월간 플라스틱코리아 - 대한민국 짝짝짝짝

Press Release for the Entsorga Trade Fair 27th to 30th of October 2009

2009-11-09T18:44:20Z

Press Release for the Entsorga Trade Fair 27th to 30th of October 2009 (Preliminary Report)

1) HERBOLD Granulator with forced feeding (patent applied for)

A new feeding device for size-reduction machines will be presented:

The material to be size-reduced is no longer introduced into the grinding chamber by gravity but the rotor is evenly and horizontally fed by a screw conveyor. This way of feeding has the following advantages in comparison to a traditional constellation:

-Higher throughput (30 % to 50 % higher capacity performances if the granulator size remains the same in comparison to traditional granulators)
-Less energy consumption (30 % to 50 % less power input in comparison to standard granulators)
-The machine is not only available in a dry grinding execution but also in a wet execution for washing contaminated waste
-Even charges of the rotor (less fines and dust in the ground material)
-reduced sound emission (no material flyback)

A special advantage for the operator is that larger quantities can be stored in the feed hopper and treated automatically. A continuous manual feeding of the machine is no longer necessary. In addition, this type of feeding provides a high degree of security for the operator since a flyback of the material is totally impossible. The elimination of the large opening necessary for manual and/or conveyor feeding means a reduced sound emission during the size-reduction process. Possible ways of feeding are now forklift truck or dump body feeding.

2) Herbold wash lines and components

The PET wash line procedure has been developed as an answer to the growing demand for a ‘reusable recycling procedure for bottles’. The greatest advantages of this new PET recycling procedure are: no quality deterioration of the material, low energy consumption and at the same time an unchanged degree of cleanness.

Other characteristic features are:
PET is not thermally deteriorated
Recrystallisation and polycondensation can be avoided
Closed water circuit
Lines available with throughput performances from 500 to 3000 kg/h

Herbold can also provide components for already existing wash lines:
wet granulators, friction washers, hydrocyclones, mechanical and thermal dryers.
Our plants for stretch film waste, our plastcompactors for densifying light materials, our shredders for size-reducing IBC containers without preliminary size-reduction and obviously our SMS and SML granulators, especially our workhorse SML 60/100, mainly chosen for barrels and bottles.

As an in-line or secondary granulator for injection moulding and blow moulding procedures, i.e. the size reduction of pre-forms or bottles, Herbold has developed the granulators of the compact C series with integrated sound insulation.

3) HGM - the so-called HOG shredder

HERBOLD Meckesheim GmbH has amplified their product range with a new series of slow-running granulators which are available in two sizes - HGM 60/100 and HGM 60/145.

The HOG shredder (HGM) is a single-rotor size-reduction machine uniting the advantages of a granulator (size-reduction by knife cutting, appropriate for relatively small screen holes) and those of a shredder (insensitive against foreign bodies, obtuse cutting angle, operation with a reduced rotation speed). It is used for size-reducing difficult materials, especially viscous ones or those containing many foreign bodies, where the service life of knives would be too short with traditional granulators, and normal shredders would not achieve the desired end product. The HOG shredder can be used in dry as well as in wet operation.

Typical fields of application are:

Pre-shredded used tyres
-Post-consumer bottles
-Metal-reinforced rubber or plastic parts
-Shredded waste from car recycling

If the design is looked at, this HOG shredder is far more massive than normal granulators or shredders: the heavy over-dimensioned rotor is equipped with staggered knives (see Fig. 3); the extremely thick-walled grinding chamber is completely armoured inside with exchangeable anti-wear plates. The centrally hinged housing can be opened hydraulically and so ensures an easy access for maintenance and cleaning operations.

The knife insertion pouches of the rotor knives can optionally be equipped with tool-steel knives or with knife holders with interchangeable inserts (see Fig. 4). Depending on the use of the machine, the knives can repeatedly be resharpened (if normal material is processed) or, after having been turned once, will have to be replaced (if very fine material is processed). The stator knives are placed in adjustable knife holders; the knives are mounted in the knife holders outside the machine and adjusted with an adjustment jig.

4) The HERBOLD plastcompactor

The HERBOLD plastcompactor is a recycling machine for transforming waste with poor flowing properties into an agglomerate with high bulk density and excellent flowing properties.

Especially the kind of waste needing a particularly gentle treatment (such as PET and PA film, filaments and fibres) can be recycled in an extremely economic way and without any or only a minimal thermal deterioration.
The end product is an agglomerate with good flowing properties and high bulk density, free from fines and, if requested, even dyed. The granule size of the end product can vary according to the customer’s requirements.

Many customers have already opted for the plastcompactor from HERBOLD MECKESHEIM GmbH (www.Herbold.com) since it best meets the high quality requirements. Due to the short residence time and the special just beginning sintering process ensuring that the material will not melt, voluminous waste with poor flowing properties can be turned into a 100 % reusable resource.

One example among many: treated PET bottles that have been turned into clean but badly flowing flat flakes after washing, separation and drying. With the help of the plastcompacting process, these flakes are not only turned into a material with excellent flowing properties, appropriate for a trouble-free gravimetrical dosing of film production lines. In one production step, the material is completely crystallized at the same time.

The HERBOLD plastcompactor HV 70 with a 250 kW drive is a workhorse obtaining a throughput of up to 1500 kg/h.

HERBOLD has made every endeavour in order to promote the automatisation of the process and currently a fully automatised machine is available ensuring a trouble-free continuous operation without manual adjustment by monitoring the temperature in the compacting chamber.

Due to the low acquisition costs of the plastcompactor, its automatic operation and its low running costs, this machine is an interesting alternative to a reclaim extruder.

Fig.1: HERBOLD Granulator model SML 60/100
Fig.2: Herbold HGM shredder type 60/145
Fig.5: HV compacting disc
Fig.6: Agglomerate

BASF specialty foam in solar collectors from the heating technology co

2009-10-13T20:47:30Z

BASF specialty foam in solar collectors from the heating technology company Viessmann

The international heating systems manufacturer Viessmann, Germany, now uses Basotect® to insulate its solar collectors. The light, flame-retardant melamine resin foam produced by BASF is fitted to the side walls and the rear of flat-plate collectors. Flat-plate collectors capture solar radiation and convert it into heat. Basotect shows good insulation properties over a long period, even when exposed to high temperatures. It positively influences the air exchange in the collector at different climatic conditions. And in contrast to conventional insulation materials, the BASF melamine resin foam can be cut into different forms. A Viessmann solar combi-system with Basotect flat-plate collector insulation was pronounced test winner by the German consumer organization “Stiftung Warentest” in March 2009, with a rating of “good”.

Long-term heat management
For collectors to absorb as much sunlight as possible throughout their entire service life, durable and heat-retardant materials are necessary. Basotect releases practically no volatile substances that could obstruct solar radiation, e.g. as fogging behind the glass panels of the collectors, and hence reduce the efficiency of the solar system. Because of its good thermal conductivity of <0.035 W/m*K and the intelligent shaping of the insulating pieces, Basotect is able to achieve the same insulating performance as mineral wool, but with less material usage. Basotect makes collector installation easier: It is flexible, fiber-free, and can easily be cut to the contours required.

