AHEAD The customer magazine of KraussMaffei Berstorff Issue 01.2012
The KraussMaffei
Group has a global
presence. Countries
with subsidiaries are
marked in blue.
In the white-coloured
regions, the Group is
represented by over
570 sales and service
partners.
Ahead
The customer magazine of KraussMaffei Berstorff Issue 01.2012
No compromising on quality for recycled EVA SHEET
SHEETS for the growing solar module
market
36D series
Increasing flexibility and
reducing material costs
KraussMaffei Group
Netstal
KraussMaffei
Injection Molding Machinery
Injection Molding Machinery
Reaction Process Machinery
KraussMaffei
Berstorff
Extrusion Technology
KraussMaffei Group
Wide-reaching expertise with Technology3
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies
for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands:
Injection Molding Machinery, Automation, Extrusion Technology and Reaction Process Machinery.
The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your
highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry.
Further information available at:
www.kraussmaffei.com
Imprint
KraussMaffei Berstorff
Editorial
CONTENTS
KraussMaffei Group appoints Dr. Hans
­Ulrich Golz as the new “President” of the
Injection Molding Machinery Segment
Cover story
4Growing solar module market – No
compromising on quality for recycled
sheet
Brand & markets
10Coextrusion – Reducing costs for
window profile production
12Award-winning – KraussMaffei
Berstorff in Brazil
13Interview with Dr. Jens Liebhold
Dear Readers,
I am very excited to present to you our new customer magazine with its new format
and fresh content. And we have given our magazine a new name: AHEAD.
With AHEAD we have purposefully chosen a strong title that, for one, clearly expresses our forward-looking approach in all areas, based on our technological expertise. It also highlights the competitive edge you gain from the high quality of our
machines and our extensive skills and knowledge base.
Our cover story provides the perfect illustration of how we are moving „ahead“ with
our strong and innovative performance. The article outlines our new system concept for the production of premium quality EVA films for photovoltaic modules. The
systems have impressive features, including film widths of over three meters and
recycling of the edge trimming into the extrusion process.
Under the heading „Processes & Products“ we will be keeping you up to date with
new products and processes. For example, we are showcasing our proven-value
extrusion lines for increased flexibility and lower material costs. In addition, we are
reporting on our new rubber profile systems in laboratory scale for the optimization
of rubber compounds and profile characteristics.
As the KraussMaffei Group is strengthening its activities in the area of injection
molding, there is a change in personnel at the top of KraussMaffei Berstorff.
Dr. Hans Golz will become President of Injection Molding Machinery across the
group . Up to now, he has successfully headed up Extrusion Technology and been
Managing Director of KraussMaffei Berstorff – which meant he was your point of
contact. We congratulate Dr. Golz on his new brief and we wish him every success.
The process to find a successor has already begun, your current contacts will remain the same.
We aim to offer you added value across your value chain. The application reports in
this magazine show how this is achieved, providing examples of our machines and
systems being successfully operated at customer sites. These success stories are
important to us, as it is our aim at AHEAD to provide you with information on our
products and applications as well as with tips from our experts and important facts
and figures relating to extrusion processes.
Wishing you an enjoyable read,
Dr. Jens Liebhold
Vice President Extrusion Technology
Processes & products
14Labstar line – expanded portfolio
of rubber profile systems
15Single-screw extruder – heading for
success thanks to flexibility
16 36D series – increasing flexibility and
reducing material costs
18 Twin-screw extruder – wear-resistance increases service life
Partners & projects
20QuickSwitch –with new functions
21Crosslink Finland Oy – proven-value
pooling of expertise
22LCC Polytar – modular system concept for PO sheet
23Making strides in the research of
technical plastic foams
KRAUSS MAFFEI GROUP
24Interview with CEO Jan Siebert
25New and strong brand presence
26 The latest from KraussMaffei
26 The latest from Netstal
27KraussMaffei Group appoints Dr. Hans
­Ulrich Golz as the new “President”
of the Injection Molding Machinery
Segment
27Imprint
The KraussMaffei Group has appointed Dr. Hans Ulrich Golz as
“President” of a common Group-wide Injection Molding Machinery
Segment. Bernhard Merki, CEO of Netstal Maschinen AG, is leaving
the company. Dr. Karlheinz Bourdon and Frank Peters, previously
responsible for the Injection Molding Machinery and Reaction Process Machinery business at KraussMaffei, will take up new posts
within the segment.
Generating additional value add for cus­
tomers The KraussMaffei Group will continue to strengthen its position on key markets and purposefully extend its presence on
growth markets. “We want to provide even
more benefits for our customers along their
entire value-adding chain. For this purpose,
we will increase our injection molding activities throughout the Group. We will therefore
maintain the independent market presence
of the Netstal and KraussMaffei brands with
a clearly defined product portfolio and separately operating sales organizations for both
brands”, said Jan Olaf Siebert, Chairman of
the Board of M
­ anagement of KraussMaffei AG.
The “President” of the Group-wide Injection
Molding ­Machinery Segment will be Dr. Hans
Ulrich Golz, a well-known expert in the field of
mechanical engineering, who has served the
company to date successfully as President of
the Extrusion Technology Segment and Chairman of the Management Board of KraussMaffei Berstorff. Bernhard Merki, CEO of Netstal
Maschinen AG, decided to step down from his
position and to leave the company. “Mr. Merki
has worked for Netstal in various functions
since 1988. We would like to thank him for all
his work and wish him all the best for the future”, said Siebert.
Dr. Karlheinz Bourdon and Frank Peters,
previously responsible for Injection Molding
­
­Machinery and Reaction Process Machinery at
KraussMaffei, will take up new posts as part
of the reorganization measures at the Injection Molding Machinery Segment. Dr. Karlheinz
Bourdon will take up the post of “Vice President Technologies” and will be amongst others responsible for the common segment activities in Research and Development, Product
Management and Process Engineering Development. As “Vice President Sales KraussMaffei” Frank Peters will have sole responsibility
for sales of injection molding machinery bearing the KraussMaffei brand. “I am very pleased
that both managers have decided to actively
support this process in a responsible position
for the benefit of the company”, said Siebert.
As the suc­cessor to Frank Peters, Nicolas Beyl
will m
­ anage the Reaction Process Machinery
Segment of KraussMaffei in future. Succession
arrange­ments in respect of Dr. Golz as Managing Director of KraussMaffei Berstorff and
President of the Extrusion Technology Segment
are currently being made.
Trade show calendar 2012 (May – October)
Technics, Belgrade, Serbia
2012-05-14 – 2012-05-18
KraussMaffei
International Engineering Fair, Nitra, Slovakia
2012-05-22 – 2012-05-25
KraussMaffei
Plastpol, Kielce, Poland
6th Congress on plastics in E&E applications,
Würzburg, Germany
KraussMaffei Japan in-house exhibition
2012-05-29 – 2012-06-01
KraussMaffei Group
2012-06-14 – 2012-06-15
KraussMaffei
2012-06-26 – 2012-06-29
KraussMaffei
DKT (German Rubber Conference), Nuremberg, Germany 2012-07-02 – 2012-07-05
KraussMaffei Berstorff
International Energy-saving & Advanced Building
Materials Exhibition, Shanghai, China (PRC)
2012-08-15 – 2012-08-17
KraussMaffei
Interplast, Joinville, Brazil
2012-08-20 – 2012-08-24
KraussMaffei Group
China Int. Exhibition on Engineering Plastics
2012-09-05 – 2012-09-08
KraussMaffei Berstorff
MSV, Brno, Czech Republic
2012-09-10 – 2012-09-14
KraussMaffei
Expoplasticos, Guadalajara, Mexico
2012-09-12 – 2012-09-14
KraussMaffei
PU China, Shenzhen, China (PRC)
2012-09-18 – 2012-09-20
KraussMaffei
Taipeiplas, Taipei, Taiwan (ROC)
2012-09-21 – 2012-09-25
KraussMaffei
Composites Europe, Düsseldorf, Germany
2012-10-09 – 2012-10-11
KraussMaffei
Colombiaplast, Bogotà, Colombia
2012-10-01 – 2012-10-05
KraussMaffei
Fakuma, Friedrichshafen, Germany
2012-10-16 – 2012-10-20
KraussMaffei Group
Imprint
Publisher:
KraussMaffei Technologies GmbH
Krauss-Maffei-Strasse 2
80997 Munich
Germany
Phone + 49/89/88 99-0
Fax + 49/89/88 99-2206
www.kraussmaffei.com
Person responsible:
Imre Szerdahelyi (responsible for content
according to German media law)
Editor-in-chief: Eva Münzenmaier
Editorial team:
Markus Betsche, Christine Grob,
Dr. Jens Liebold, Eva Münzenmaier (EM),
Toni Nippe, Annemarie Pabst (AP),
Prof. Dr. Bernd Poltersdorf, Holger Schaarschmidt, Hans-Peter Schneider, Claudia
Stadler (CS), Imre Szerdahelyi, Joachim
Weber, Andreas Weseler (AW)
Photo credits:
Harald Mehnert, Eberhard Franke,
Stefan Kruppa, customer photo collection.
