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Machines, systems and technologies for more cost-efficiency

19.10.2016
At K 2016, KraussMaffei Berstorff is presenting a wide spectrum of innovative technologies, all related to the theme of Overall Equipment Effectiveness.

(Munich, October 19, 2016) KraussMaffei Berstorff is presenting its exhibits with a focus on Overall Equipment Efficiency (OEE) at the K 2016 trade show in Düsseldorf (October 19 to 26, 2016, Building 15, Booth B27/C24/C27/D24). The all-encompassing approach to cost-effective and efficient production, which combines the requirements for perfect performance, high product quality and maximum system availability, provides the processor with added value. KraussMaffei Berstorff presents this added value to its customers as a competitive advantage under the blanket term "OEE Plus." "We offer more than just machines and systems. We offer more than just hardware and software units. We give our customers the ability to compete," explains Peter Roos, President of the Extrusion Technology Segment of the KraussMaffei Group and Managing Director of KraussMaffei Berstorff.

QuickSwitch technology for a boost to availability

QuickSwitch is a top-of-the-line pipe extrusion technology from the standpoint of maximum system availability. This one-of-a-kind technology for changing dimensions automatically has been used successfully in several production operations for years and has been demonstrating the enormous advantages of economical PO pipe production. "At K 2016, we are presenting our maximum version for the 280 – 500 mm dimension range and offering customers even more flexibility and delivery availability through small batch sizes," says Roos.

System expertise: Production of pipes with filled formulations and multifunctional layers, giving a boost to quality

By releasing a series of pipe heads, KraussMaffei Berstorff definitively proves its pipe technology expertise, in both PO and PVC processing. "In production of multi-layered pipes in particular, the important factors are precision and cost-efficiency," states Roos. "Our pipe heads are designed to guarantee a uniform layer distribution, optimal adhesion of the layers as well as low specific weights for high mechanical stress," Roos continues. The following exhibits will be on display:
The KM-3L RK 42 pipe head for the flexible production of PVC multi-layer pipes. The KM-RK 20 S PVC pipe head – designed as a double compression model – covers the small diameter range of 12 – 63 mm. The prototype is being developed further to increase pipe quality and production reliability for the future use of various customer formulations worldwide. The KM-5L RKW 01-40 model produces five-layered PO pipes that are used particularly frequently during installation of floor and ceiling temperature control systems. All models provide the customer with a boost to competitiveness, as they achieve optimal finished product quality.

Efficient PVC pipe production with high-performance extruders for a boost to performance

The combination of two KMD 108-36 E2/R twin-screw extruders is oriented toward processors who mass-produce U-PVC pipes. The compactly designed system is designed for a throughput of 2000 kg/h – with very low space requirements. In combination with the KM-RK 23-250 pipe head, it provides a boost to output and thus clearly demonstrates the efforts of KraussMaffei Berstorff to achieve high overall equipment effectiveness.

Profile extrusion with the KMD 73 K/P coextruder for a boost to cost-efficiency

The trend towards increased use of recycled materials is unabated, even in the highly competitive profile market. "Therefore, we have been offering space-saving coextrusion models for many years that enable processors to use cost-effective formulations for the core, which is not visible," states Roos. The KMD 73 K/P exhibit is an addition to the conical twin-screw series in the upper output range. The extruder is installed on columns and stands out thanks to its space-saving design. It also has a swiveling metering unit and is highly versatile.

The new ZE 28 BluePower laboratory extruder with a boost to availability

Research and development is also becoming increasingly concerned with speed, productivity and efficiency in all dimensions. The new ZE 28 BluePower laboratory extruder takes these requirements into account and expands the spectrum of processing tasks considerably.

"With the 28-millimeter twin-screw extruder, KraussMaffei Berstorff is expanding the ZE BluePower machine series, introduced three years ago, to include smaller models," reports Roos. "It is suitable for more than just research and development tasks. It also features a significantly expanded process window for small batch production compared to the existing laboratory extruder," Roos adds. The new machine is of particular interest to compounding operations that are increasingly confronted with ever-greater product variety accompanied by ever-smaller batches.

The new BPC Touch machine control system supports Plastics 4.0
"K 2016 will see the launch of the new intuitive machine control system software," reports Roos. "The BPC Touch is one example of the Integrated Production area within Plastics 4.0. It allows the new control system to link the order and production systems. "It makes it possible to query order data, apply presetting data and initiate processes," says Roos. The control system is equipped with a remote maintenance interface for targeted and expanded services. This makes it possible to install other available interactive services retroactively.

The trade show will also mark the launch of the BPC Touch for the ZE BluePower, ZE UTX and ZE Basic twin-screw extruder series.

The GE 90 rubber extruder with a straight extrusion die for a boost to quality

Increased productivity with higher product quality and simultaneously lower raw material consumption are the requirements of the hose manufacturers for a straight extrusion die. The special features of the extrusion die exhibited at K 2016 are not immediately obvious. The classic configuration has the wall thicknesses in the front head area adjusted via a nozzle that moves axially. But the critical innovation of the new die is the redesigned nozzle holder with hydraulic mold-centering device.

Innovative extrusion process for a boost to quality

KraussMaffei Berstorff is presenting innovative extrusion systems for recycling plastics using the various concepts of cascade extrusion. This extrusion processes gives recyclers or compounders an ideal option for manufacturing high-quality recompounds from PE and PP waste, as well as from recycled materials from other polymers in one step and without intermediate steps.

Demonstration of a perfectly coordinated compounding system for a boost to performance

Specialty manufacturers are the primary target audience for the compounding system with a KraussMaffei Berstorff ZE 42 BluePower twin-screw extruder. The demonstration line at K 2016 shows the production of a high-intensity color masterbatch made of linear low-density polyethylene (LLDPE). The material leaves the system in the form of microgranulate with a diameter of 0.4 to 0.5 millimeters.

The components of the compounding system include ZE 42 BluePower, an Eprotec melt pump with downstream screen changer, an ECON underwater pelletizer and an ECON process water system with centrifugal dryer. The throughput for this application is about 70 kg/h. The system will be on display at the ECON GmbH trade show booth in Hall 9, Booth C55.

KraussMaffei Berstorff at K 2016
Hall 15, Booth B27/C24/C27/D24

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