“With the BASF specialty foam, we have found a material that improves the quality of our flat-plate collectors and, at the same time, makes it easier for us to manufacture them,” says Sigurd von Wenzler, project leader for solar technology at Viessmann. “Compared to the previous standards, we have further increased the efficiency of our new generation of collectors, thanks to Basotect. This means that we are able to offer our customers systems that are of greater interest from an economic point of view.”

Energy savings with flat-plate collectors
Flat-plate collectors consist principally of a safety glass panel, an absorber (usually a selectively coated metal sheet) and metal piping, through which an antifreeze fluid flows. When sunlight shines through the glass panel onto the absorber, the absorber transforms the radiation into heat and delivers it to the fluid in the pipes. From there, the heat is transported into the hot water circuit of the house. If the solar collector system is complemented by a heating supplement, house owners can save up to 30 percent of the annual cost of conventional fuel for the heating of the house.

Basotect, the jack-of-all-trades
Thanks to its favorable combination of different properties ? it is temperature-resistant and flame-retardant, lightweight, flexible, sound-absorbing and thermally insulating ? Basotect is used to acoustically and thermally insulate buildings, cars and trains. The thermoset foam is available in several grades for various applications. For example, it protects the sensitive satellites that the Ariane 5 launcher delivers into space. It is used in Beijing's Olympic swimming stadium as acoustic damping in a new type of suspended structure, and it will soon be found in the planes by the American aircraft manufacturer Boeing.

tag : 에너지, 지붕, Basotect, BASF, 바스프, 단열, 한국바스프, Viessmann

Lightweight Stabilizer from ContiTech made of BASF Polyamide in the ne

2009-10-13T20:44:52Z

Lightweight Stabilizer from ContiTech made of BASF Polyamide in the new Gran Turismo Porsche Panamera

-From the virtual world to directly under the hood

Sustainable solutions for lightweight vehicles that also fulfill aesthetic requirements: this is what today’s automakers are looking for. ContiTech Vibration Control, internationally successful manufacturer of engine mounts for the automotive industry and BASF have joined forces to create such solutions. The result is an innovative stabilizer for the new Porsche Panamera. The high-performance integrated component is made of a high-strength polyamide from the Ultramid® CR family and a functionally optimized NR+ natural rubber mixture. It reliably withstands engine torques up to 650 Nm while providing very good sound absorption and secure mounting of the engine in the vehicle. Compared to a metal component with comparable functionality, the sports car manufacturer is able to achieve a weight savings of 35 percent.

Requirement: Permanence and esthetics
With a power of up to 500 HP, the Panamera is the Porsche among the four-doored Premium-Gran Turismo. Such high-performance vehicles present special challenges when it comes to engine mounts. For this innovative automobile, Porsche selected an equally novel material solution. Since the stabilizer is visible when the hood is open, ContiTech Vibration Control worked in close cooperation with Porsche’s design department to give it a visually appealing textured surface.

“The stabilizer has to bear high loads but must also work as a visible part and therefore has to fulfill aesthetic requirements. ContiTech Vibration Control thus built a special mold for the part to achieve an optically high-quality surface”, explains Stefan Wohler, responsible for product development at ContiTech Vibration Control.

No prototypes: Developed on the computer from concept to series

From the very beginning, the component was designed almost entirely on the computer in BASF’s polyamide Ultramid with the aid of BASF’s universally applicable ULTRASIM™ simulation package. “As material specialists and development partner BASF thus supports its customers with a field-tested simulation technology that includes numerous newly developed elements”, comments Bernhard Aumer, ULTRASIM expert from BASF’s Engineering Plastics.

The challenge was to satisfy the criteria for a certain functionality and load-bearing capability within specified spatial constraints. After a few iterations, BASF had a component concept that ContiTech Vibration Control, the system supplier responsible for the entire integrated elastomeric mount, was able to convert directly into a construction near to series quality. No additional testing of prototypes was required and optimization cycles were reduced to a minimum, which translates into enormous time and cost savings in automobile development. Test bench trials at ContiTech Vibration Control and vehicle trials at Porsche confirmed the results.

Installed at two suspension points lengthwise, the stabilizer in the Porsche

Panamera not only fulfills the function of securely mounting the engine, but also satisfies the demanding requirements for an appearance part with an aesthetically appealing surface in the engine compartment. With this in mind, the injection mold was optimized at ContiTech Vibration Control to achieve a fine, matte surface texture. The unique plastic component made of Ultramid® A3WG7 CR replaces a comparable component made of metal: By employing BASF’s ULTRASIM™ simulation package, it was possible to design the component as a production part directly on the computer and without a prototype phase.

tag : Porsche, Basf, Polyamide, Lightweight, Ultramid, 바스프, 한국바스프, ContiTech, Hood, ULTRASIM

Rhodia and its Polyamide 6.6 have been chosen for under-the-hood appli

2009-10-13T20:27:54Z

Rhodia and its Polyamide 6.6 have been chosen for under-the-hood applications in biofuel engines

Magneti Marelli has chosen Rhodia’s Technyl® to produce the air intake manifold (AIM) and the fuel rail of the Citroen C4 and the C5 2l biofuel engines in Brazil. This choice is extended to Peugeot 407, 307 and 308 series.

An efficient international partnership

The two partners have worked in closed collaboration on this project, as Rhodia Brazil developed the simulation analysis while Magneti Marelli Brazil dealt with parts validations.

The intercontinental collaboration of European and Brazilian teams from PSA, Magneti Marelli and Rhodia has led to the homologation of Technyl® A 218 V30 black, a glass fibre reinforced 6.6 polyamide, for both the AIM as well as the fuel rail used for Brazilian market, a large user of bio-fuels with the flex-fuel system.

Rhodia’s expertise at its clients’ service

Leading the polyamide market in the zone, Rhodia has already developed a strong experience in under-the-hood applications for flex-fuel engines.

Indeed, besides its position of major actor of the PA 6.6 market and its Brazilian experience, Rhodia has developed a strong expertise in the field of permeation, acquired in its CNRS shared laboratory. Rhodia can thus support its automotive customers to face the new challenges imposed by European norms.