Group-internal photo collection
Concept and design:
Kirchhoff Consult AG, Hamburg, Germany
www.kirchhoff.de
Press:
Druckerei Kriechbaumer, Taufkirchen,
Germany
The customer magazine is published twice a year in
German and English. The magazine may only be reprinted with the written permission of the publisher.
27
Content
KraussMaffei Berstorff
4
rowing solar module market –
G
No compromising on quality for recycled sheet
23
Making strides in the research of technical plastic foams
10
Coextrusion – future system for reducing costs in window
profile production
3
4
Cover story
AHEAD Issue 01.2012
No compromising on quality for recycled EVA SHEET
EVA SHEETs for the
growing solar
module market
Cover story
KraussMaffei Berstorff
5
Versatile
Twin screw extruder
ZE UTX processes the
EVA material gently.
With the new, patent-pending technology of a specific flat-sheet line,
Krauss Maffei Berstorff is offering an ecologically-friendly and economical
solution for the production of EVA sheets.
Text: Toni Nippe, Holger Scha arschMidt, Prof. Dr. Bernd Poltersdorf Photos: Harald Mehnert, Stock
E
thylene vinyl acetate (EVA) is regularly used as a raw material for technical sheets as it is more cost-effective than its alternatives while still providing suitable mechanical properties for individual operating uses. For this reason EVA sheets
are now used as standard as encapsulation sheets for silicon
cells in solar panels. They are used in 95 percent of all applications. For­
the same reasons, EVA sheets may well become standard in laminated
safety glass panes – they are more cost-effective than the currently­
used sheets made of polyvinyl butyral (PVB) and easier to produce.
Both application areas offer considerable potential for growth for EVA
sheets in the coming years.
Previously, EVA sheets have predominantly been manufactured to a
width of 1 m and at relatively slow speeds. Shrinkage of up to 45 per­­cent is normal and the degree to which EVA sheets can be recycled
has not been fully clarified. KraussMaffei Berstorff has now found an
answer to these limitations and questions. A new flat-sheet extrusion­
system has been developed which enables high-speed manufactur-
ing of EVA sheets with a width of up to 3.2 m. At the same time, numerous trials have shown that the sheets manufactured using this
system have optimum visual characteristics and low shrinkage of a
maximum of 5 percent, both of which aspects still apply after the material has been recycled several times. The option of recycling the
sheet makes the whole process considerably more cost-effective and
therefore much more lucrative for the manufacturers of solar modules and laminated safety glass.
Benefits for sheet manufacturers The new system technology offers a
number of benefits both for the sheet manufacturer and the end user.
The main benefits for the sheet manufacturer are the achievable width
feeding the edge trims back into the extruder. These benefits have
been achieved by the excellent combination of the implemented twinscrew extruder with optimized downstream equipment. The downstream equipment is a technical solution which ensures that the sheet
is processed using defined parameters which produce the optimum
product properties described later.
Cover story
Recycling possible The main advantage of
the new system technology is the option of
recycling the edge trimming that is always
produced when manufacturing the encapsulation sheet back into the production process
and thereby saving on raw materials. At the
same time savings are made on waste disposal costs for production waste. To prove
the recycling qualities of the product, numerous tests were carried out at the Fraunhofer
Center for Silicon Photovoltaics (CSP) in
Halle. The results clearly showed that there
is no loss in quality to the sheet even when it
is reprocessed several times in the extruder.
The main reason for the problem-free recycling is the twin screw extruder that is used
in the system, guaranteeing gentle but thorough raw material homogenization. The twin
screw extruder provides additional added
value as it enables the processing company
to process individual components instead of
expensive precompounds. At the same time,
the sheet manufacturer is more independent
in their choice of formulation and is able to
react flexibly to changing requirements.
Simple to use For manufacturers of photovoltaic modules, it is essential that EVA sheet
is of the right quality for the end products in
AHEAD Issue 01.2012
which it is to be used. In addition, good processing properties are essential, alongside
the important quality criteria of good shrinkage and high transmission levels. Depending on the application, it may also be of inte­
rest to receive sheet that is embossed on
both sides, something which can easily be
achieved with the new system technology.
Good visual properties For the test samples
that were examined at the Fraunhofer CSP,
KraussMaffei Berstorff extruded various
formulations in the development lab. First
of all, a typical EVA formulation of brand
new material as well as silanes and peroxides was used. From this product, a proportion was ground in the edge strip granulator and reintroduced to the production
process at a percentage by weight of 20 percent. This created sample no. 2. For the third
sample, an EVA formulation was regranulated three times and extruded again as an
EVA sheet These three different EVA sheet
materials were then laminated between two
2.9 mm thick panes of glass by the researchers at the Fraunhofer Institute and then submitted to various tests alongside a pure
glass test sample to determine their reflection and transmission behavior. The results
Tr ansmission le vel
(gl ass, E VA SHEET)
Transmission level (%)
6
Wavelenght (nm)
Transmission level (glass, EVA SHEET)
The EVA sheets are highly transparent with an
average transmission level of > 99 percent in the
spectral range of 420 to 1,100 nm.
Below 420 nm, the UV absorption
of the EVA sheet takes effect.
At approx. 365 nm, the transmission level of the EVA
sheet is 50 percent.
Source: Fraunhofer Center for Silicon
Photo­voltaics CSP
Glass
EVA sheet
Solar cells
Back layer
Layers
Typical configuration of
a photovoltaic module
Cover story
KraussMaffei Berstorff
7
Quality
Proof of shrinkage of
the sheet samples in the
untreated condition after heating in the oven
and after the water
bath method. Result:
Outstanding shrinkage
values < 5 percent
showed that the three different samples were more or less identical
in their properties, thus proving the recyclability of the EVA sheets. At
the same time, the researchers ascertained that the transmission of
the EVA sheet in a glass-EVA-glass test sample in the spectral range
between 420 and 1,100 nm is 99 percent. The reduced transmission
capability compared with pure glass is explained from the reflection
on both glass/sheet interfaces. The reflectance in the same spectral
range was only 0.2 percent and was also the same for all three sample materials.
Low shrinkage Another important processing criterion for the processing company is the shrinkage behavior of an EVA sheet. Even
though a number of processors have already adjusted their production processes to size the sheet larger for solar module production and
to adapt the laminating parameters accordingly in order to compensate for the shrinkage, product quality issues can still occur due to excessive shrinkage. The change in the molecular structure of the sheet
during shrinkage can result in microcracks in the solar cells or voids
or defects in the sheet and therefore a reduction in quality, reduced
efficiency and a shortened service life.
In order to check the shrinkage behavior of the EVA sheet p
­ roduced
on the new flat-sheet line, both established test methods were used: In
one configuration, the samples were laid in a water bath at a temperature of 85°C and in the second configuration on a preheated glass
plate with an applied talcum bed and placed in an oven for 5 minutes
at a temperature of 160°C. The results in both cases were absolutely convincing; shrinkage for all samples was below 5 percent, representing an enormous improvement compared with standard EVA
sheets in use today, which have shrinkage levels of up to 45 percent.
Convincing proof The tests that have been carried out on the transmission and shrinkage behavior as well as the recyclability of the EVA
sheets clearly proved that the new system technology from KraussMaffei Berstorff is perfectly suitable for the job. In combination with
the considerable expansion of the sheet width up to 3.2 m, it is now
possible for the first time to produce EVA sheets economically for
manufacturing both photovoltaics and laminated safety glass.
YOUR CONTACT:
Dipl.-Ing. Toni Nippe
Project Manager in the sheet extrusion department
KraussMaffei Berstorff GmbH
toni.nippe@kraussmaffei.com
YOUR CONTACT:
Dipl.-Ing. Holger Schaarschmidt
Divisional Manager for the foam, sheet and sheet extrusion processing
department
KraussMaffei Berstorff GmbH
holger.schaarschmidt@kraussmaffei.com
YOUR CONTACT:
Prof. Dr. Bernd Poltersdorf
Business Director for foam, sheet and sheet extrusion systems
KraussMaffei Berstorff GmbH
bernd.poltersdorf@kraussmaffei.com
8
Brand & markets
Brand & markets
AHEAD Issue 01.2012
Brand & markets
KraussMaffei Berstorff
9
Coextrusion
Coextrusion is the hot topic in the profile extrusion sector.
