Chinaplas 2019: KraussMaffei Berstorff launches ZE GP Agile twin-screw extruder
KRAUSSMAFFEI Berstorff . showcased its new ZE GP Agile twin-screw extruder series at this year's Chinaplas in Guangzhou. This extruder generation manufactured at the Haiyan production site of KraussMaffei Group is specifically aimed at compounding companies on the growth track that intend to substantially increase their productivity.
“For KraussMaffei Berstorff, China is an extremely important market as the growth trend is expected to continue in the years to come,” says Leo Yuan, Vice President Extrusion China of Shanghai KraussMaffei Machinery. “The development of the new series was focused on the key requirements of customers in China and in the Asian region in general: unparalleled productivity, outstanding reliability and a highly attractive price-performance ratio.”
The series comes in three sizes with screw diameters of 52, 62 and 77 mm and is suited for a wide range of different applications and output rates. The extruders can be driven by two different water-cooled motors designed for screw speeds of 600 rpm or 900 rpm.
State-of-the-art twin-screw extruder
The new ZE GP Agile extruder generation is equipped with screw elements and shafts made of special material, enabling compounders to achieve maximum throughput rates. In addition, the innovative series scores with an extended range of 4 and 6D barrel housings to precisely tailor the processing section to specific customer requirements. All barrel housings are characterized by precise temperature control. While cooling is based on cooling water injection, high-performance electric cartridge heaters are used for direct and rapid heating. The C-clamp flange system facilitates assembly and disassembly of the barrel housings and substantially reduces set-up times during barrel housing changes.
The standard equipment comprises the sturdy base frame designed to accommodate the temperature control units and the oil lubrication system. The state-of-the-art control software can be seamlessly integrated into the digital factory, ready for Industry 4.0. The on-board operating panel with display of all important extruder information saves time and provides enhanced ease of use. The new series is characterized by a constant level of excellent product quality, easy operation and uncompromising reliability. Its high productivity makes it a safe investment with a short payback period. It is aimed specifically at Chinese compounding companies with standard compounding applications.
Further information from: Andreas Weseler KraussMaffei Berstorff Hanover, Germany Phone: + 49 (0)511 570 25 86 Email: firstname.lastname@example.org
WINTEC exhibits two high-efficient machines
WINTEC, a member of the ENGEL Group, showcased at CHINAPLAS 2019, two machines that exhibit how high quality combines with the high efficiency. Customers can witness WINTEC's product lines of a servo-hydraulic and an all-electric injection moulding machines which cover a broad spectrum of applications.
t-win: High energy efficiency and sensitive mould protection
The servo-hydraulic injection moulding machines of the t-win series are offered with clamping forces from 4,500 to 17,500 kN, which means they are particularly ideal to produce large or three-dimensionally complex components.
During CHINAPLAS, a t-win 13500-7000 injection moulding machine with a clamping force of 1350t impressively demonstrated the performance of the series by producing auto lamp housings made from polypropylene. The shot weight is 1,200 grams in a 2 cavity mold, while each cycle takes less than 70 seconds.
The t-win machines are equipped with the servowin servo-hydraulics as standard, which reduces energy consumption by more than 60% in comparison with conventional hydraulic injection moulding machines.
Other advantages that ensure a high degree of energy efficiency include operating point optimisation and the dual-platen design of the clamping unit with low moving masses and exposed tie-bars.
The dual-platen clamping unit was developed in Europe and guarantees precise mould guiding and maximum platen parallelism throughout the machine's long service life, which leads to sensitive mould protection, outstanding dynamics and short dry cycle times. Parallel auxiliary movements such as the ejector, core pulls, or jets, are optional features.
The t-win 13500-7000 at CHINAPLAS is equipped with a viper 40 from ENGEL's linear robot series. The viper removes the finished parts from the mould and places them on the conveyor belt.
All-electric e-win for high precision and process stability
In the injection moulding machines of the e-win series, all machine movements are servo-electrical driven. The precision of movements ensures stable processes and a consistently high component quality, guaranteeing a fast return on investment. The e-win series also allows for shorter cycle times. These are realized by the parallel movements of the drive axles as well as the breath-taking acceleration, up to 22 m/s², of the injection axle.
Additional factors that contribute to efficiency are the low power consumption and the compact design. With clamping forces from 500 kN to 2,800 kN, the machines are used in a wide range of applications, where clean, high precision and quality processes are required.
At CHINAPLAS, an e-win 1000-170 with a clamping force of 100t is used to produce flip-top caps from polypropylene with a cycle time of 8.5 seconds.
Insights into intelligent manufacturing
As a member of the ENGEL Group, WINTEC is committed to the advanced concepts of the group. During CHINAPLAS, its exhibits operational data from the booth is transferred online and displayed in a manufacturing intelligence room in a remote location.