Technyl® PA 6.6 is then the material of choice, resisting to high temperature and providing good permeability resistance for under-the-hood applications of the new vehicles.

tag : PA6, PA66, 폴리아미드, Rhodia, 폴리아마이드, Polyamide, 로디아, Manifold

Milliken Showcases Global Leadership in Polyolefin Enhancement~

2009-10-13T20:24:41Z

Milliken Showcases Global Leadership in Polyolefin Enhancement with Launch of New Hyperform® Reinforcing Agent
New Hyperform HPR-803 offers weight savings plus improved surface finish; broadens application possibilities for PP

With the recent decision of the European Parliament setting CO2 emission performance standards for new passenger cars in the form of Regulation (EC) No 443/2009, weight reduction promises to become even more imperative for the automotive industry. To help automakers and suppliers achieve greater weight reduction, Milliken Chemical, a division of Milliken & Company, is introducing Hyperform® HPR-803 high performance reinforcing agent for polyolefins. New Hyperform HPR-803 reduces weight by up to 15 percent vs. traditional mineral-filled systems while delivering an outstanding balance of stiffness and impact strength. Further, the new Milliken agent offers comparable surface finish to talc-filled compounds that cannot be achieved with chopped glass fiber reinforcement. The company’s continuing innovation is enabling customers to improve the appearance, performance, and productivity of their products, and expand potential polyolefin application areas.

The European union will require automakers to drastically reduce CO2 emissions in the coming years, with a target of 95g/km by 2020. Automakers will have to pay penalty payments if they don’t meet the new requirements. To a large extent, lighter cars result in cleaner cars. Plastics such as polyolefins are already playing an important role in reducing vehicle weight.

“Polypropylene is a versatile material that is increasingly selected for interior and exterior automotive parts - in fact, about 50 to 70 kilograms of PP are used per vehicle, on average, depending on where you are in the world,” said Wouter Reyntjens, Business Development Manager, Milliken Chemical. “However, the traditional reinforcements used with PP either add undesirable weight or provide an unsatisfactory appearance.”

Reyntjens continues, “Milliken has a strong history of innovation and leadership in additives that improve the aesthetics, processability and physical/mechanical properties of polyolefins. Hyperform nucleating agents are commonly used to improve dimensional stability, optimize productivity, improve barrier and enhance mechanical properties.

The property space targeted by reinforcing agents is a natural technology extension for Milliken, and Hyperform HPR-803 complements our existing offering to polyolefin formulators and converters. With its unique combination of attributes, we believe customers will find Hyperform HPR-803 the best polyolefin reinforcement for today’s most demanding applications.”

Complementing Milliken’s other Hyperform additives, including the company’s Hyperform hyper-nucleating agent, the new reinforcing agent was developed to meet the needs of the automotive and appliance industries. Advantages of using Hyperform HPR-803 include:

- Replacing high loadings of heavy mineral fillers, such as talc, with lower loadings for comparable performance. This can reduce the weight of polyolefin parts by up to 15 percent.
- Offering improved stiffness vs. talc and other minerals at higher loadings.
- Providing high heat deflection temperatures (HDT) exceeding high levels of talc.
- Offering an improved surface finish that surpasses chopped glass fiber.

By utilizing Hyperform HPR-803 reinforcement as a replacement for chopped glass fiber, customers can expand applications for PP and other polyolefins beyond current “hidden” structural automotive and appliance parts to encompass highly visible components such as bumpers and door panels. And by replacing talc and other mineral reinforcements with the new Milliken technology, customers can achieve significant lightweighting of parts while maintaining or exceeding existing performance properties.

The new high performance reinforcing agent is available today globally.

Potential Applications for Milliken’s Hyperform® HPR-803 Include Bumpers and Door Panels To help automakers and suppliers achieve greater weight-out, Milliken Chemical, a division of Milliken & Company, is introducing Hyperform® HPR-803 high performance reinforcing agent for polyolefins. New Hyperform HPR-803 reduces weight by up to 15 percent vs. traditional mineral-filled systems while delivering an outstanding balance of stiffness and impact strength. Further, the new Milliken agent offers comparable surface finish to talc-filled compounds that cannot be achieved with chopped glass fiber reinforcement. By utilizing Hyperform HPR-803 reinforcement as a replacement for chopped glass fiber, customers can expand applications for polypropylene and other polyolefins beyond current “hidden” structural automotive and appliance parts to encompass highly visible components such as bumpers and door panels.

tag : Hyperform, Milliken, PP, Co2, ShowcasePolyolefin, HPR-803

Fully automatic Husqvarna mower for large lawns made from Luran S

2009-10-13T20:19:48Z

Fully automatic Husqvarna mower for large lawns made from Luran S

Pixies on the meadow

The new Automower® 260 ACX automatic lawnmower from the Swedish lawn and garden equipment manufacturer Husqvarna makes the tedious job of mowing large lawns a thing of the past. As the largest in the Automower Series of lawnmowers for semi-professional use, the freely programmable machine is able to handle 6,000 square meters and has been developed specifically for the large lawns typically found in recreational areas or on company grounds. To protect the expensive electronics from the effects of wind and weather, the designers at Husqvarna selected Luran® S, the ASA (acrylic ester-styrene-acrylonitrile copolymer) from BASF, for the approximately 80-cm-long, almost square housing. This especially weather-resistant material withstands extreme heat and rain and the surface, here dark grey, retains its high-gloss appearance after years of use.

UV-stable, unpainted and easy-flowing

The first development partnership began in summer 2005 at the production facility in Aycliffe, United Kingdom, as Husqvarna was searching for a very special resin for a smaller mower version: The material needed to be injection moldable, UV-stabile, heat-resistant and exhibit the highest possible mechanical strength. “Originally, the Automower was produced using a standard resin and had to be painted to prevent the color from fading”, said Geoff Nelson, BASF Account Manager for styrenic specialty plastics. “This is no longer necessary with the UV-stable Luran S, which means that the housing can be produced faster and more economically.”

Since the Luran S 757 G grade used exhibits especially good flow characteristics, the large, complex lawnmower housing can be produced in a single step. While the upper part has a high-gloss appearance, the edges were designed intentionally to have a fine, matte texture. “BASF provided convincing technical support during the joint optimization phase", recalls Gary Blenkinsopp, Technical Manager at Husqvarna, Aycliffe.

tag : UV, Luran, ASA, BASF, 바스프, 한국바스프, ACX, Automower, Aycliffe

Greiner Packaging manages its business sustainably and counts on R-PET

2009-10-13T20:16:59Z

Greiner Packaging manages its business sustainably and counts on R-PET

Using recycled PET (in short R-PET) for packaging production reduces energy consumption and CO2 emissions

Climate protection is a major topic globally requiring sustainable corporate management. The Austrian packaging producer Greiner Packaging is meeting the challenge of this development with two approaches. Robert Obermayr, Product Group Director K1/K2, explains: “On the one hand, we are continuously optimising energy consumption and the production processes for processing classical plastic materials. On the other hand, we are pushing the use of alternative materials, in particular R-PET.”

The responsible handling of raw materials and resources characterises the sustainable actions taken by Greiner Packaging. Examples include saving energy through production equipment or reducing the weight of new packaging solutions. A particularly environmentally-friendly packaging technology is K3, the plastics-cardboard combination. It saves plastic material and can be separated well in terms of recycling. By using cardboard and recycled cardboard, we speak of renewable raw materials.