In profile extrusion, a coextrusion solution can allow the
core or other non-visible window parts to be made of recyclates or more cost-effective formulations; while the visible
surfaces are made of color-fast brand new material.
KraussMaffei Berstorff offers a wide product range in
coextruders and space-saving coextrusion concepts such
as column or piggyback combinations.
10
Brand & markets
AHEAD Issue 01.2012
Coextrusion
Future system for reducing costs
in window profile production
The window profile extrusion sector has seen constantly increasing demand for coextrusion systems in
recent years. Producers faced with continually increasing material costs as well as stagnating profile
sales prices are looking for economical solutions that can guarantee a reliable processing of more costeffective materials or recyclates. KraussMaffei Berstorff offers the right extruder combinations for this.
Text: Hans-Peter Schneider
Symposium during the Interplastica in Moscow is very well
received The subject “Solutions for cost-effective window profile
extrusion” was also the main theme of the symposium held by
KraussMaffei Berstorff in cooperation with the well-known companies
Greiner, Bärlocher and Omya as part of the Interplastica 2012 in Moscow. The organizers welcomed around 70 interested customers to the
event. Peter Oswald, Head of the Profile Product Group at KraussMaffei Berstorff, received an outstanding response to his paper on “Cost
optimization in coextrusion”, where he focused on intelligent extruder concepts together with different and premium quality coextrusion
solutions. Coextrusion is an attractive alternative as this concept enables cost-effective material mixes or recyclates to be used for the
non-visible core of the profile. The thin outer layer is then produced
using color-fast brand new material. “From the point of view of reducing costs, coextrusion is becoming increasingly interesting, and not
just to our Russian customers”, emphasizes Oswald. “The technically
advanced coextrusion lines are already in great demand and certainly
represent the future in window profile extrusion”.
Twin-screw extruders with the perfect processing concept for various profile extrusion requirements The parallel twin-screw extruders from the 32D series of the KraussMaffei Berstorff product range
are ideally suited for use at medium and high output levels. The single-conical models come into their own with their robust and compact design. The processing concept for all the machines ensures
optimum melt homogeneity as well as processing of a wide range of
formulations with a single screw geometry. The screws of all series
are coated with molybdenum armoring and, in combination with deepnitrided barrels, offer active wear-resistance when processing dryblend
with various levels of filler material as well as when using recyclates.
1
2
KraussMaffei Berstorff's innovative product range of coextrusion
models for a wide range of applications KraussMaffei Berstorff offers a wide range of space-saving coextrusion concepts such as column or piggyback combinations. Ultimately, the extruder setup is dependent on the individual machine application but also on the amount
of space available to the customer. The following examples should
help to provide an insight into the wide range of different coextrusion
systems already in operation.
For example, the company Schüco International KG produces
window profiles with coating technology in the double strand procedure
with an extruder combination featuring the two models KMD 90-32/P.
Both extruders process regrind and brand new material in the ratio 60
to 40 percent – with an output of 700 kg/h (see picture 1).
Using a concept combining the main extruder KMD 114-32/P and two
coextruders KMD 63 K/P (see picture 2), the customer Profine in Berlin (KBE Profine) produces window profiles using mixing technology –
also using the double strand procedure. The main extruder processes
regrind (up to 55 percent of the overall output), while the two coextruders process the brand new material; the total output of the line
equals 800 – 1,000 kg/h.
The piggyback concept (shown in picture 3) – comprising a conical
twin-screw extruder KMD 63 K/P on the parallel twin-screw extruder KMD 114-32/P – provides an example of main window profile manufacturing using core technology and the monostrand procedure. In
this instance, approximately 35 percent regrind is processed with a
total output for the machine combination of 450 – 600 kg/h.
3
Brand & markets
KraussMaffei Berstorff
4
5
The conical twin-screw extruder also allows processing of different
materials, such as white regrind, colored regrind, colored fine regrind,
regranulate or dryblend with a single screw geometry. The processing
concept is also designed in such a way that, at a maximum output of
220 kg/h and a melt pressure of 470 bar, the melt temperature of 195°
is not exceeded. In addition, the option exists to add a further coextruder to the existing machine combination.
Picture 4 shows an extruder combination made up of the twin-screw
extruder KMD 90-32/P and the coextruder KMD 63 K/P. For the core
technology, the coextruder is used to extrude the regrind core, while
for the coating process, the same machine produces the outer profile
layer from brand new material. The output of this extruder combination is between 450 and 550 kg/h.
Picture 5 shows a combination of two conical models that are used to
produce gutters (see picture 5a). While the main extruder KMD 63K/P
processes dryblend, the coextruder KMD 43K/P uses granulate to produce the high-gloss surface layer at a production speed of 6 m/min
and an output of 200 – 220 kg/h.
In addition to a large selection of different extruder combinations,
KraussMaffei Berstorff also offers coextruders in stand-alone designs. These models can be quickly adjusted and easily moved in all
directions. This enables flexible injection from a wide range of positions when using various different molds.
6
7
11
5a
The coextruders can be supplied with a control unit integrated in the main extruder (picture 6) or with their own C5 control
(see picture 7).
All combinations offer appealing solutions with their flexible processing technology and extreme user-friendliness during assembly and
maintenance. The extruders are designed in such a way that the processor can easily dismantle the screws and has easy access to the degassing units.
YOUR CONTACT:
Dipl.-Ing. (FH) Hans-Peter Schneider
Project Manager – development of processing technology for
twin-screw extruders for the KraussMaffei Berstorff brand at
KraussMaffei Technologies GmbH
hans-peter.schneider@kraussmaffei.com
12
Brand & markets
AHEAD Issue 01.2012
AWARD-WINNING
KRAUSS MAFFEI BERSTORFF –
BEST FOREIGN SUPPLIER IN BRAZIL
The machines and systems of KraussMaffei Berstorff have won the award “Best foreign
supplier of extrusion technology” in an annual competition organized by the trade journal
Plasticos em Revista. A notable, continuous increase in orders received illustrates even
further the expansion of a strong market position not just in Brazil, but throughout the
entire South American continent.
Best foreign extruder supplier Every year, the renowned trade journal Plasticos em Revista carries out an independent survey of all processing companies covering a wide range of plastics technology issues. For the competition in 2011, more than 1,000 participants from
the plastics industry were asked to evaluate a wide range of criteria
regarding technologies, machine engineering and even levels of service. The extrusion lines of KraussMaffei Berstorff won the award for
best machine technology, best quality and best service by a foreign
supplier.
KraussMaffei Berstorff is experiencing particularly high demand in
the area of PVC pipe processing in which the proven machine technology of the 36D twin-screw extruder is used for fresh water, waste­
water and drainage pipes and cable sheathing applications. KraussMaffei is also very much on trend in the profile and sheet extrusion
sectors. This was shown in the recent sales of two machines for the
extrusion of thin-walled ceiling profiles for cladding. In the sheet sector, it is mainly PVC sheet lines that are in demand, e.g. for foamed
end products.
Strengthening market presence in South America The award reflects the outstanding market position of KraussMaffei Berstorff in
the South American market. “We impress our customers with the
quality of our products, and also with our quick and efficient service”,
explains a happy Bruno Sommer, Extrusion Technology Manager at
the KraussMaffei subsidiary Group do Brasil. “The customers appreciate the high level of technical competence of our local service and
sales employees. And in addition, we are in a position to react quickly
and decisively thanks to our extensive spare parts warehouse”.
Increased demand through large events KraussMaffei Berstorff
added a number of projects to its books at the NPE, generally
viewed as the trendsetter for North America, as the event location
in Orlando also attracted a number of South American producers.
Demand for KraussMaffei Berstorff products is also high in other South
American countries, such as Argentina, Colombia, Chile, Ecuador
and Peru. The signs are that impetus remains strong and that growth
will continue, as building investments, and therefore the need for extrusion products from the infrastructure sector, will increase exponentially thanks to development work for large events such as the
World Cup in 2014 and the Olympic Games in 2016 in Brazil. AP
In demand
KraussMaffei Berstorff
twin-screw extruder with
single venting KMD 75-36
B/R for processing a wide
range of PVC mixtures
Interview
KraussMaffei Berstorff
13
Always offering added
value to customers
Dr. Jens Liebhold is the Vice President Extrusion
Technology at KraussMaffei Berstorff in Munich.
In an interview with Ahead, he discusses current
business performance, the strengths of KraussMaffei Berstorff as well as trends in extrusion
technology.
The interview was conducted by ANNemarie Pabst
Dr. Jens Liebhold
Ahead: Dr. Liebhold, could you briefly outline the current business
performance of KraussMaffei Berstorff?