Via internet connection with real time machine data, WINTEC presents its leading concepts of future factory automation and Industry 4.0 readiness and demonstrates the benefits brought by digitization in manufacturing.
ILLIG's new IC-RDM 73K thermoformer makes Asian debut ILLIG, the German leading global supplier of thermoforming systems and mold systems for thermoplastics, highlighted automatic roll-fed machines at CHINAPLAS 2019. One of the highlights is the new IC-RDM 73K thermoformer which was displayed in Asia for the first time. The machine is integrated in a fully automated production line for drinking cups made of A-PET and A-PLA. At the same time, the IC-RDK 80 automatic roll-fed machine is in live production on the line of an oval A-PET tray.
IC-RDM 73K: High output and quick-change system for molds
IC-RDM-K machines are designed specifically for serial production of cups in various shapes and sizes from thermoplastic material. The new IC-RDM 73K has a high output and a quick-change system for molds. Moreover, ILLIG consistently implemented the Cleantivity concept in the machine.
Compared to the IC-RDM 70K machine, the forming area of the new machine is enlarged by 23%. Subject to applications, all improvements together contribute to an up to 25% increased production.Besides, a new, easy to use system for block change of molds reduces tool installation and removal times by more than 50%, which means the change can be performed in less than 60 minutes.
At the show, drinking cups were produced on the line using a 32-up mold, at a speed of 50 cycles per minute. The cups are made of A-PET and A-PLA films (0.7 mm thick). The machine on stage was combined with an in-line PH 73 stacking machine which can be variably equipped with different discharge options.
Machines of the IC-RDM-K series are also frequently used as in-line systems with pre-linked extruders, e.g. for large-volume production of drinking cups in quantities of millions. The ILLIG IC supports the aspects relevant for large-volume production. It includes modules for general process optimization, high productivity and availability as well as minimization of operation costs.
IC-RDK 80: High availability and easy operation
With IC-RDK series, ILLIG developed a forming and punching technology suitable to achieve excellent part quality and reproducibility of rays and hinged packs, used for protection of food during transport and as sales packs. The machines featured high availability and easy operation. Heated materials are formed by means of pre-stretcher and compressed air, and the part is punched out of the material in the same cycle. Thanks to this method, parts can be manufactured without punching mismatch in the rim area, and thus automatic pack processing is improved.
The company also showcased the IC-RDK 80 automatic roll-fed machine with live production on the line of an oval A-PET tray made of a 0.4 mm thick film with A/B stacking using a 10-up mold, at a speed of 50 cycles per minute.
Milacron sells Uniloy Blow Molding Business
MILACRON has sold its Uniloy Blow Molding Business to Osgood Group and Cyprium Investment Partners, LLC. Tom Goeke, Milacron President and Chief Executive Officer (CEO), said, “The sale of the Uniloy Blow Molding business is being transacted in the best interests of Milacron, its stockholders, and its customers. Uniloy has operated as a Milacron product brand since 1998, and we are confident it will continue to thrive under its new ownership in the years ahead. This divestiture is consistent with our decision to concentrate on our core industry-leading technologies including Milacron injection molding machines, Milacron extrusion equipment, Mold-Masters hot runner and control systems, DME mold components, and our Cimcool fluid technologies.”
The new Uniloy organisation will be led by Brian Marston, and he will serve as President and CEO. Marston is currently President of Blow Molding and Extrusion with Milacron. He has held leadership roles within the plastics and blow molding industry for 35 years. Osgood Capital's President, Joseph S. Levy, who has over 25 years' experience in the plastics and packaging industry was quoted as saying, “We are excited to have this opportunity to work with the outstanding Uniloy management team led by Brian. We expect to deliver world class service and solutions for all our customers' blow molding needs as well as strong growth in Global Uniloy brands for years to come.”
Mr. Marston was quoted, “The new Uniloy organisation will continue to provide the same high-performance machinery, technical expertise and aftermarket support that our customers have experienced since the 1960s. The Uniloy brand will continue to be recognised as a global leader in the blow molding industry. We will be working hand in hand with Milacron to make this a seamless transition for our customers. All existing orders will continue to be manufactured to the industry's highest standards.”
Sharp fall in orders for German machine tool industry
ORDERS received by the German machine tool industry in the first quarter of 2019 were 21 per cent down on the same period last year. Orders from Germany fell by 10 per cent whereas those from abroad were down by 27 per cent. “These dips are due not least to the extremely buoyant first half of 2018,” said Dr. Wilfried Schäfer, Executive Director of the VDW (Verein Deutscher Werkzeugmaschinenfabriken – German Machine Tool Builders' Association), Frankfurt am Main, commenting on the result. This base effect is expected to decrease significantly in the second half of 2019.