R-PET is gaining ground
R-PET is taking an ever increasing role with respect to CO2 emissions and the conservation of non-renewable resources. Greiner Packaging can process R-PET at any existing PS plant at various production locations. Obermayr claims: “Major benefits when using R-PET are the reduction of the sealing temperature and very good peeling properties. Thus, valuable energy can be saved during the production process and CO2 emissions are reduced.” Greiner Packaging has already provided an array of packaging solutions made from R-PET for customers in Great Britain.

Business groups are setting the agenda
Great Britain and the USA in particular give fresh impetus to an increased use of R-PET. Major trading groups are making huge efforts towards climate protection. In doing so, they offer the means for orientation, such as scorecards or carbon footprint labels to manufacturers, suppliers and consumers. These contain information on the CO2 emissions generated during the production of the product concerned. “The less CO2 emitted during the production of the package, the more interesting the final product is,” explains Obermayr and he adds: “Moreover on the market in Great Britain, rubbish collection fees are reduced in proportion to the percentage of recycled R-PET contained.“

The PET bottles become R-PET
R-PET originates from PET bottles, which become part of the so-called “homogeneous material circuit”. They are pressed in bales and then cut up and cleaned in specialised recycling companies. During this procedure flakes are created, which are normally processed further into granulate. The further processing of R-PET includes the reconstruction of the molecular chain.

Corporate Data
Greiner Packaging is one of the leading companies in the European packaging industry. In 2008, the company achieved annual sales of EUR 376 million or 34 per cent of the total Greiner Group sales. Greiner Packaging employs a workforce of 2,935 employees at 21 production sites throughout Europe.

tag : Cup, PET, Packaging, Bottle, Co2, Greiner, R-PET

Ferromatik Milacron Brings its New High-Performance Hybrid and All-Ele

2009-10-13T20:12:09Z

Ferromatik Milacron Brings its New High-Performance Hybrid and All-Electric Machines to Fakuma -High Speed and Energy Efficiency

Injection molding machine maker Ferromatik Milacron will present two exhibits at booth B3-3203 during Fakuma in Friedrichshafen, October 13 through 17, 2009. The new high-performance hybrid VITESSE 300 shows just how fast an injection molding machine can be. The ELEKTRA evolution 230 is a study in energy efficiency.

Fast, Faster, VITESSE
The new VITESSE series was previewed in May 2009 for a select group of packaging industry experts. At Fakuma the machine will be unveiled to the public. “The VITESSE takes its name from the French word for “speed”, the most remarkable feature of the new machine series”, said Robert Trube, Director Sales & Marketing at Ferromatik Milacron.

They are the fastest injection molding machines available”, he added .The electric screw drive of the VITESSE allows for parallel functions, resulting in extremely short cycle times. The stability required for the excellent machine dynamics is provided by a reinforced machine base with linear guides. The result is reliable performance at the highest speeds.

The VITESSE series comes in clamping force sizes of 2,000, 3,000, 4,000 and 5,000 kN, and can be equipped with injection units of international sizes 1,000, 1,650, 2,650 and 4,400. In total ten combinations are available.

The VITESSE comes standard with Ferromatik Milacron’s GreenLine energy saving package, comprised of the three elements:
-Energy-efficient drive technology: the hydraulic pump comes with a high-efficiency motor
-Energy management: the hydraulic accumulator is only filled to the required level for each application ? in addition, parallel movements are avoided where not needed, minimizing expensive energy peaks
-Energy measurement: detailed quantification of energy usage by cycle, hour, and shift

The new VITESSE series also includes Ferromatik Milacron’s Teleservice for remote-maintenance of machines and process optimization. Teleservice includes all the necessary hardware and software for connecting the machine to the internet. Machine data and parameters can be analyzed and modified from Ferromatik Milacron’s main facility in Malterdingen, Germany. Since no technician needs to travel to the customer’s facility to perform these services, both time and additional costs are saved.

Frromatik Milacron provides a three-phase warranty package with the VITESSE:
-Full warranty up to 2 years, or 15,000 operating hours
-Warranty for electrical and electronic parts up to 3 years, or 22,500 operating hours
-Warranty for constructed parts of steel or cast materials up to 4 years, or 30,000 operating hours

At Fakuma a VITESSE 300 with a clamping force of 3,000 kN and an international size 2,650 injection unit will be demonstrated in a complete production cell with an in-mold labeling system from Star Automation. Using a single-cavity mold from Abate Basilio, the machine will demonstrate production of a 5.7 liter polypropylene bucket with in-mold labeling and a cycle time of 8.2 seconds. Standard equipment on this machine includes a high-performance barrier screw with a mixing head and an L/D of 25:1 for optimal melt quality and even color distribution.

ELEKTRA Stands for Energy Efficiency
The all-electric ELEKTRA series from Ferromatik Milacron uses 50-70% less energy and water than hydraulic injection molding machines. Thanks to parallel machine movements, the ELEKTRA offers molders remarkable dynamics and short cycle times. The machine axes are accurate within 0.01 mm for exceptional precision and superior part quality. Maximum machine availability and repeatability ensure high productivity and a low scrap rate. In addition, the all-electric ELEKTRA series run clean and quiet.

The ELEKTRA series comes in clamping force sizes of 300, 500, 750, 1,100, 1,550, 1,800, 2,300, and 3,000 kN and can be combined with injection units of international sizes from 55 to 1,540.

At Fakuma an ELEKTRA evolution 230 with a clamping force of 2,300 kN will demonstrate production of plypropelene syringe housings on a 48-cavity hotrunner mold from Schottli and a cycle time of 9.7 seconds. This medical technology part will be removed by a robot from Sepro for quality control and then released. The ELEKTRA evolution 230 is equipped with the largest injection unit available for this machine, an international size 1,540 with a double motor for extremely high-speed injection. The ejector platen is supported by linear bearings for easy mold movement which ensures high precision parts.

tag : Fakuma, 전동사출기, 밀라크론, ELEKTRA

A world’s first by MORETTO at FAKUMA

2009-10-13T20:07:24Z

A world’s first by MORETTO at FAKUMA - Hall B4, Stand B4-4209
The realization of the perfect temperature controller

When asking moulders about their mental picture relating to temperature controllers, replies frequently include expressions such as: “low-cost purchase or leasing, easy installation, switch on and forget about it until the next mould change.”

MORETTO S.p.A., based at Massanzago in Italy, one of the world’s leading manufacturers of automation equipment for the processing of plastics, has exhaustively looked at the subject of mould cavity temperature control, undertaken research and finally presented the gathered requirements to its in-house research and development department. The aim was to introduce a complete market-ready family of temperature controllers at FAKUMA for the first time worldwide, named TE-KO, comprising two stand-alone product ranges, one based on water, one on oil, each with eight models, satisfying present and future market requirements. Those requirements are solved as follows, taking into specific consideration fast and impeccable commissioning:

1.Working controls: the device controls volume and checks operating pressure, ensuring that the coolant volume is actually circulating.