Dr. Liebhold: At the moment, we are completely satisfied with how the
business is performing. The demand for our machines and systems
as well as for plastics and rubber technology continues to be very high
in 2012. The order books are full and I can say with a good conscience
that KraussMaffei Berstorff is enjoying a high level of recognition as
a market-leading company for reliable and proven-value extrusion
technology.
Ahead: What makes KraussMaffei Berstorff special?
Dr. Liebhold: Compared to our competitors, KraussMaffei Berstorff
has the most extensive and premium quality portfolio in my opinion.
Our ten product areas put us in an excellent position and each team is
able to act flexibly as a medium-sized business. As a system and solution partner, we respond specifically to our customers' requirements
and our experts configure all machines and systems precisely according to their requests. And we do this all over the world, in the automotive, construction, chemical, pharmaceutical and packaging industries, among others. Thanks to our innovative approach, we are also
in a good position in niche markets, for example in the areas of foam
extrusion or special foils or roof sheeting made of olefin-based thermoplastic elastomers (TPO) or polyvinyl chloride (PVC). Last but not
least, mention must also be made of our systems for manufacturing
tire components, which are specifically designed for processing the
abrasive filler material silicic acid.
Ahead: Which trends can you see for extrusion technology within
the plastics and rubber industry?
Dr. Liebhold: I can see three main trends at the moment. First of all,
more and more producers are focusing intensively on the use of technologically premium quality materials as well as on complex material systems. Secondly, processors appear to be striving increasingly
to reduce energy, costs and resources in order to enhance productivity.
And thirdly, producers are placing ever greater value on high flexibility within the manufacturing process. We are well-positioned to meet
these demands.
“We always aim to provide the
customer with extra benefits
or value-added service.”
Ahead: And what solutions is KraussMaffei Berstorff offering its
customers?
Dr. Liebhold: Our line concept for PE-Xa pipe extrusion or our system
for manufacturing EVA sheets for solar modules, for example, satisfy
the primary demand for premium quality materials outstandingly. IPC
technology for internal pipe cooling is a new innovation that has been
very well received in the market as a way of increasing productivity.
Manufacturers can also increase flexibility using our modular compounding systems, the proven 36D twin-screw series or our coextrusion solution for manufacturing window profiles, for example.
Ahead: KraussMaffei Berstorff is well-positioned across the sector
with a number of new innovations and you are still aiming to generate
further growth. In what areas will you continue to develop KraussMaffei Berstorff?
Dr. Liebhold: Our customers must continue to benefit over the long
term from a high level of quality in our machines and systems as
well as in the services we provide. For this reason, we are currently
investing in our TechCenters in Munich and Hanover to continue to
strengthen the system capability of our extrusion solutions, to improve
customer demonstrations and testing of new materials and to advance
the development of new systems, processes and procedures. Furthermore, we are developing our services, for example with regard
to delivery capability of spare parts or improvement of performance
quality and speed. We always aim to provide the customer with extra
benefits or value-added service. We have outlined this expectation
very clearly in our new service promise: Engineering Value.
14
Processes & Products
AHEAD Issue 01.2012
Processes & Products
Profile production system Labstar line
is ideally suited for research projects and
compound development.
Labstar line
expanded portfolio of manufacturing
­systems for rubber profiles
KraussMaffei Berstorff presented a new rubber profile production system for laboratory applications at
the Tires + Rubber trade fair in Moscow in April 2012. The compact Labstar line is designed particularly
for small output rates thanks to its short change-over times. Based on reliable technology for production
systems, the system concept ensures a stable and reproducible manufacturing process.
High flexibility paired with simple operation “The new profile production system is particularly suitable for research projects and compound
development due to low material consumption of just 8 kg/h, as it can
manufacture test specimens and sealing profiles with a diameter smaller than 1 cm2”, explains Harald Hepke, Technical Manager of Rubber
Technology at KraussMaffei Berstorff in Hanover. “Rubber compounds
for the extrusion process and for various profile characteristics can be
optimized using the profiles in further practical trials”, continues Hepke.
The lab system is purposefully designed for the productive manufacture of single component profiles, it provides a high degree of process
flexibility and, at the same time, is extremely easy to operate. Due to its
modular design, the system can be quickly adapted for different tasks.
The machine is built around a GE 25 x 18D rubber extruder for continuous material forming, and is equipped with a mobile control panel for
operating the system. The subsequent pre-vulcanization of the profile is
carried out by a shock module with short-wave infrared emitters.
Fast cleaning saves time “When developing the new vulcanization unit,
KraussMaffei Berstorff concentrated particularly on the need for simple
operation and high system reliability”, says Hepke. The compact combination of microwave and hot-air channels is based on production system technology and scores points due to an effective hot air channeling
system which conducts the energy to the product in the most efficient
way. The easy-opening covers make it possible to position the product easily during start-up and to clean the process chamber quickly.
Special emphasis was also given to the machine's operating concept.
A control panel and touchscreen on the vulcanization unit enable easy
operation and excellent visuals. Operating the unit on site means that
each setting can be checked visually at the same time. aw
Processes & Products
KraussMaffei Berstorff
15
Single-screw extruder for PO processing
Flexibility paves
the road to success
Within a very short period of time, KraussMaffei Berstorff has sold more than
25 KME 38-30 B/R single-screw extruders in this series, particularly in ­Europe
and on the American continent. Demand remains high, not least thanks to a
worldwide trend toward multi-layer pipes.
Flexible concept wins the day “Our customers especially appreciated
the compact construction and flexibility of this model”, emphasizes Andreas Kessler, General Sales Manager at KraussMaffei Berstorff. The
extruder can be used as a coextruder across a wide range of applications, for example in the extrusion of multi-layer pipes as well as in the
application of paint strips, bonding agents, thin inner or outer layers, oxygen barrier layers or sealing lips. The flexible design concept enables
space-saving operation. The piggyback version using a main extruder in
the production of multi-layer pipes requires less space in comparison
with the production of single-layer pipes. Depending on the application,
the control system of the coextruder operates autonomously or is integrated in the control system of the main extruder.
flexible
KraussMaffei Berstorff KME
38-30 B/R single-screw
extruder
Versatile application This model can also be used as a main extruder for the production of smaller pipes. The barrier-mixing screw concept results in thermal and material homogeneity of the melt and in low
melt temperatures, creating a premium quality end product. The optimally dimensioned drive concept with AC motor ensures energy-saving
production. The single-screw extruder is also suitable for the production of polyolefin sheets or multi-layer technical profiles. ap
16
Processes & Products
AHEAD Issue 01.2012
Proven
KraussMaffei Berstorff KMD 90-36 E/R 36D
twin-screw extruder with multicomponent
gravimetrics for processing materials with
high filler content
36D series
Increasing flexibility and reducing material
costs – with the twin-screw extruder
As a result of ever increasing material costs, the need among pipe manufacturers to process
raw materials with as high a filler content as possible is growing steadily. With immediate effect,
KraussMaffei Berstorff is offering an efficient procedure using a special version of its proven 36D
twin-screw extruder with single venting. It is equipped with multi-component gravimetrics – and
fully satisfies current market demands for flexibility and material cost savings.
Enormous cost savings “We have equipped the innovative machine
concept with multi-component gravimetrics with up to six components, three of which can be added gravimetrically or volumetrically”,
explains Michael Hofhus, Head of the Pipe Extrusion Product Group at
KraussMaffei Berstorff. The concept offers producers enormous material cost savings, as it enables maximum metering of cost-cutting
material mixtures. This means that with gravimetric weighing, highly
filled dryblends (up to 100 percent of the total output), regrinds and regranulates (up to 20 percent of the total output) or even pure chalk (up
to 40 percent of the total output) can be processed, mostly for waste
water pipes.
Maximum flexibility in the production process Using volumetric metering, microgranulate blow agents (depending on application, up to
three percent of the maximum output) can be added for the production
of, for example, foamcore pipes or paint masterbatches (up to a maximum of five percent). The system is equipped with a corresponding
storage container and a vacuum hopper for this application. In addition,
it is possible to prevent PVC residue clogging the extruder when the system is shut down by adding so-called purging compounds. “Besides the
huge competitive edge which the customer achieves thanks to the high
level of flexibility, they also benefit from very simple material conveying and handling”, adds Hofhus. The complicated mixing procedure required in standard systems is not needed in this case. The concept also
prevents segregation of the material. The material handling procedure
is designed very flexibly, so that the individual component ratios of the
mixture can be changed at any time.
