively interest from visitors was the EcoPower 300/1330, equipped with WITTMANN BATTENFELD’s own “AIRMOULD®” gas injection technology, on which a hockey stick was manufactured from LGF-PP (supplied by Borealis) in a mold from Haidlmair (A). Equipped with the new combined nitrogen and pressure generator, a gas channel with a total length of 1300 mm was achieved in this molded part. The hockey stick was produced by a partial filling process. First, a piece of sheet supplied by Verstraete (B) was in-
Assembly of Playmobil unicorns
Plastics & Rubber Review | November-December 2013 | 43
IML decoration of 4 injection-molded cups on a TM Xpress 210
serted at the end of the flow path; here the gripper was designed for handling the insertion of the sheet as well as parts removal. To counteract warpage of the part over its entire length and keep the cooling time as short as possible, the parts were deposited in a cooling station specially developed for this purpose. Combination of very good surface and light part In cooperation between WITTMANN BATTENFELD and Schaumform (D), an interior component in structured foam technology was manufactured. In this application, the WITTMANN BATTENFELD process CELLMOULD® and variothermic process VARIOMOULD were combined with the HiP (High Precision Opening) opening program to enable the production of light-weight structured foam
parts with a high-quality surface. The parts were inspected via in-line thermography. In this process, the parts were presented to a camera in several different positions immediately after demolding. The parts were presented to a camera in several different positions immediately after demolding. The evaluation of the thermographic pictures was displayed on a monitor, any deviations from the release status were visualized and calculated for each segment for the connected WITTMANN FLOWCON flow regulator. Any temperature changes which were necessary could thus be implemented in real time. LSR injection molding On a further machine of the EcoPower series, an EcoPower 110/350, LSR penholders were manufactured in a 4-cavity mold supplied by RO-RA (A). The mold
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technology used allowed molded parts to be manufactured from liquid silicone without sprue, virtually free of ridges, without waste and fully automatically. Lab on a chip – part through 2c micro injection molding The visitors also showed keen interest in the demonstration of a medical technology application, consisting of 2 MicroPower 15/10 machines which produced by assembly injection molding under clean-room conditions a “lab on a chip” component for analyzing particles contained in blood. The two machines were connected with each other by a clean-room tunnel. The first machine produced the two carrier parts in a 2-cavity mold, which were then directly put together on the transfer carriage and subsequently transported via a servo-electric linear axis into the
second machine, where the part was overmolded with TPE. BFMOLD® and inline surface inspection On a hydraulic HM 110/525 machine with an insider cell, high-gloss flush panels for sanitary installations were manufactured in a single-cavity mold supplied by Sanit, Germany. The parts were produced using the variothermic BFMOLD® process combined with the CELLMOULD® structured foam process. Following parts removal by a W818 robot, the parts were passed on to an “in-line surface inspection unit” integrated in the machine. By this method developed by PCCL (Polymer Competence Center Leoben, A) for the detection of surface defects, the entire surface of the molded part is checked for
T E C H N O L O G Y
sink marks. 2-component technology A further process highlight which met with lively interest was the multi-component technology demonstrated on a servo-hydraulic HM 180/525H/210S multi-component machine with ServoPower drive, on which a sprayer for the cosmetics industry was manufactured from PP and SEBS with a 4+4+4-cavity mold. A process known as IMA (In-Mold Assembling) makes it possible to produce such complex hollow parts in a single step. For this purpose, the two half-shells were brought into an overlapping position by means of an adaptive index platen drive supplied by Grosfilley, F, which cooperated with a WITTMANN robot. In this position, the parts were subsequently joined together and sealed by overmolding. WebService 24/7 The exhibition program of WITTMANN BATTENFELD was rounded off by a presentation of its Web-
Service 24/7. WebService 24/7 stands for the online service from WITTMANN BATTENFELD, which is available round the clock on 7 days a week. Visitors to the K show had the opportunity to experience the operation of WebService 24/7 firsthand via a live connection at the service center specially installed for this purpose. The automation and peripheral equipment highlights in hall 10/A04: Robot innovations At this year’s K, a W833 pro was presented to introduce the new W8 pro robot series. The consistent use of light-weight technology for the axes, combined with the drive concept specially developed by WITTMANN for linear robots, makes the models of the W8 pro series extremely dynamic with extremely low energy consumption as well. The robot range was presented by eye-catching movement models which greatly fascinated the visitors, such as robots playing basketball. Another showpiece
as the assembly of a small plastic unicorn from Playmobil, controlled by the WITTMANN CNC8 control system. Innovations in temperature control In the area of temperature control, the FLOWCON plus was showcased, which comes with a proportionally controlled multiphase motor and wear-resistant flow controller. The latter replaces the magnetic valves of the predecessor model and thus ensures proportional regulation of the valves, which leads to a substantial improvement in temperature control.