2.Heating: the resistors located in two different areas increase the relevant performance

3.Cooling: a tubular stainless steel heat exchanger with double winding generates 50 kW refrigerating capacity. Heat accumulation is impossible.

4.Electrical connections: TE-KO comes with power supply cable. RS485 serial port.

5.Hydraulic connections: TE-KO has 4 input and 4 output connections as standard, in order to solve the issue of branchings, connections and manifolds once and for all.

6.Filter: available with high capacity, accessible from the outside, due to fast lock feature (optional). The cooling liquid contains glycol or anti-freeze agents. The large filter absorbs sediment over long periods of time, thus maintaining optimum long-term heat exchange capability.

7.Volume: the 16 liter capacity of the super tank is double that of conventional systems. The oval shape of the trough ensures ideal mixing of the coolant; the stainless steel construction guarantees a long service life.

These are the principal characteristics of the new TE-KO temperature controller, entirely constructed of AISI 304 stainless steel, thus perfectly resistant to water-induced corrosion. In addition, TE-KO is equipped with a display feature, enabling the user to access a variety of real-time data. The device is equipped with PID-control technology via a micro processor, managing all relevant functions. Temperature control is based on values transmitted by solid-state relays. Moreover, Moretto uses the most reliable pumps on the market for guar-anteeing duration in time.

Great emphasis has been placed on accessibility, so that all essential tasks required for problem-free operation of the equipment are easy to perform. A version designed to operate under vacuum - to prevent possible loss of liquid - completes this range of products which are designed specifically for a long operation lifespan - LIFELONG.

Considering the current economic climate, moulders will show particular interest in product longevity, easy operation, cost reduction, and optimisation of energy consumption. With the coming together of state-of-the-art technology in construction and performance optimisation at low energy consumption, providing attainable solutions for a number of customer re-quirements, MORETTO products will receive an excellent response. MORETTO S.p.A. constantly maintains its quest for continuous development of new applications and innovative solutions in the automation of plastics processing.

tag : 전시회, 냉각기, Controller, 온도조절기, 온조기, Temperature, Fakuma, Moretto, 프리드리히샤펜

Agilent Technologies Launches Next-Generation Microplate Labeler for L

2009-10-13T20:02:29Z

Agilent Technologies Launches Next-Generation Microplate Labeler for Life Science Laboratories

Agilent Technologies Inc. (NYSE: A) today introduced a new microplate labeling system for automated on-demand and barcode print-and-apply applications in life science laboratories.

The new Agilent Microplate Labeler combines the easy-to-integrate form factor, speed and proven label applicator of its predecessor with a thermal label printer that provides 600 dpi resolution, crisp images and an expansive array of 1D and 2D coding symbologies.

“This next-generation product is a direct response to industry and end-user requests for a reliable, high-performance microplate labeler that offers true unattended operation,” said Nitin Sood, general manager, Agilent Automation Solutions. “Authentic Agilent automation-certified labels with application-matched ribbons guarantee the highest level of system performance as well as superior instrument and applications support.”

The Agilent Microplate Labeler achieves its excellent repeatability and reliability through high-precision registration; a tensioned peeling system that ensures label backings stay taut; certified designed-for-automation labels; and durable die-cast aluminum construction.

With its compact size, the microplate labeler fits easily on a benchtop. Its ability to print and apply labels at speeds of up to one label every four seconds allows users to achieve ambitious throughput goals. When integrated into automated systems, the Agilent Microplate Labeler is powered by VWorks software, a powerful application capable of importing data and creating custom labels for the microplate labeler. The software enables the user to apply unique sets of data to labels on all four sides of a microplate.

The microplate labeler can be operated as a standalone instrument using the included PlateTag software. It can be integrated into third-party systems via the included ActiveX control and RS-232 serial or RJ45 Ethernet ports.

tag : Label, Microplate, Agilent, Print

LED 산업 성장세 플라스틱업계에도 ‘효자’노릇

2009-09-24T08:58:53Z

LED 산업 성장세 플라스틱업계에도 ‘효자’노릇

국가 신성장동력으로 부상…에너지 효율화 정책 겹치며 관련 산업 ‘호황’
LED 제품 인기 끌면서 "올 중대형 LED패널 출하량 1억대 돌파"
리드프레임 사출성형업체 휴일도 없이 가동…新 블루오션 등장

발광다이오드(LED)가 우리 생활 속에 자리 자리잡아 가고 있다. 지난 몇 년 동안 업계가 ‘과연 이 산업 분야가 얼마나 발전할까’라는 막연한 논의에 빠져 있었다면, 올해 들어 ‘LED 산업이 반도체·디스플레이·휴대폰에 이어 미래 한국을 먹여 살리는 산업이 될 수 있을까’라는 한 차원 높은 고민을 하기 시작했다. 세계시장은 이미 한국 LED 산업을 주목하기 시작했다. 세계적인 실리콘 기업인 다우코닝이 올 초 국내에 LED 전용 생산 라인을 준공했다. 이 자리에 참석한 이 회사 주요 임원은 한국이 전 세계 LED 시장의 요충지가 될 것이라는 의견을 내놨다. 그는 소니가 선택한 RGB(적록청)타입 LED 백라이트유닛(BLU) TV의 실패를 교훈삼아 백색LED를 이용한 대중적인 LED BLU TV 시장을 연 것에 주목했다.

앞으로도 LED의 활용 분야는 광범위해질 것으로 보인다. 기존 모든 조명을 교체할 수 있을 뿐 아니라 응용 기술로 기존 광원으로 상상할 수 없던 분야까지 영역이 확대될 수 있다. 매년 20% 이상 급성장으로 2015년 전 세계 2000억달러의 황금 시장이 될 것이란 부푼 기대 속에 LED 산업의 한축을 담당하고 있는 플라스틱 업계에서는 LED 리드프레임 생산업체를 중심으로 사업성장에 가속도가 붙고 있다. 세계 시장의 영역을 넓혀가고 있는 LED 시장에 플라스틱업계의 동향은 어떠한지 점검해본다. -편집자 주-

자원부족을 겪고있는 대한민국에서 ‘그린에너지’가 새로운 성장 동력 산업으로 각광받고 있다. LED 태양광, 바이오매스, 폐기물 처리, 하이브리드카, 등 대다수 그린에너지들이 국가성장도력으로 각광받기 시작했다. 그린에너지 분야 중 LED 산업은 IT와 그린에너지가 융합한 분야다. 정부는 최근 ‘IT코리아 5대 미래 전략’을 통해 IT 분야에 향후 5년간 약 1백89조원을 투입하는 정책을 추진하고 있다. 여기에 정부의 에너지 효율화 정책이 겹치면서 국내 LED 관련 기업들의 주가는 가파르게 상승하고 있다.