The proven processing concept of 36D twin-screw technology with single venting also ensures completely safe material degassing. The tungsten-carbide coated process unit provides reliable wear-resistance
which is necessary for the processing of highly filled materials. The metering system can be used for pipe production as well as for sheeting
and profile production and granulation.
Current systems for the Turkish customer Hakan In the near future, several of these machines will be installed in various sizes for the
KraussMaffei Berstorff client Hakan, a long-standing and loyal customer. One of the leading plastic manufacturers for pipes and fittings
in Turkey, they are set to increase their production capacities for PVC
waste water pipes as part of an expansion program with KraussMaffei
Berstorff machines mid 2012. ap
KraussMaffei Berstorff
Processes & Products
Flexible
KraussMaffei Berstorff KMD 90-36 E/R
36D twin-screw extruder with multicomponent gravimetrics for processing
highly-filled materials
17
18
Processes & Products
AHEAD Issue 01.2012
KraussMaffei Berstorff sets new standards
Premium quality wear-resistance on
counter-rotating twin-screw extruders
with plasma transferred arc welding
Whether in pipe, profile or sheet extrusion: processors are being confronted with increasingly stringent
requirements for economical and efficient production. The counter-rotating twin-screw extruders from
KraussMaffei Berstorff provide outstanding, active wear-resistance for processing a wide range of different materials; they stand out with their very high machine quality which has won the trust of processing companies around the world. The producers are therefore able to reduce their maintenance costs as
a result of the high machine service life and minimum wear, and they benefit from economical production conditions and the resulting highly increased levels of competitiveness.
Text: Dr. Jens Liebhold
KraussMaffei Berstorff plasma transferred arc welding “With the
plasma transferred arc welding process (PTA) for hardfacing top rootface edges on counter-rotating twin-screw extruders, we are now offering even greater wear-resistance for all parallel and conical twin-screw
extruders”, explains Dr. Jens Liebhold, Head of the Extrusion Technology department at KraussMaffei Berstorff in Munich. The PTA system
(see picture 1) achieves hardfacing for screw diameters of 43 to 184 mm.
Specially developed software for this application enables a continuous
welding process even with changes in gradient of the root faces which
are being surfaced as well as welding of the runouts in relation to the
selected screw geometry.
Adhesive wear with counter-rotating twin-screw extruders Counterrotating twin-screw extruders transport (as a result of the principle of
movement) the material almost completely in the axial direction in an
enclosed chamber system (see picture 2). In the comb-out area of the
screws, the speed and pressure conditions caused by the system result
in a so-called calendar effect with flow conditions. In both the solids and
melt handling areas, this calendar flow under high surface pressures
leads to adhesive wear effects resulting from the screw shafts being
pushed apart, and the screw shafts can only support themselves on the
barrel (see picture 3). As a result of this abrasive wear mechanism, permanent damage can be caused during manufacturing to screws and
barrels, which can sometimes lead to a complete failure of the system.
PTA hardfacing of the top root-face edges using a molybdenum base
KraussMaffei Berstorff applies wear-resistant molybdenum-based PTA
hardfacing as standard to the top root-face edges of all parallel and conical twin screws in the diameter range 43-184 mm. Optimized welding
process parameters such as, for example, the current in relation to the
screw outer diameter and the customized composition of the flux powder ensure the production of PTA-molybdenum hardfacing that is practically free of cracks with the lowest possible dilution especially in the
outer areas of the weld (see picture 4). “Since we have been using the
improved welding technology, we have seen a significant increase in the
service life of the processing units”, emphasizes Liebhold. “As a result,
the processor enjoys increased equipment availability during the production process; and the machines are much better protected against
partial damage such as localized breakages”.
PTA hardfacing of the top root-face edges using a tungsten-carbide
base KraussMaffei Berstorff is also now offering a PTA-produced highwearing surface coating for all parallel twin-screw extruders with tungsten-carbide reinforcement. The welding material, which has an Ni-CrB-Si matrix base, guarantees optimum friction behavior at the lowest
possible coefficient of friction with its tribologically optimized friction
partners. KraussMaffei Berstorff has paid special attention to the careful selection of the flux powder and the metallurgical qualification of
the tungsten-carbide welding technology (see picture 5). Tungstencarbide coatings are used for heavy adhesive wear, for example for the
processing of natural fiber composites for decking profiles. The screws
of the twin-screw extruders for WPC processing are therefore equipped
with tungsten-carbide armoring. As a result, the KraussMaffei Berstorff
extruders achieve much higher service times compared with standard
Processes & Products
KraussMaffei Berstorff
19
1
1 Plasma transferred arc welding system
machines, which, depending on the formulation and correct operation
of the machines, can add between 12,000 and 20,000 operating hours
for WPC processing.
Tungsten-carbide coated processing units are also being used increasingly on KraussMaffei Berstorff extruders when using PVC formulations
with a high proportion of filler materials (up to 30 parts) and medium filler
material grain size distribution (greater than 10µm), with the aim of safely achieving the required service life levels of over 15,000 operating hours.
2
3
5
YOUR CONTACT:
Dr. Jens Liebhold
Vice President Extrusion Technology
KraussMaffei Technologies GmbH
jens.liebhold@kraussmaffei.com
4
2 Transverse and axial closed system with counter-rotating
twin-screw extruder
3 Specific wear for tribocontact screw vs. barrel through
expansion force formation
4 Finely dispersed, isotropic join of a molybdenum hardfacing
5 H
omogeneous, isotropic carbide distribution of
a tungsten-carbide hardfacing
20
Partners & projects
AHEAD Issue 01.2012
Partners & projects
QuickSwitch
Even more effective
with new functions
The long proven and extremely flexible QuickSwitch system from KraussMaffei Berstorff offers numerous
advantages. For example, the producer can change the pipe dimension in just a few minutes at the touch
of a button without having to stop the machine. Furthermore, manufacturers can enjoy increased competitiveness through short order lead times, small batches, reduction of downtimes and reduced material
and labor costs. They are also able to react quickly to market conditions, which are increasingly paying
more attention to ecological efficiency.
QuickSwitch and IPC in one system Effective
immediately, KraussMaffei Berstorff is also
offering the integration of the new IPC system in QuickSwitch units for effective internal
pipe cooling. “We are increasing cost-effectiveness in the application by combining it with
our highly efficient internal pipe cooling system”, explains Andreas Kessler, General Sales
Manager at KraussMaffei Berstorff. “This will
make our customers even more competitive:
on the one hand thanks to the enormous reduction in material, storage and labor costs;
on the other hand by reducing investment
costs on account of a reduction of up to 40
percent in the cooling zone in the IPC system”.
With the IPC technology, producers reduce energy consumption simply and effectively, as
the system works with pure ambient air and
does not require any special cooling media.
This innovative technology offers pipe manufacturers considerable efficiency savings, in
particular when producing thick-walled pipes,
as the investment costs in new equipment are
drastically lowered as a result of the shorter
cooling section and space requirements are
also considerably reduced. Alternatively the
output of an existing system can be increased
by up to 60 percent without having to lengthen
the cooling section as would normally otherwise be the case.
QuickSwitch integration in C5 control In addition the QuickSwitch system has also been
available since February 2012 as an “all-inone control”. The QuickSwitch functionalities, which were previously regulated via a
separate control unit, are now integrated in
an overriding C5 system control unit. Further
benefits lie, for example, in a standardized operating philosophy, standardized hardware,
flexible expandability or simple updates. Existing systems fitted with a C4 control unit can
also easily be upgraded. With these innovative
developments, KraussMaffei Berstorff is once
again demonstrating its expertise and ability
to deliver solutions with proven value. AP
Effective
KraussMaffei Berstorff
QuickSwitch system for the
production of multi-layer
PO pipes with 36D singlescrew extruder, multilayer
pipehead with IPC and C5
control
Partners & projects
KraussMaffei Berstorff
21
Pooled expertise
PE-Xa pipes produced on
KraussMaffei Berstorff lines
CROSSLINK FINLAND 0Y
pooling of expertise
in PE-Xa pipe production
KraussMaffei Berstorff and Crosslink Finland Oy from Tampere sealed a very promising partnership as
they signed a cooperation agreement. With this exclusive cooperation, the two innovative and leading
suppliers in the field of extrusion technology for hot water pipes are pooling their expertise. Combined
product development and marketing of complete systems for the extrusion of peroxide crosslinked polyethylene pipes are at the center of this technological cooperation.
