KraussMaffei shows extrusion, recycling and injection technology

By Bill Bregar
Senior Staff Reporter

Published: June 27, 2013 2:52 pm ET
Updated: June 27, 2013 4:06 pm ET

Image By: Bill Bregar, Plastics News Attendees at KraussMaffei Corp.'s recent open house in Florence, Ky., got to see a coextrusion line capable of making vinyl window profiles with an inner layer of recycled PVC

Related to this story

Topics Construction, Machinery, K 2013
Companies & Associations KraussMaffei AG

FLORENCE, KY. — KraussMaffei Corp.'s open house drew about 200 people to Florence June 13, where they saw a coextruded window extrusion line, recycling equipment and injection presses molding packaging and automotive parts.

The attendees also heard technical presentations and toured Mauer USA, a packaging molder in Hebron, Ky.

KraussMaffei Corp. CEO Paul Caprio said a U.S. open house is important, even in a K-show year, since many U.S. processors do not send people to the world's largest plastics trade show, in Düsseldorf, Germany.

"This is for our market. That's what this event is — to show how technology can move the industry forward," Caprio said as the one-day event wound down.

Caprio said more Americans are attending the K show than in the past. Twenty years ago, maybe 10 KM customers from the United States would journey to show in Germany. KM expects 100 to 200 of them will go over for K2013, set for Oct. 16-23.

Caprio said the K show offers an unparalleled chance to look ahead and see "the next big thing," since machinery companies show future models that may not even be commercial yet. Exhibitors also show brand new technology.

"The K is really kind of the race to new technology," he said.

Open house attendees in Florence got a taste of coextrusion technology from KraussMaffei Berstorff to make vinyl windows with an outer layer of virgin PVC and inner profiles — those unseen by the end customer — from recycled PVC. The machinery company has sold the line to Atrium Extrusion Services Inc.

The coextruded window technology is popular in Europe, where regulations call for window manufacturers to take back all old PVC windows and recycle the material into new windows, said Matt Sieverding, general manager for KM's extrusion division in Florence. The inner material also can use highly filled materials, such as calcium carbonate, to cut costs.

At the open house, the company ran window profiles of virgin and recycled PVC, using a conical KMD 43 K/P twin-screw extruder to extrude the virgin visible portion of the window. That was paired with a parallel twin-screw extruder, a KMD 75-32/P. Greiner Extrusion GmbH provided the coexrtrusion manifold and die.

The KMD 43 was equipped for quick adjustment up and down, to move the extruder into the proper position to feed the manifold.

In another extrusion demonstration, a ZE 60 A x 40 UTXi used a K-Tron feeder to run recycled polypropylene bottle flake through a special dewatering section to remove moisture, then down the twin screw extruder and through an Ettlinger rotating melt, and finally through a Gala underwater pelletizer, then to a Witte classifier.

Sieverding poured water into feeding area, to demonstrate how the dewatering section can handle recycled plastic material with up to 50 percent water content. The machine squeezes out the water, which exists as steam and also a flow of water out of a chute to a storage bucket.

Martin Mack, vice president of extrusion research and development, said co-rotating twin-screw extruder using venting, to run recycled post-consumer plastics, reducing the need for separate pre-drying. In a presentation, he said a process called "upcycling" is turning a base recycled material into a finished product in a single step, without having to repelletize the material.

"It's more than park benches," Macks said. He cited applications like plastic pipe. Plus, the twin-screw format uses modular screw elements that can be arranged to run the specific application.

Noah Grade, an extrusion application engineer in the Florence facility, gave a presentation about directly adding calcium carbonate at the feedthroat. You need a special twin-screw feeder and a stirring unit. The filler can dramatically reduce costs, since three-fourths of the cost of any PVC profile is the vinyl resin and additives, he said.

Direct addition allows much higher filler loading and flexibility in formulations. "And you have a stable process, which is what it's all about," Grade said.

He said five companies have formed a group dubbed the "More Chalk Network" to figure out how to add more calcium carbonate. They are: KraussMaffei, Greiner Extrusionstechnik, calcium carbonate supplier Omya GmbH and Baerlocher GmbH, which makes PVC stabilizers and lubricants.