LED는 일단 친환경적이다. 형광등·백열등보다 수명이 길고 소비 전력이 작다. 사용 분야도 늘어나고 있다. 휴대전화 광원으로만 사용되었지만 노트북, TV, 자동차, 조명 등에도 적용 중이다. 차세대 LED로 불리는 ‘OLED(Organic Light Emitting Diode)’는 자체 발광형 유기물질로 일반 LCD와 비교해 화질이 뛰어나 휴대전화·카메라 등 소형 화면 분야에서 유리하다. 최근 휴대전화로 인기를 끌고 있는 아몰레드(AMOLED)를 보면 알 수 있다. 앞으로도 성장이 예상되는 대목이다.

이러한 전망을 증명이라도 하듯 LED TV가 대중화 바람을 타고 있다. 최고급 LCD TV사양인 LED TV의 가격하락이 이뤄지면서 판매량도 증가하고 있다. 국내 전자전문양판점에 따르면, 올 3월과 5월 삼성전자와 LG전자가 본격적인 LED TV 신제품을 내놓고 경쟁에 돌입할 당시보다 8월 기준 제품별로 적게는 50만원에서 많게는 130만원까지 가격이 떨어진 것으로 나타났다.여기에 추가로 모델에 따라 기프트카드가 10만~40만원 규모로 제공된다는 점을 감안하면, 국내 시장에서 LED TV 가격이 90만~170만원까지 올 중반기에 하락했다는 분석이다. 이처럼 LED TV 가격이 인하되면서 평판TV 수요자들이 LED TV로 몰리는 경향을 보이고 있다. 유통가에서는 LED TV 매출이 증가한 가장 큰 이유는 제품 가격이 최고 100만원 가량 떨어지면서 소비자의 부담이 상대적으로 줄었기 때문이라는 분석이다.

대형가전판매매장 관게자들은 “판매 초창기에는 LED TV가 절전 성능은 뛰어났지만 가격이 상대적으로 비싸다는 인식으로 활발한 판매로 이어지지 못했던 것이 사실이었다”면서 “하지만 단점으로 작용했던 가격이 어느 정도 충족되면서 대중적인 LCD TV로 부상할 날도 머지 않아 보인다”라고 말하고 있다. 이러한 전망은 TV뿐만 아니라 노트북 등 중대형 전자제품에서 LED 백라이트 LCD 패널(이하 LED 패널) 채용이 급속히 확산되면서, 중대형 LED 패널 출하량이 올해 1억대를 넘어설 것이라는 예측으로 이어지고 있다.

시장조사기관인 디스플레이서치에 따르면 지난 2분기 넷북 이상의 중대형 LED 패널 출하물량은 2300만대로, 1분기에 비해 116% 증가했다. 분야별로는 노트북 PC용이 1,430만대로 가장 많았고, 넷북 790만대, TV 60만대, 모니터 10만대로 집계됐다. 올해 3분기와 4분기에는 총 3,760만대와 4,330만대가 각각 출하돼, LCD 패널시장에서 차지하는 비중이 25%와 29%에 달할 것으로 예상됐다.

LCD 패널은 백라이트에 따라 냉음극형광등(CCFL) 기반과 LED 기반으로 나뉜다. 2009년 전체 물량은 1억1450만대로, 전체 LCD의 22%를 점유할 전망이다. 높은 관심을 끌고 있는 TV용 LED 패널의 출하량은 3분기 130만대, 4분기 220만대로, 상반기의 100만대를 포함하면 450만대가 될 것으로 보인다. 또 가장 큰 비중을 차지하는 노트북 PC 시장에서는 3분기에만 2550만대의 LED 패널이 출하돼, CCFL 기반 LCD 패널 출하량(1750만대)을 넘어설 것으로 예측됐다. 4분기에는 3020만대가 출하돼 연간 물량은 7600만대에 달할 전망이다. 넷북 시장에서는 2분기에 출하된 전 제품에 LED 패널이 사용돼, 보급률 100%를 기록했다. LG디스플레이는 2분기 노트북용 LED 패널시장에서 39%의 점유율로 1위를 기록했고, 대만의 AUO(28%)와 삼성전자(19%)가 그 뒤를 이었다. 반면 TV 시장에서는 삼성전자가 91%를 점유해 압도적 우위를 나타냈다.

전문가들은 향후 몇년간 LED가 LCD 시장의 견인차 역할을 할 것으로 보고 있다.
안성호 유진투자증권 연구원은 “올해 1분기에 12%였던 LED 백라이트 패널의 보급률이 4분기에는 29%까지 늘어날 것으로 보인다”며 “현재는 넷북같이 얇은 제품에 주로 채용되고 있지만 LED 생산량이 늘면서 15인치 이상의 노트북이나 모니터, TV 등으로 보급이 빠르게 증가할 것”이라고 말했다.

핵심 성장동력 육성 BLUㆍ조명 선도업체 부상

LG이노텍(대표 허영호)은 올해 LED사업을 핵심 성장동력 사업으로 육성한다는 전략 아래 LED BLU와 LED 조명사업을 핵심 축으로 강화해가고 있다. LG이노텍은 올 연초에 LED BLU사업에서 중대형 LED BLU의 선도업체로 부상한다는 전략을 세우고 대형 LED BLU의 기술 경쟁력 강화와 초슬림 LED BLU 등 차별화된 제품을 개발했다. LG이노텍은 LED칩에서 패키지, 응용제품에 이르기까지 기술 및 가격경쟁력을 갖춘 제품을 제공, 고객에게 고품질의 LED 종합 솔루션을 제공하고 있다. 이 회사는 이미 LED용 에피웨이퍼 개발에서 소자생산(FAB), 패키지, 모듈에 이르는 전 공정의 생산라인을 구축했으며 LED분야의 R&D 및 생산 부문에서 확실한 시너지 효과를 창출해내고 있다.

LG이노텍의 LED 생산라인은 소재와 칩, 패키징에 이르는 모든 LED관련 제품을 생산하고 있다. 1억개 이상의 LED칩을 찍어낼 수 있는 규모도 갖췄다. 특히 이 회사의 LED부문 경쟁 우위는 바로 자이오비(XiOB)라는 독자적인 기술력에 있다. 기존 LED패키지가 리드프레임(lead frame)이나 PCB타입의 패키지 프레임에 LED칩을 넣어 만든 것이라면 자이오비는 반도체 공정에서 쓰이는 실리콘 웨이퍼를 사용한다. 공정 또한 반도체 공정과 거의 유사하다.

패키징(Packaging) 비용이 저렴하고 패키징 디자인의 융통성이 커서, 세트 업체들이 요구하는 신규 휴대폰 모델 개발과 적용 소요 시간을 획기적으로 줄일 수 있는 점이 장점이다. 또한 웨이퍼 레벨이어서 대량 생산이 가능하며 특히 크기가 작고 두께가 얇아 콤팩트한 고출력LED 패키지에 적합한 특징이 있다. 이러한 기술력으로 LG이노텍은 휴대폰에 들어가는 카메라 플래시용 초슬림 0.4mm 두께 LED WLP(Wafer Level Package)를 개발한 바 있다. 이러한 기술을 응용해 LED조명사업은 이미 확보한 LED칩, 모듈부문의 기술경쟁력을 활용해 고객 접점을 확대하고 전략고객을 확보해 나갈 방침이다.

