At the drinktec 2009 in Munich, KraussMaffei is showcasing efficient systems solutions for the beverage industry that have been engineered to optimize production costs. Three exhibits with machines in action demonstrate the engineering competence of the Munich company, which spans almost the whole logistics chain for the industry. During the drinktec, KraussMaffei will be demonstrating machinery at its plant in Munich-Allach. A PETForm system type 320-4500 CS will be producing bottle preforms in a 96-cavity mould, while an EX 120-750 is injection moulding the closures (cycle time only 2.7 s), A MX 1000-17200 from KraussMaffei’s range of large injection moulding machines, will be operating in a cost-effective cell producing beverage crates. Finally, visitors can see an IMC Injection Moulding Compounder used to produce pallets.
PETForm – high-precision, high-performance production cell for preforms
| Every PET bottle starts life as a preform. The necks of hotfill PET preforms are crystallized in a separate post-mould process. Shrinkage during crystallization means that the tolerances for hotfill preform necks are very tight, so that their production is even more challenging than other preforms. The provenly successful PETForm system that KraussMaffei is demonstrating at the drinktec 2009 features a vertical clamp unit, capable of producing flawless preforms without complicated temperature control, even with a high cavity count. 27 g preforms for 0.5-0.6 l bottles are produced in a 96-cavity mould in a cycle time of just 17 seconds. Outstanding platen parallelism extends the mould service life to a maximum and makes it possible to produce preforms within tight tolerances. |
With KraussMaffei’s vertical clamp, preforms drop into the gripper under gravity. Gripper design can be very simple; complicated mechanisms are not necessary. Because of the small mass to be moved, only a relatively small motor is needed to move the gripper rapidly into and out of the mould. This means faster stripping and shorter cycles.
The fast, precise movements of the vertical clamp and the high-speed stripper result in extremely short dry cycle times. In combination with the high throughput of HPX high performance screws and the extremely effective 4-stage cooling station, this adds up to short cycle times and outstanding productivity. An electric drive for the plasticizing unit and the efficient plasticizing performance of the HPX screws guarantee consistent melt quality and lower power consumption. This makes PETForm systems cost-effective, high-performance production cells – a solution the beverage industry can rely on.
Hotfill applications have been running on PETForm systems for many years, using moulds without separate needle controls. In the whole time – thanks to the high-precision mould movements – the moulds have not needed any refurbishing. They’ve already clocked up around 15 million production cycles without the slightest problem. Compared with competitor systems, this brings significant savings in service and maintenance costs for the mould. Lower costs in this area contribute to lower unit costs.
Extremely fast and efficient – producing bottle closures with the EX series
The high-speed machine from the EX premium series running a 24-cavity mould is making 2.0-g HDPE closures in a cycle time of less than 2.7 seconds. The bottle closures, in PCO1810 design, are for medium carbonated beverages. The mould comes from the well-know mouldmaker Erwes Reifenberg. Since its founding in 1976, Erwes Reifenberg has specialized in precision moulds for plastic closures; it supports its customers in the development of innovative closure systems.
Closures can be produced ultra-fast and efficiently on machines from the EX series
In addition to the short cycles and constant shotweights, the outstanding characteristic of this EX machine is its reduced energy consumption. Once out of the mould, the closures move along a cooling conveyor. This reduces the risk of their deforming during the storage / transport process.
The EX 120-750 is ideal for packaging applications because the short dry-cycle time and high injection speeds make it very fast. Typical EX characteristics, such as ultra-high productivity, cleanliness, high availability with minimal maintenance and repair effort, and low power consumption fit well with the requirements of the packaging industry.
At the core of this all-electric injection moulding machine is a Z-toggle, which delivers the short cycle times and high precision. The electric drive technology, with optimized servomotors capable of transforming braking energy into electricity, ensures low power consumption – depending on the product, consumption can be as much as 50% lower than with hydraulic machines. Since the same water is used to cool converters and drives, water consumption can be as much as 50% lower, depending on the product, than for hydraulic machines.
The Z toggle has fewer pivot points than a conventional toggle system. Reducing the number of moving parts means lower friction losses and fewer lubrication points. The remaining lubrication points form a closed system – they are completely encapsulated, with circulating oil lubrication. There is absolutely no risk of the production area being contaminated with lubricant. This is why EX machines are perfectly suited not only to high-performance packaging applications but also for medical technology products.