their compact design and great variability of the main technical components: the pump (0.75 kW – 200 l/min – 2.35 bar or 1.5 kW – 200 l/min – 3.65 bar), the heating capacity (9 kW or 18 kW) and the cooling valves (⅜” or ½”). TEMPRO basic C120 temperature controllers are also available in a slightly larger version, in which the capacity of the pumps ranges from 0.75 kW to 4 kW.
Moreover, the TEMPRO plus D L was on display. This appliance is a complete novelty. It is fitted with two heat exchangers for every circuit, each of which can provide 18 kW heating capacity and up to 40 kW cooling capacity.
Innovations in drying The new DRYMAX Aton2 F30 was now introduced at the K 2013 as the third model in the innovative segmented wheel dryer series from WITTMANN. The segmented wheel dryers with dry air volumes of 70 m³/h and 120 m³/h, which have met with an excellent reception by the market, are now also available in a smaller version with 30 m³/h capacity, represented by the F30 model.
The exhibits also included appliances from the TEMPRO basic C120 series, which stand out by
Furthermore, the battery dryers DRYMAX E and DRYMAX E FC were also on display. These dryers are
The MacroPower 1500 – the trade fair highlight of WITTMANN BATTENFELD
Plastics & Rubber Review | November-December 2013 | 45
Well-frequented booth of WITTMANN BATTENFELD at K Show
equipped with two desiccant beds and thus continuously supply process air with a constant dry air quality for perfect drying of plastic granulate. Innovations in dosing The new control system of the GRAVIMAX G series of blenders offers a previously unknown new function for what is known as parallel dosing. This function enables an up to 30% increase in throughput without making any mechanical changes to the appliances as such. This is made possible by simultaneously addressing several metering valves in order to increase the material flow. Here, dosing accuracy is also ensured by RTLS technology (realtime weighing) as in the predecessor models. Innovations in material handling The FEEDMAX S3 net single loader
from WITTMANN combines the advantages of single loaders with those of a central control system. Several loaders can be connected with each other by CAN-BUS and thus controlled via a single control panel. For this purpose, WITTMANN offers a high-resolution 4.3� TFT touch screen, which gives detailed information about the status of every individual appliance. For even higher capacity to cover large distances in material conveying, a model with a central vacuum generator is also available: FEEDMAX BS net. FEEDMAX BS net comes in several different sizes and can be combined with blowers of up to 7,500 W capacity.
models Minor 2 and Junior 2 Compact, MAS beside-the-press granulators for inline recycling of molded parts and sprue, and the medium-sized, extremely versatile MC 34 Primus. IML with camera inspection Last but not least, simultaneous IML decoration of 4 injectionmolded cups, each with 300 ml capacity, was demonstrated at the WITTMANN booth in hall 10 on a TM Xpress 210 injection molding machine from WITTMANN BATTENFELD, using banderole labels. The cycle time was 4.5 seconds, the operation time of the robot below 0.7 seconds. The WITTMANN Group
Granulators From the extensive range of granulators, the appliances on display at the K 2013 were the compact
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The WITTMANN Group based in Vienna/Austria is one of the world’s leading manufacturers of robots and peripheral equipment for the
plastics industry. The WITTMANN product portfolio includes robots and automation equipment, automatic material loaders and material dryers as well as equipment for plastics recycling, mold tempering and cooling, and volumetric and gravimetric metering appliances. WITTMANN BATTENFELD, a company of the WITTMANN Group with its headquarters and production facility in Kottingbrunn (Lower Austria), is a leading manufacturer of injection molding machinery and equipment for the plastics industry. The company is present in about 60 countries with its own sales and service companies as well as representative offices, thus offering optimal support to its customers in all matters concerning injection molding technology. For more information, please visit: www.wittmann-group.com