LG이노텍은 특히 지방자치단체, 공공기관 등의 LED조명 시범사업 수주를 통해 제품 경쟁력 뿐만 아니라 설치 및 운영 능력까지 입증할 계획이다. 이를 통해 국내 LED 조명시장을 선점하고 프리미엄 브랜드 이미지를 구축한다는 전략이다.
지난 해 경기도 광주 곤지암 리조트에 LED보안등과 실내등을 설치했으며, 서울시 상암동 디지털미디어시티(DMC) 1차 가로등 설치를 완료한 바 있다. 또한 부천 상동 호수공원 보안등, 우체국 조명설치 사업, 광주광역시 김대중 컨벤션 센터 조명교체사업 등을 수주하며 경쟁력을 입증해 가고 있다.아울러 LG이노텍은 국내 LED조명시장 선점 뿐만 아니라 해외 시장 진출을 위해 글로벌 조명기기업체들과의 협력도 적극 추진 중에 있다.

LG이노텍 관계자는 “수직 통합형 LED사업모델을 구축해 연구개발부터 생산, 마케팅에 이르기까지 효율성을 극대화하고 각 공정간의 협력을 통해 제품 및 가격 경쟁력을 강화하고 있다”며 “글로벌 전략고객을 확보해 나가는 한편 LED BLU 및 LED 조명의 급격한 수요 증가에 대비해 사업경쟁력 강화에 만전을 기할 것”이라고 밝혔다.

LED 사업과 함께 성장하고 있는 리드프레임 사출성형업체

대기업 LED 업체가 급성장하면서 사업파트너 쉽을 맺고 있는 업체도 덩달아 성장하고 있다. LG에 LED리드프레임을 공급하고 있는 (주)정진넥스텍은 경기도로부터 ‘일자리 우수기업’으로 선정될 만큼 비약적인 성장을 이루고 있다. 올해에만 67명 증원을 하면서 300억대의 연매출을 내다보고 있는 (주)정진넥스텍(대표 김용담)은 지난 8월 27일 도내 중소기업 중 가장 많은 인력 증원으로 경기도 일자리 우수기업으로 선정됐다.

정진넥스텍은 설립 8년이 채 되지 않은 지금 국내 LED lead frame 부품소재 분야 1위를 차지하고 이 분야에서 국내 최초로 해외 수출시장을 개척하는 등 국내 유망기업으로 주목받고 있다. 창립 당시 경험과 능력을 믿고 전자제품 사출성형분야로 시작했지만 얼마되지 않아 시장개척 등 어려움이 많았지만 2003년 6월 국내에선 다소 생소했던 LED부품소재산업으로 눈길을 돌렸다. 당시 국내 LED부품소재산업 거의 새로운 산업으로 취급되고 있는 상태로 중소기업진흥공단(중진공) 관계자들 조차 낯설어했다는 것이 회사 관게자의 전언이다.

당시 국내 LED리드프레임 생산하기 위해선 장비와 기술력 등을 독일과 일본에서 수입해야만 했기에 정진은 경쟁력을 갖추기 위해 생산기술의 국산화가 필요하다 판단했다. 알려진 특허를 피해 독자적 방식을 개발을 추진한 결과 2003년 생산기술의 국산화를 성공했다. LED리드프레임 생산기술 국산화를 성공한 정진은 우리나라 굴지의 대기업인 삼성과 협력을 맺기 시작해 급성장하기 시작했다. 생산제조 공정도 하나씩 내재화하면서 경쟁력을 키워가다보니 지금은 전 공정 프로세스 100% 내제화에 성공하는 쾌거를 이뤄냈다. 뿐만아니라 정진이 만들어낸 국산화 기술은 국내 LED산업의 경쟁력도 끌어올리는 단초를 마련, 삼성전기와 LG이노텍, 서울반도체 등 국내 3대 LED메이커들이 해외시장에서 유리한 고지를 점할 수 있게 한 결정적 역할을 했다.

경제사정이 악화됐던 지난해 금융위기에 정진은 반대로 투자를 결정, 현재 오산 가장산업단지에 건물을 신축했다. 인원감축 등의 고육지책을 펼치기도 했으나 휴대폰, 노트북, TV에 이어 조명시장까지 점차 확대되고 있는 LED산업과 정진이 쌓아온 기술력으로 약 200억원이었던 연매출 목표를 300억원으로 상향조정해 새로운 시장을 개척해 나가고 있다.

종합부품사로 '탈바꿈'한다
20년 넘게 커넥터를 주력아이템으로 삼아왔으며, 이로 인해 2006년에는 수출 1억불탑을 수상하기도 했던 (주)히로세코리아(대표:이춘재). 그들은 한단계 도약하기 위해서 사업다각화를 꾀하고 있다. 발빠르게 변화하는 전자산업에 능동적으로 대처하는 한편 커넥터만으로는 한계에 부딪쳐, 다른 성장의 돌파구를 찾기 위해서였다. 그래서 뛰어든 것이 LED리드프레임, 안테나, 스위치, 자동차용 모듈로 등 종합부품회사. 뛰어난 금형·사출·프레스 기술력과 50명의 개발전담인력을 활용, 국내외 시장 개척에 나선다는 전략이다.

히로세코리아는 전자부품의 코어 역할을 하는 금형기술을 일본에서 전수받아 제품을 저가에 생산할 수 있으며 개발기간도 짧다고 강조했다. 히로세코리아 관계자는 “현재 매출의 90% 이상을 커넥터가 차지하고 있지만, 2∼3년내 70∼80% 수준으로 낮출 것”이라면서 “LED리드프레임을 시작으로 신개념 안테나 등 다양한 제품들을 선보일 것”이라고 설명했다.
히로세코리아가 가장 먼저 성과를 내고 있는 것은 LED리드프레임이다. 2000년대 초반부터 사업을 준비, 지난해 9·10월에는 월 생산량이 1억개에 달하면서 100억원 정도의 매출을 달성했다. 사이드뷰, 탑뷰, 파워LED 등 다양한 제품군을 보유하고 있으며, 자체 클린룸 설비로 국내 20개 업체와의 경쟁에서 선두 위치를 달리고 있다.

이 관계자는 “올해 LED가 TV에도 채택이 늘면서 기대를 하고 있으며, 대만·중국 등에 수출도 계획하고 있다”고 말했다. 이밖에도 CDMA·GPS용 인테나와 DMB·RFID 태그 안테나도 개발하고 있으며, 마이크로스위치·파워스위치도 속속 내놓고 있다. 신규 사업인 LED 리드프레임 부문에서는 자체 기술과 제품만으로 국내 시장 30%를 점유하고 있다. 조명용 하이파워，미들파워부터 LCD BLU용 '사이드뷰 타입'까지 다양한 종류의 LED 리드프레임을 생산한다.