Powerful extruders from KraussMaffei Berstorff “As a result of the
partnership with Crosslink Finland Oy, a specialist and innovative manufacturer of infrared crosslinking ovens and expert in the crosslinking
of polyethylene pipes, we will in future be offering our customers customized solutions for the manufacturing of PE-Xa pipes. Since all the
system components can be perfectly matched to each other, we can
guarantee the very highest quality during the production process”, explains Andreas Kessler, General Sales Manager at KraussMaffei Berstorff. A special system technology has been developed for the production of PE-Xa pipes. The complete line from the twin-screw extruder
via the pipe head through to the calibration and cooling system is perfectly matched to the processing of a ready-mixed compound. This is
made up of polyethylene, a stabilizer and peroxide. After these three
components have been mixed, a diffusion process takes place: the liquid peroxide is absorbed by the granulated polyethylene. This produces
an extremely homogeneous material mixture since the peroxide then
not only lies on the outer layer of a single PE grain, but is also homogeneously distributed inside the grain. The system also ensures extremely reliable and constant process conditions, i.e. perfect product quality
with a consistently high degree of crosslinking.
Crosslinking ovens from Crosslink Finland Oy The actual crosslinking of the PE pipe takes place in the infrared crosslinking oven, which
is supplied by the partner Crosslink Finland Oy and is integrated in
the overall system concept. “I am proud to be able to cooperate with
KraussMaffei Berstorff, one of the leading international extrusion system manufacturers”; enthuses Aarne Heino, Managing Director of
Crosslink Finland Oy. Heino is very optimistic about the future: “I am
anticipating much more interest in PE-Xa pipe extrusion and especially in our solution.” KraussMaffei Berstorff is also expecting growth in
the PE-Xa pipe extrusion sector over the long term and is committed to
a long-term partnership with Crosslink, also with a view to further developments in the areas of higher production speeds, greater pipe dia­
meters and multi-layer pipes.
Peroxide crosslinked pipes in many application areas Peroxide crosslinked pipes are characterized by numerous product properties, for example high flexibility and great resistance to heat and cracking. They
are used in panel and radiator heating systems, as well as in the supply
of hot water, drinking water and gas. PE-Xa pipes are also being used to
an increasing extent for alternative routing methods. AP
22
Partners & projects
AHEAD Issue 01.2012
LCC POLYTAR
Russian plastics ­manufacturer convinced
by modular system ­concept for PO sheet
LCC Polytar, one of the most important plastics processing companies in the Russian Republic of
Bashkortostan, is investing in a KraussMaffei Berstorff system for the production of polyolefin sheets.
The system will shortly come on stream at the company's head office in Salavat. Polytar, a whollyowned subsidiary of the Russian Gazprom Neftechim Salavat Group, is planning to press ahead with
the latest plastics processing technologies in the region.
Flexible system concept The complete production line featuring the KraussMaffei Berstorff
KME 150-36 B/V single-screw extruder as the
key component has a modular design which
permits gradual retrofitting at any time to increase processing flexibility. “We place particular value on the modularity of our line
concept. This enables us to produce various end products without any difficulty, as
we gain a considerable competitive advantage with a very wide range of products”, emphasizes Alexei Vital­yevitch Nikolaev Director
of Polytar. “We are also totally impressed by
the process engineering expertise of KraussMaffei Berstorff.” The system will initially produce 2.5-meter-wide polyolefin sheets up to
40 millimeters thick. In the next phase, the
customer can process polystyrene, acrylonitrite butadiene styrene and thin sheets (with
a thickness ranging between 0.5 and 2 millimeters). These thin sheets can be rolled since
the system concept ensures a quick changeover from stacked sheets to rolls through simple transversal adjustment of the stacking
unit and winder at the end of the line. In the
long term, the system can be retrofitted with
coextruders to produce multi-layer sheets by
using cost-effective materials or recyclates.
Process engineering expertise “The process engineering concept of our 36D single-screw extruder comprising a grooved
bush and a degassing unit also means that
both compact and chemically foamed sheets
can be produced. Production can also be
changed with the aid of a vented screw to
polystyrene and acrylonitrite butadiene styrene”, says Peter Oswald, Manager of the
Sheet Extrusion Product Group at KraussMaffei Berstorff. In addition, the machines
are also characterized by high melt specifications and gentle melt preparation. These
factors are the main reason for the excellent product quality. In addition, KraussMaffei
Berstorff has many years of application and
process experience in integrating downstream
injection units and submodules in the overall
system concept.
Refinement of raw materials Polytar refines
the raw materials produced within the parent group Gazprom Neftechim Salavat to produce premium quality end products such as
sheets, geotextiles or highly impact-resistant
polystyrene sheets, e.g. for the packaging industry, primarily for the domestic market or for
sale in CIS states. Around 7,500 tonnes of polymers are processed annually - and the trend
is still upwards. Polytar is planning, for example, to extend production capacities, increase
the product port­folio to include other extrusion
areas and con­struct a new technology center in
Salavat. AP
Excellent quality
Compact, coextruded
embossed and foamed
PO sheet
Partners & projects
KraussMaffei Berstorff
23
Fraunhofer ICT
Making strides in the research of
technical plastic foams
New worlds
The specified settings of the laboratory Schaumtandex system ZE 30 / KE 60 can easily be transferred to a large-scale system.
Until now the chemists of the Fraunhofer ICT had
to limit themselves to particle foams. A system
from KraussMaffei Berstorff is opening up whole
new worlds to them.
For around 15 years now, a department of the Fraunhofer Institute for
Chemical Technology (ICT) in Pfinztal has specialized in the research
and development of foamed plastics. A Schaumtandex system from
KraussMaffei Berstorff has now opened up a whole new realm of possibilities for them. “For the first time we are able to manufacture products using a direct foaming process. In addition to material modifications, we can now also develop new types of process”, enthuses the
Head of the Foaming Department, Florian Rapp.
Foamed plastic products are always in demand, when it comes to insulation and proofing, whether against heat, cold or noise: foam products are used in the construction and packaging sectors as well as in
the automotive industry. Constantly changing requirements for the material properties and the blowing agents used for manufacturing means
that there is considerable scope for research opportunities. The ICT de-
velops products and formulations as part of its own projects as well as
in cooperation with partners in industry. That said, the research work
up until now has been limited to particle foams.
That has now changed with the commissioning of the ZE 30 / KE 60
laboratory Schaumtandex system. The researchers can now produce
foamed semifinished products directly. Bio foams are an especially interesting subject area that is receiving a lot of interest. They have the
advantage of combining all the positive properties of foams, for example dimensional stability, lightness and insulating effect, with environmental friendliness.
The ICT has already had very good results in various projects with cellulose- and PLA-based particle foams. It now wants to transfer this to extruded foams, along with expertise in the area of foams from technical
plastics such as PET or PA.
With more than 80 installed systems of the type ZE/KE, KraussMaffei
Berstorff is one of the market leaders in this sector. With its combination of twin-screw and single-screw extruders it has a unique position
in the market. AW
24
KraussMaffei Group
AHEAD Issue 01.2012
KraussMaffei Group
Interview
Changing technology
leadership into
global market
leadership
Jan Siebert has been CEO of KraussMaffei AG since
January 1, 2012. In an interview with Ahead's editor,
the Aerospace Engineering graduate talked about the
potential of the KraussMaffei Group.
The interview was conducted by Imre Szerdahelyi.
Ahead: Mr. Siebert, for a little more than four months now you have
been at the top of the KraussMaffei Group. How would you summarize
the first months?
Siebert: The first months have been very positive for me. I have visited
many locations and purposely focused on entering into personal
conversations with employees at all levels. By doing so, I gained a very
good overview of current projects and processes. Additionally, I spoke
with numerous customers and business partners worldwide, who have
given me a good sense of their interests. This provided me with a wellfounded overview of the requirements of the markets and customers.
Ahead: What made a particular impression on you?
Siebert: My customer visits assured me of the great acceptance for
the high quality and performance of the machines and systems of
our KraussMaffei, KraussMaffei Berstorff, and Netstal brands. This
made a particular impression on me at the Chinaplas trade show
in Shanghai. I was also impressed by the high level of specialized
expertise of our employees in regard to technologies, procedures, and
applications. That makes us the most treasured partner worldwide at
the side of our customers. Additionally, I perceived strong motivation
in the company, passionate commitment, and unconditional striving to
develop the best possible solution for the customer at all times.
Ahead: Now you have the “typical” 100 days in the company behind
you. Are you already able to make some statements about the future
strategy of the KraussMaffei Group?