Big strides in performance – making beverage crates with big MX injection moulding machines
Where shall we put the finished PET bottles? In a crate, of course – also made on a KraussMaffei machine. KraussMaffei has the know-how and machinery to cover the whole logistics chain. In this case it’s an MX 1000-17200 that will be producing double crates type 12 x 1l PETCYCLE during the drinktec 2009. Krauss-Maffei's big injection moulding machines are engineered for tough, non-stop production of large parts. Their outstanding features are the fast two-platen clamp and the high-performance plasticizing unit, both of which are engineered to deliver very high and sustained productivity.
KraussMaffei’s MX machine series is capable of producing beverage crates at consistently high performance levels
KraussMaffei’s MX machines are well-established in the packaging sector. They are used to manufacture products such as beverage crates, all types of large containers, pallets and transport boxes. To produce these large products, the injection moulding machine must be capable of processing large volumes of polymer in a very short time. It’s essential that melt quality remains constant even at these very high throughput rates. Configured with a plasticizing unit and screws from KraussMaffei’s comprehensive list, an MX is more than capable of delivering the necessary performance and quality. Apart from its standard units, Krauss-Maffei also offers high-performance plasticizing units, such as the HPS plasticizing system, for specific applications.
At the heart of an MX is its innovative two-platen technology. The two-platen clamp features short dry cycle times, excellent platen parallelism and good access to the mould. Fast movement sequences make the machine highly dynamic. The multistage mould locking system is easy to set and can be finely adjusted, protecting against the damage to the mould. The result is lower maintenance effort and longer mould life.
All MX machines operate under the new MC5 control system. The MC5 is user-friendly, with clear, easy-to-understand graphics, error-resistant input software, and fast process analyses. Machine states, inputs and alarm messages are all logged allowing detailed quality control.
KraussMaffei’s in-house expertise covers all phases of the production process. Customers benefit, for example, from our specialized know-how in building and integrating robots. Integrating automation into an MX machine creates an efficient manufacturing cell where it’s even possible to use in-mould labelling (IML) on the beverage crates. This is achieved by combining a label robot with the loading/ unloading robot.
The high-tech system guarantees that labels are positioned very precisely in the mould; using an industrial robot makes for more flexibility and precision in fixing. The processor profits from higher product quality, due to precision label positioning, and short cycle times. An in-line quality check can be integrated. Another benefit is the speed and ease of a model change, whether it’s the label or the crate or both.
Plastic and WPC pallets – with Technology to the Power of Three
The last step in the beverage bottle logistics chain is palletizing ready for delivery and here too KraussMaffei has a production solution. The big MX machines have all the attributes needed for cost-effective pallet production. This means a fast-acting, two-platen clamp and high-performance plasticizing. This is where the large SP 55000, SP75000 and SP101000 injection units come into their own.
Hallmarks of these injection units are the big screw diameters, high shotweights, optimized wear protection and outstanding plasticizing performance (up to 1,000 g/s for polyolefins). Advanced barrier screws ensure excellent melt quality, even at top throughput rates and short dwell times. No trade-offs are necessary either when it comes to injection performance. Even at its highest injection speed, the injection unit achieves and holds the maximum injection pressure – over the whole injection stroke.
For still higher material throughput and the option of incorporating filler, it’s worth considering an IMC Injection Moulding Compounder. The IMC integrates a twin-screw extruder with an injection moulding unit. The IMC is ideal for processing Wood Plastic Compounds (WPC). The extruder operates continuously to compound the materials – plastic plus up to 50% wood fibre – while the injection unit operates discontinuously. These WPC pallets have a lifespan up to 15 times longer than wooden pallets, at the same time they save up to 50% of the material costs.
Only KraussMaffei has the multitechnology know-how in-house to successfully integrate injection moulding and extrusion in one IMC system. The IMC process is the basis for embedding wood fibres in a polymer matrix. The raw materials are compounded immediately prior to injection moulding, eliminating the conventional cooling and replasticizing processes. All the separate components are gravimetrically metred. WPC offers much better material properties, including around 50% less shrinkage.
Using lower cost raw materials and eliminating the intermediate cooling/replasticizing stage results in material costs that are 0.15 to 0.3 euros/kg lower than a conventional plastic pallet. The IMC is engineered to keep formulations precisely constant, the outcome is constant material quality. Reducing cycle times to 65 seconds results in productivity increases of around 15% compared with conventional injection moulding.
With the solutions on show at its main plant in Munich-Allach during the drinktec, KraussMaffei once again demonstrates its competence in delivering excellent packaging solutions for almost the whole beverage industry logistics chain. From fast-cycling machines and rugged, energy-saving machines for round-the-clock operation, through to innovative, exclusive processes to reduce material costs.
Hall B3, booth 408