Dr. Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association), Frankfurt am Main (Source: Uwe Nölke)
“Nevertheless, the cooling of the global economy is now finally impacting on the German machine tool industry, too,” Schäfer continued. Domestic business, long a counterweight to the decline in foreign orders, has lost a great deal of momentum. The only bright spot is the euro zone, which is now much more stable and saw only a 3 per cent downturn.
However, it can only stabilise the loss from the non-euro zone to a marginal extent.
The causes of the downturn are easily identified: politically motivated disruptions to world trade which affect the emerging markets, weak growth in China, structural weaknesses in the automotive industry (the largest client market), and the slump in the semiconductor industry. “In 2018, the international automotive industry halved its capital spending to less than 4 per cent compared with the previous year, and it is likely to plan an even lower figure for 2019,” explained Schäfer.
Machine tool order levels are below those of sales for the first time again since mid-2014. Sales increased by 6 per cent in the first three months of 2019. “Many companies are currently relying on their order backlog from the previous boom,” said Schäfer. The excessive delivery times are shortening again. This makes procurement more flexible again for customers and reduces plant production throughput times for manufacturers. Capacity utilisation In April of this year was at 86.5 per cent and thus below last year's average. “The VDW nevertheless expects production to grow by 1 per cent in 2019,” emphasised Schäfer from the VDW. On the other hand, he is expecting demand to pick up in the second half of the year. The order backlog should also provide sustenance for some time to come.
Moretto showcased energy-saving and intelligent auxiliary systems at ChinaPlas
AT the booth of Italian leading auxiliary equipment manufacturer Moretto, the innovative solutions that take center stage are the result of a continuous investment on technological development. They are distinguished by being efficient and low energy consumption machines, conceived with the criteria of Industry 4.0 and based on the respect for environmental needs.
One of those on display at CHINAPLAS 2019 was the Moisture Meter Manager, a real excellence in Moretto's drying range. This revolutionary device reads in-line the moisture content of the granule, manages and controls in close loop the drying process, guaranteeing product certification and energy savings.
Moisture Meter Manager is equipped with the sensor MM CROWN for measuring the moisture of the granule.
When it enters the hopper, this detection allows the system to accurately predict the drying process that the dryer must handle. The dried material exiting by the hopper is further analyzed by the MM BOX sensor that, thanks to the exclusive Power-Peak technology, measures with an extraordinary precision the exact content of water present in the polymer (from 3000 up to 15 ppm, with a temperature range of 20-180°C).
Using the range between initial and final moisture levels allows Moisture Meter Manager to automatically manage the dryer working conditions and to maximize process performances only using the strictly necessary energy. This creates a perfect close loop that integrates the dryer into a fully automatic adaptive system. Moretto also showcased some “mini dryers” proposals.
The X Comb range, thanks to its powerful turbocompressors, zeolite technology, dew point equalizer (up to -60°C) and exclusive OTX hopper, is suitable for drying small quantities of material (hourly production from 1 to 20 Kg/h) in the medical sector. Maximum efficiency and auto calibration are strategic factors for an optimal transport of plastic materials. For this area, the company presented EXA, a flexible conveying system able to manage up to 6 Kasko receivers, including powerful suction units with side channels VS E, cyclone filter FC suitable for the transport of large quantities of granules or dusty regrinds. The system is connected with MOWIS, Moretto's supervising system and is manageable by portable devices Master K key pad and Master 300 touch view. The Exa system is complete equipment which ensures high control, performance and great flexibility in case of expansion of the system. In the process of transformation of plastic materials, dosing is a matter of precision, but also of control and monitoring. Moretto displays its new loss-in-weight dosing unit DPK, the gravimetric dosing unit DGM Gravix and DBK Gramixo, which are excellent for extrusion. These devices allow high precision dosing, modularity, reaction speed, connectivity and remote control. Te-Ko temperature controllers complete the displayed range of products. They ensure absolute efficiency and precision in the automatic temperature control both in the molds of the injection molding machines and in the cylinders and rollers of the extruders.
Surpass yourself - New generation molding system
DUE to the requirement of diversification, products of single color and single material is getting hard to satisfy consumers, that more concentrate on delicate and complicated products. Therefore the injection molding machines are required to be power-saving, clean and high efficient in response to the trend of intelligent production. FCS's advanced servo hydraulic injection molding machine - FA series, the injection unit and the clamping unit are upgraded to create a variety of products and stable performance quality. It provides integration service of differentiation which is applicable for houseware, stationary, automotive, 3C, food packaging and thin-walled container industries.