Extrusion did not get all the attention as the open house, as presentations also examined injection.

Sean Brolley described Tool Stats, which maintains a central, web-based database of injection mold information, such as production history, changes, the bill of materials, maintenance recorda and service reports. Each mold gets a metal plaque with a scannable QR code, or you can get on the Tool Stats website, said Brolley, business development manager of the firm in Warren, Mich.

John Williams presented a new technology for multi-component injection molding, the Flexi-Cube mold from GB Boucherie NV of Izegem, Belgium. He is president of Boucherie USA Inc. in Knoxville, Tenn.

In spinning-cube molds, a center multi-based mold rotates between two or more injection units. But on the Flexi-Cube, the central cube remains fixed. Instead, a series of transport-arm part holders move the parts to the different mold faces. The servo-driven transport holders ride on tracks around the mold, through several molding steps, cooling and part ejection.

On the KraussMaffei shop floor, visitors saw four running injection molding machines: a KraussMaffei GX wide-platen hybrid molding closures; a KM CX equipped a Single rapid mold heating/cooling unit to mold an automotive light cover; another CX press ran the RocTool heating/cooling process to mold a car grill section; and a Netstal Elion press with 320 metric tons of clamping force making a PP 402-size lid.

The Elion ran a four-by-four-cavity stack mold at a dry cycle of 3.5 seconds, said Netstal General Manager Mike Sansoucy. He said the high-speed Elion 3200 has a hybrid drive, using an electric screw drive and clamp and hydraulic injection, with an accumulator.


Comments

KraussMaffei shows extrusion, recycling and injection technology

By Bill Bregar
Senior Staff Reporter

Published: June 27, 2013 2:52 pm ET
Updated: June 27, 2013 4:06 pm ET

Post Your Comments


Back to story


More stories

Image

Who are the fastest growing pipe, profile and tubing extruders?

July 28, 2014 3:09 pm ET

Question: What's the word on this week's Plastics News annual ranking of the top Pipe, Profile and Tubing extruders in North America? Answer: Up....    More

Image

Australian trade group battles non-compliant PVC pipe fittings

July 28, 2014 2:19 pm ET

An Australian plastics industry association is battling against imported, non-conforming PVC pipe fittings, but is stymied by a convoluted web of...    More

Image

Material Insights: Bioplastics firms win government funding

July 28, 2014 12:51 pm ET

Also this week, a study takes a look plastic at the ocean surface and comes away with a surprise finding, and new materials capacity announced.    More

Image

Gear pump maker Witte expands in Germany and USA

July 25, 2014 2:15 pm ET

Witte Pumps & Technology GmbH, the German maker of gear pumps for extrusion, has moved into a new headquarters factory in the Hamburg area, and the...    More

Image

DuPont resins help take Nike golf balls 'Fore!'ward

July 25, 2014 1:07 pm ET

It may be difficult to imagine just how much science, not to mention rubber and plastic components, go into a golf ball. But global giant DuPont Co. b...    More

Market Reports

Plastics Recyclers Data Report & Directory

This exclusive MS Excel database contains all the companies from Plastics News' ranking of top North American Recyclers and Brokers by reprocessed volume and also includes a directory with materials processes, services offered and company contact information. Data is based on primary research by PN editorial staff.

Learn more

2014 Injection Molding Industry Report

GROWTH, OPPORTUNITY IN SIGHT FOR INJECTION MOLDERS IN 2014

In the wake of the economic turbulence earlier in this decade, molders today find themselves in much better shape. Molders are gaining a competitive advantage by investing in people, equipment and seeking inroads into new markets on a global scale.

Growth in the injection molding industry is going to be driven by low financing costs and a continued move to reshore some business.

Learn more

Shale Gas Market - Analysis of North American Region

This report highlights the impact of shale-based natural gas on the North American plastics market and features an in-depth analysis of production trends in the United States during 2013 and a forecast for 2014 and beyond.

Learn more

Upcoming Plastics News Events

September 10, 2014 - September 12, 2014Plastics Caps & Closures 2014

January 14, 2015 - January 14, 2015Plastics in Automotive

February 4, 2015 - February 6, 2015Plastics News Executive Forum 2015

More Events