Siebert: Our strategy for the KraussMaffei Group is in place and we
will now implement it in the company, so I would like to give just a
rough outline here. In principle I see us as very well positioned worldwide. We will consistently work to strengthen business in the core
markets as well as to expand our presence in the worldwide growth
markets, especially in the BRIC countries and Asia. An essential
foundation for improving delivery capability is the expansion of our
international production capacities, particularly in China. In addition, we will concentrate more consistently on being market-oriented
and providing our customers with a range of products and services
that is high-quality and requirements-based, but also affordable. We
Jan Siebert, CEO (*1966)
As an Aerospace Engineering graduate, Jan Siebert has more than 18 years
of experience in leading management positions with esteemed industrial companies in the areas of strategy, Research and Development as well as Sales
and Marketing.
will stand by our customers with this range of products and services
across their entire value chain and offer them significant added value
with respect to efficiency and productivity.
Ahead: The KraussMaffei Group has distinguished itself with its leadership in technology and innovation. Where do you see potential here?
Siebert: Here we have a clear competitive advantage and we will
continue to push this forward. As a technology leader, in the future we
will continue to invest in the consistent further development of our
machine and systems engineering as well as in our leading application
knowledge. I see future potential for our technology portfolio particularly due to processors' efforts toward sustainable and economical management. This includes resource conservation and material
savings as well as improved energy, process, and product efficiency. In
the future we will continue to develop new trendsetting processes with
which we will make a significant contribution to the economic success
of our customers. Along with this, however, I have the task of developing our technological leadership into a global market leadership.
Ahead: Where do you see the greatest growth potential overall?
Siebert: I see numerous global market trends that lead to an increased demand for high-quality machines and systems for producing
and processing plastic and rubber. Along with the described trend
towards sustainability, I see the greatest growth potential in aspects
such as the continuously growing world population and an increasing rise in the standard of living in growing and emerging countries.
This presents numerous business opportunities for us, including in
the areas of medicine, infrastructure, and the packaging industry for
foodstuffs and consumer goods. The KraussMaffei Group is positioned
very well technologically with its product and service portfolio – and
we want to take advantage of that.
KraussMaffei Group
KraussMaffei Berstorff
25
Corporate Identity
New and strong brand presence
Starting immediately, the KraussMaffei Group with its three strong brands –
KraussMaffei, KraussMaffei Berstorff, and Netstal – has a new appearance.
Text: Eva Münzenmaier
Coca-Cola, adidas, BMW: Brands play a large role in consumer
business. They stand for lifestyle, prestige and – not to be underestimated – quality and utility. Brands convey emotions and specific value
perceptions. To a certain extent, this also applies to the global market
of investment goods, though this more rational world clearly gives
priority to other factors: customer benefit, the gain in productivity,
efficiency and flexibility.
the capability of integrating all areas of application in injection molding, extrusion, and reaction technology.
The KraussMaffei Group is characterized by the fact that it has
had three strong brands for many years. These are KraussMaffei,
KraussMaffei Berstorff and Netstal. “In order to solidify our claim
to market leadership, we improved the brand image of the KraussMaffei Group in cooperation with customers and enhanced the profile of each individual brand,” explains Imre Szerdahelyi, who as
Corporate Communications and Marketing Manager is responsible
for the new profile. “The result clearly distinguishes us from our
competitors and ensures an individual and unmistakable profile of
each individual brand on the market, which significantly increases
the respective product and technology expertise.” Furthermore, a
consistent group profile is ensured that reflects our brand-encompassing expertise and the unique selling proposition of Technology 3 –
→ K raussMaffei Berstorff stands internationally for state-of-the-art
and high-quality solutions in extrusion technology: engaged, reliable, proven value– Engineering Value
The starting shot for the new brand
concept was a uniform profile of all
three brands at the Fakuma 2011
trade show.
→ K raussMaffei is internationally synonymous with future-oriented
and cross-technology system and process solutions in injection
molding machinery, reaction process machinery and automation.
proven, powerful, passionate – Engineering Passion
→ Netstal stands internationally for premium quality high-performance
and high-precision injection molding technology and system solutions: fascinating, continuous, first-class – Engineering Excellence
The current image of the three brands is a consistent thread through
all short-term and long-term communications media and venues that
customers of the KraussMaffei Group encounter. The starting shot
for implementation was fired at the Fakuma 2011 trade show, where
the visitors could marvel at the new profile on two trade show stands.
“Because we make our products exclusively
with machines from the KraussMaffei Group,
their booth at the Fakuma trade show is of
course an important starting point for us.
There, we can speak professionally with
plastics specialists on the subject and learn
more about the newest development trends
and service options. Of course, it is also
interesting to experience the new systems
engineering once again in person. With the
integrated trade show concept of the three
brands, the synergy potential of the various
plastic finishing areas of injection molding
technology, reaction technology, automation
and extrusion are for the first time presented to us visually as well.”
Alfred Becker, Managing Director at Becker Kunststofftechnik GmbH
26
KraussMaffei Group
AHEAD Issue 01.2012
Polyurethane (PUR)
75 years young
Four and a half decades of process and machine expertise at KraussMaffei
Text: Markus Betsche Photo: Harald Mehnert
It would be hard to think of everyday
plastics without also thinking of products made of polyurethane (commonly called PU or PUR). The versatile chemistry of polyurethanes facilitates the creation of components
with virtually unlimited property profiles – from soft foams in automotive seat upholstery through to extremely light, high-strength carbon
fiber composites. Polyurethanes are found in virtually all industries and
areas of application.
KraussMaffei starts machine production in record time
Polyurethanes are an extremely young group of materials. Their “birth
certificate” is represented by the German Patent DRP 728.981, issued to
the inventor Otto Bayer on November 13, 1937. Since then, polyurethane
has been continuously breaking new ground in finding ever more new applications. KraussMaffei has been engaged in producing machines and
systems for processing polyurethane for 45 years – making us a pioneer
in the use of polyurethane. As early as one year after the start in 1967, the
first machines were appearing on the market. In close collabo­ration with
raw material manufacturers and processors, we developed ever more
new fields of application, processes and machines.
Expertise presentation in Florida
Just at the time of polyurethane's anniversary, we were opportunely able to demonstrate polyurethane processing “live” at the trade fair
in Orlando based on an armrest which was created using the SkinForm process. “That allowed us to demonstrate the Technology3 exper­
tise of KraussMaffei”, says Nicolas Beyl, Head of the Reaction Process
Machinery Division at KraussMaffei. “Machines, automation, tool technology and a solution for trimming - we provided all these things”.
Innovative
Armrests manufactured
using the SkinForm
process
PEt activities
Bundled expertise in the PET area
In 2011 the KraussMaffei Group brought together all of its PET activities under the umbrella of Netstal.
Customers benefit from a larger product range.
Text: CHRISTINE GROB Photo: Group-internal stock photo
Both Netstal and KraussMaffei have been working successfully for years in the global PET market
(PET: polyethylene terephthalate, a plastic for beverage bottles). We consolidated Sales and Marketing for the PET-LINE series of the Netstal brand and the PETForm series of the KraussMaffei brand under one roof. This step was greeted
by skepticism from the industry. “However, our customers quickly realized the advantages – as shown by the number of orders received,” emphasizes Thomas Anderegg, Marketing Manager, Sales and Application
­Techno­logy at Netstal.
MARKET LEADERS
In the beverage industry,
approxi­mately 80 percent of the
PET packagings worldwide are
used for carbonated soft drinks
(CSD) or non-carbonated water
and juices.
Clearly, the larger product portfolio from a single source is convincing.
This way we can configure a system for each customer that is perfectly
tailored to their individual needs. PET-LINE from Netstal is a state-ofthe-art production system on a platform basis for PET preforms. A wide
variety of mold and cavity sizes can be combined on the basis of three
clamping force sizes: 2000 kN, 4000 kN, and 6000 kN. The advantage is
minimum production costs at maximum output.
The PETForm series of the KraussMaffei brand is also an efficient module platform for manufacturing PET bottle preforms. With their vertical clamping unit design and an electric plasticizing unit, the machines
distinguish themselves above all by their high efficiency and excellent
uptime. The low production costs and long mold service life make PETForm systems a reliable solution for the beverage industry.
Imprint
KraussMaffei Berstorff
Editorial
CONTENTS
KraussMaffei Group appoints Dr. Hans
­Ulrich Golz as the new “President” of the
Injection Molding Machinery Segment
Cover story
4Growing solar module market – No
compromising on quality for recycled
sheet
Brand & markets
10Coextrusion – Reducing costs for
window profile production
12Award-winning – KraussMaffei
Berstorff in Brazil
13Interview with Dr. Jens Liebhold
Dear Readers,
I am very excited to present to you our new customer magazine with its new format
and fresh content. And we have given our magazine a new name: AHEAD.
With AHEAD we have purposefully chosen a strong title that, for one, clearly expresses our forward-looking approach in all areas, based on our technological expertise. It also highlights the competitive edge you gain from the high quality of our
machines and our extensive skills and knowledge base.