- Servo injection closed-loop system could accurately control the speed of each shot, the injection time stability is < 0.1%, and with stable molding product weight.
- The integrated and optimized hydraulic manifold and cylinder, improve the injection response, and expand the product application range.
- Clamping unit adopted electric motor with brake which could offer stable adjusting control and position.
- Tie bar spacing increase that more flexible choices for mold application.
- Platen strength improvement that increase rigidity by 30%, lower deformation of mold plate, and improve the mold lifetime.
- Optional modular specification, offering the high-speed type for option to flexibly meet the requirement such as food packaging and thin-walled container industries.
New generation molding system (FA-160).
Newly control unit and application:
- Newly interface design, illustration and support OPC protocol which make the operation most convenient and easy maintain the software and hardware.
- Provide statistical process control and injection waveforms to improve production quality and efficiency.
- The position control accuracy is 0.1mm which can precisely control the movement stroke.
- Have production quality recording, machine utilization rate and production capacity statistics which can be exported for visual management.
Be capable for iMF4.0 system and application:
- IMM and peripherals communicate with each to autonomously control the process quality.
- Applying process quality sensor monitoring to improve the yield and reduce waste.
- Have plan maintenance in advance and reduce unexpected downtime.
FCS's brand new machine – FA series offer excellent performances which meet the needs of customization and high efficiency from various industries, is worthy to choose.
Further details from: www.fcs.com.tw
New laboratory size for STS extruder series
THE STS twin screw extruder from Coperion is celebrating its 15th birthday this year. Thanks to the ongoing technological and design development, the STS extruder has proven itself today as a strong performing quality product for numerous compounding processes on the market. Just in time for this anniversary, Coperion has expanded the STS series by one more extruder size: The new STS 25 Mc11 extruder with a 25 mm screw diameter is designed especially for research and development tasks as well as for production of small batch sizes of 2 kg and more, achieving throughputs of up to 80 kg/h. It will be shown for the first time at CHINAPLAS 2019.
STS extruder now in laboratory size
The new STS 25 Mc11 extruder boasts all the advantages of the STS Mc11 series, has a simple design, is operator-friendly and easy to clean. Its feed barrel is equipped with an exchangeable sleeve insert to facilitate cleaning. In addition the die head is in quick-release design for easy operation and accelerates product changes again. The base frame has a closed, simple to clean surface and is equipped with castors for easy movement of the extruder and fast installation. Water cooling, vacuum unit and air supply can be integrated into the base frame as an option.
For maximum efficiency and energy savings Coperion has equipped the new STS 25 Mc11 extruder with cartridge heaters for precise single zone tempering of each individual barrel. By having the same screw diameter ratio Do/Di (outer screw diameter to inner screw diameter) of 1.55 and the same maximum specific torque Md/a³ of 11.3 Nm/cm³ as the whole STS Mc11 extruder series, production parameters of the STS 25 Mc11 can be reliably scaled up to larger STS sizes which makes it the ideal compounding system for recipe development and basic scientific research.
15 years of the STS twin screw extruder
15 years after its introduction, the STS systems from Coperion serve as reliable high-performance extruders for a variety of applications, primarily in plastics compounding. When the first model of this extruder type was delivered in 2004, the STS twin screw extruder was equipped with a torque of 8.7 Nm/cm³ and achieved screw speeds of up to 600 min-1. Throughput was limited to 1,200 kg/h with the then-largest machine size, the STS 75 with a 75 mm screw diameter. At that point, rapid development of the STS extruder series' technology, design and quality followed which was barely imaginable for the time. In 2008, the STS advanced with specific torque of 10 Nm/cm³ and screw speeds up to 800 min-1 launched successfully. Today's high-performance, high-quality STS Mc11 was introduced to the market in 2015 and has set new standards. It has a maximum specific torque of 11.3 Nm/cm³ and screw speeds of up to 900 min-1. In its largest extruder size, the STS 96 Mc11, today throughputs of up to 4,200 kg/h are achieved. Screw elements and barrels are available in various materials from standard versions to highly wear and corrosion resistant solutions, individually tailored to applications' requirements and high throughput rates. The screw diameter ratio Do/Di of the STS extruder is 1.55, which is the same ratio that Coperion uses for numerous ZSK extruders and that has proven itself for an optimal combination for most plastics processing applications. The STS Mc11 extruder is equipped exclusively with high-quality Coperion-brand gearboxes manufactured in Europe. STS Mc11 is produced at Coperion in Nanjing, China in accordance with CE guidelines and the highest Coperion standards of quality, and is distinguished by its very attractive price-to-performance ratio.
For more information please visit:www.coperion.com/stsmc11.