Our cover story provides the perfect illustration of how we are moving „ahead“ with
our strong and innovative performance. The article outlines our new system concept for the production of premium quality EVA films for photovoltaic modules. The
systems have impressive features, including film widths of over three meters and
recycling of the edge trimming into the extrusion process.
Under the heading „Processes & Products“ we will be keeping you up to date with
new products and processes. For example, we are showcasing our proven-value
extrusion lines for increased flexibility and lower material costs. In addition, we are
reporting on our new rubber profile systems in laboratory scale for the optimization
of rubber compounds and profile characteristics.
As the KraussMaffei Group is strengthening its activities in the area of injection
molding, there is a change in personnel at the top of KraussMaffei Berstorff.
Dr. Hans Golz will become President of Injection Molding Machinery across the
group . Up to now, he has successfully headed up Extrusion Technology and been
Managing Director of KraussMaffei Berstorff – which meant he was your point of
contact. We congratulate Dr. Golz on his new brief and we wish him every success.
The process to find a successor has already begun, your current contacts will remain the same.
We aim to offer you added value across your value chain. The application reports in
this magazine show how this is achieved, providing examples of our machines and
systems being successfully operated at customer sites. These success stories are
important to us, as it is our aim at AHEAD to provide you with information on our
products and applications as well as with tips from our experts and important facts
and figures relating to extrusion processes.
Wishing you an enjoyable read,
Dr. Jens Liebhold
Vice President Extrusion Technology
Processes & products
14Labstar line – expanded portfolio
of rubber profile systems
15Single-screw extruder – heading for
success thanks to flexibility
16 36D series – increasing flexibility and
reducing material costs
18 Twin-screw extruder – wear-resistance increases service life
Partners & projects
20QuickSwitch –with new functions
21Crosslink Finland Oy – proven-value
pooling of expertise
22LCC Polytar – modular system concept for PO sheet
23Making strides in the research of
technical plastic foams
KRAUSS MAFFEI GROUP
24Interview with CEO Jan Siebert
25New and strong brand presence
26 The latest from KraussMaffei
26 The latest from Netstal
27KraussMaffei Group appoints Dr. Hans
­Ulrich Golz as the new “President”
of the Injection Molding Machinery
Segment
27Imprint
The KraussMaffei Group has appointed Dr. Hans Ulrich Golz as
“President” of a common Group-wide Injection Molding Machinery
Segment. Bernhard Merki, CEO of Netstal Maschinen AG, is leaving
the company. Dr. Karlheinz Bourdon and Frank Peters, previously
responsible for the Injection Molding Machinery and Reaction Process Machinery business at KraussMaffei, will take up new posts
within the segment.
Generating additional value add for cus­
tomers The KraussMaffei Group will continue to strengthen its position on key markets and purposefully extend its presence on
growth markets. “We want to provide even
more benefits for our customers along their
entire value-adding chain. For this purpose,
we will increase our injection molding activities throughout the Group. We will therefore
maintain the independent market presence
of the Netstal and KraussMaffei brands with
a clearly defined product portfolio and separately operating sales organizations for both
brands”, said Jan Olaf Siebert, Chairman of
the Board of M
­ anagement of KraussMaffei AG.
The “President” of the Group-wide Injection
Molding ­Machinery Segment will be Dr. Hans
Ulrich Golz, a well-known expert in the field of
mechanical engineering, who has served the
company to date successfully as President of
the Extrusion Technology Segment and Chairman of the Management Board of KraussMaffei Berstorff. Bernhard Merki, CEO of Netstal
Maschinen AG, decided to step down from his
position and to leave the company. “Mr. Merki
has worked for Netstal in various functions
since 1988. We would like to thank him for all
his work and wish him all the best for the future”, said Siebert.
Dr. Karlheinz Bourdon and Frank Peters,
previously responsible for Injection Molding
­
­Machinery and Reaction Process Machinery at
KraussMaffei, will take up new posts as part
of the reorganization measures at the Injection Molding Machinery Segment. Dr. Karlheinz
Bourdon will take up the post of “Vice President Technologies” and will be amongst others responsible for the common segment activities in Research and Development, Product
Management and Process Engineering Development. As “Vice President Sales KraussMaffei” Frank Peters will have sole responsibility
for sales of injection molding machinery bearing the KraussMaffei brand. “I am very pleased
that both managers have decided to actively
support this process in a responsible position
for the benefit of the company”, said Siebert.
As the suc­cessor to Frank Peters, Nicolas Beyl
will m
­ anage the Reaction Process Machinery
Segment of KraussMaffei in future. Succession
arrange­ments in respect of Dr. Golz as Managing Director of KraussMaffei Berstorff and
President of the Extrusion Technology Segment
are currently being made.
Trade show calendar 2012 (May – October)
Technics, Belgrade, Serbia
2012-05-14 – 2012-05-18
KraussMaffei
International Engineering Fair, Nitra, Slovakia
2012-05-22 – 2012-05-25
KraussMaffei
Plastpol, Kielce, Poland
6th Congress on plastics in E&E applications,
Würzburg, Germany
KraussMaffei Japan in-house exhibition
2012-05-29 – 2012-06-01
KraussMaffei Group
2012-06-14 – 2012-06-15
KraussMaffei
2012-06-26 – 2012-06-29
KraussMaffei
DKT (German Rubber Conference), Nuremberg, Germany 2012-07-02 – 2012-07-05
KraussMaffei Berstorff
International Energy-saving & Advanced Building
Materials Exhibition, Shanghai, China (PRC)
2012-08-15 – 2012-08-17
KraussMaffei
Interplast, Joinville, Brazil
2012-08-20 – 2012-08-24
KraussMaffei Group
China Int. Exhibition on Engineering Plastics
2012-09-05 – 2012-09-08
KraussMaffei Berstorff
MSV, Brno, Czech Republic
2012-09-10 – 2012-09-14
KraussMaffei
Expoplasticos, Guadalajara, Mexico
2012-09-12 – 2012-09-14
KraussMaffei
PU China, Shenzhen, China (PRC)
2012-09-18 – 2012-09-20
KraussMaffei
Taipeiplas, Taipei, Taiwan (ROC)
2012-09-21 – 2012-09-25
KraussMaffei
Composites Europe, Düsseldorf, Germany
2012-10-09 – 2012-10-11
KraussMaffei
Colombiaplast, Bogotà, Colombia
2012-10-01 – 2012-10-05
KraussMaffei
Fakuma, Friedrichshafen, Germany
2012-10-16 – 2012-10-20
KraussMaffei Group
Imprint
Publisher:
KraussMaffei Technologies GmbH
Krauss-Maffei-Strasse 2
80997 Munich
Germany
Phone + 49/89/88 99-0
Fax + 49/89/88 99-2206
www.kraussmaffei.com
Person responsible:
Imre Szerdahelyi (responsible for content
according to German media law)
Editor-in-chief: Eva Münzenmaier
Editorial team:
Markus Betsche, Christine Grob,
Dr. Jens Liebold, Eva Münzenmaier (EM),
Toni Nippe, Annemarie Pabst (AP),
Prof. Dr. Bernd Poltersdorf, Holger Schaarschmidt, Hans-Peter Schneider, Claudia
Stadler (CS), Imre Szerdahelyi, Joachim
Weber, Andreas Weseler (AW)
Photo credits:
Harald Mehnert, Eberhard Franke,
Stefan Kruppa, customer photo collection.
Group-internal photo collection
Concept and design:
Kirchhoff Consult AG, Hamburg, Germany
www.kirchhoff.de
Press:
Druckerei Kriechbaumer, Taufkirchen,
Germany
The customer magazine is published twice a year in
German and English. The magazine may only be reprinted with the written permission of the publisher.
27
AHEAD The customer magazine of KraussMaffei Berstorff Issue 01.2012
The KraussMaffei
Group has a global
presence. Countries
with subsidiaries are
marked in blue.
In the white-coloured
regions, the Group is
represented by over
570 sales and service
partners.
Ahead
The customer magazine of KraussMaffei Berstorff Issue 01.2012
No compromising on quality for recycled EVA SHEET
SHEETS for the growing solar module
market
36D series
Increasing flexibility and
reducing material costs
KraussMaffei Group
Netstal
KraussMaffei
Injection Molding Machinery
Injection Molding Machinery
Reaction Process Machinery
KraussMaffei
Berstorff
Extrusion Technology
KraussMaffei Group
Wide-reaching expertise with Technology3
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies
for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands:
Injection Molding Machinery, Automation, Extrusion Technology and Reaction Process Machinery.
The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your
highly skilled and integrated partner. Use our comprehensive and unique expertise in the industry.
Further information available at:
www.kraussmaffei.com