이 회사는 제품설계부터 금형설계，금형제작까지 모두 수행할 수 있는 인력，설비，공정노하우를 갖추고 있다. 독자기술력으로 토털솔루션을 제공하는 것. 여기에 국내 LED 리드프레임 업체로는 유일하게 클린 룸 시설을 보유해 반도체 공정수준의 청정도를 유지하고 있다.

최근에는 초박형 0.4t 사이드뷰 타입 제품을 출시하면서 일본 금형기술의 아성을 무너뜨리는 '사건'을 일으키기도 했다. 시장에서 상업화가 진행 중인 LED 부품 'High Power'>Power L/F'는 이미 2004년부터 양산하고 있어 타 업체와 차별화된 기술력을 자랑한다.

중국시장 개척·첨단 미래형 기술 개발 박차

한국단자공업은 발광다이오드(LED) 리드프레임 전용 공장을 착공하고 신성장 동력 사업 추진을 본격화하고 있다. 경기 회복세에 따라 중국시장 공략, 친환경 자동차 부품 개발 등에도 적극 나서고 있는 것. 한국단자는 지난 9월 10일 파주 선유단지에 대지 1만7045㎡(5200평), 연면적 1만2289㎡(3717평) 규모의 LED 리드프레임 공장 건설을 위한 착공식을 열었다.
공장은 지상 2층, 사출라인, 프레스, 식당 및 기숙사 등 3개 동으로 이뤄지며 내년 2월10일 완공할 예정이다.

우선 LED TV용 부품생산을 중심으로 하지만 기술개발과 생산 확대에 따라 자동차용 램프 및 산업용 전등 등으로 영역을 넓힐 계획이다. 이를 위해 내년 3분기까지 250억 원을 투자한다. 특히 한국단자는 자동차용 LED사업이 기존 주력부문인 자동차용 커넥터사업과 시너지효과를 창출할 것으로 기대한다. 현재 삼성전자 전자와 월 5억 개, 연 400억 원 규모의 계약을 맺고 이달부터 평택공장에서 양산에 돌입, 공급을 시작하고 있다.또 한국단자는 중국시장 공략도 강화할 방침이다. 현지 생산법인에서 비야디, 체리기차, 지리기차 등 중국 로컬 완성차 브랜드로 바로 수출하는 방안을 적극 추진 중이다. 올해 안까지 중국지사도 운영할 예정이다.

전 직원의 20%에 달하는 연구개발인력(120여명)은 신기술 개발에 집중하고 있다. 한국단자는 최근 지식경제부와 '그린카 부품산업 기술혁신을 위한 양해각서(MOU)'를 체결하고 하이브리드차 및 전기차용 커넥터를 개발 중이다. 내년 출시될 쏘나타 하이브리드차에도 한국단자의 관련부품이 공급된다. 한국단자 관계자는 “글로벌 위기로 잠시 신사업 추진이 주춤했지만 최악의 시기가 지나간 만큼 다시 본격화할 것”이라며 “2500억원 안팎에 머물던 매출액이 오는 2012년에는 5600억 원에 달할 것으로 예상된다”고 밝혔다.

공동 기술 개발로 세계 시장서 경쟁…산학협동도 가시화
몇 년전 삼성전기와 연호전자는 발광다이오드(LED)의 핵심 부품인 리드프레임(Lead Frame)을 공동 개발했다.
두 회사는 리드프레임 양산체제를 확립하기 위해 2006년 3월부터 공동 개발에 착수했다. 그 결과 선진 기술 수준인 95% 이상의 수율과 100% 이상의 생산성 향상은 물론이고 세계 최초로 초박막 사이드 뷰 LED용 리드프레임을 개발하는 데 성공했다. 이를 통해 연호전자는 3년간 신규 매출 1000억원, 2년간 200여명의 고용창출 효과를 얻었다. 또한 삼성전기는 3년간 9000억원 정도의 시장선점 효과를 달성할 수 있었다. 두 업체는 이후에도 꾸준하게 공동 연구개발을 진행하고 있다.

에이치와이티씨(대표 김육중 www.hyseoul.com)는 지난 2000년에 설립한 금형 전문회사다. 국내 금형회사 중에는 20∼30년의 업력을 자랑하는 경우도 많아 에이치와이티씨라는 회사가 알려진 지는 오래되지 않았다. 이 회사는 국내에서 손꼽는 LED 금형 제조사며, 2차전지 부품용 금형, 에어컨 튜브 생산용 압출 금형 부문에서 기술력을 인정받고 있다.
에이치와이티씨는 2005년부터 LED 금형을 만들기 시작했다. 32∼128캐비티(한 금형에서 한 번의 사출로 찍어낼 수 있는 제품수)를 찍어내는 기술을 개발했다. 32캐비티밖에 찍을 수 없는 일본 제품보다 원가에서 월등히 앞섰다. 에이치와이티씨는 현재 국내 LED 업체들에 월 5세트의 금형을 공급하고 있다. 연말까지 생산량을 월 10세트로 늘릴 예정이다. 지난달부터는 대만에 LED 리드프레임을 수출하고 있다. 리드프레임은 반도체 칩을 부착하는 금속기판으로, 에이치와이티씨는 올해 대만으로 이 제품을 수출해 40억원 이상의 매출을 기대하고 있다. 아울러 각형·원통형·폴리머 등 2차전지를 만드는 데 필요한 금형도 5년 전부터 생산하고 있다.

지난해 58억원의 매출을 올린데 이어 올해는 100억원의 매출 목표를 내걸었다. 조만간 일본 대기업에 초정밀 금형 부품을 공급하는 사업에도 나선다. 이르면 3분기부터 정식 납품에 들어간다. 금형 강국인 일본에 제품을 수출한다는 것은 이 회사가 가진 기술과 설비 등의 경쟁력을 인정받았다는 것이다.회사는 지난 1월 KAIST 에너지환경센터 내에 연구소를 개설했다. 이 곳에서는 태양광 반사방지 글래스를 개발한다. 얼핏 보면 금형과 상관이 없는 과제라고 볼 수 있으나, 장치산업인 금형기술의 노하우가 접목된 분야라고 회사 측은 설명했다. 김육중 사장은 “가공기술에선 대한민국에서 최고 회사로 불리는 것이 목표”라며 “변화무쌍한 전자산업의 핵심 제품을 생산하는만큼 기술 개발에 총력을 다할 것”이라고 강조했다.

한편 대구경북지역 LED 융합산업 분야 연구기관들이 서로 손을 맞잡고 본격적인 활동에 나섰다. 대구테크노파크 나노부품실용화센터(센터장 송규호)는 영남대 LED-IT 융합산업화 연구센터(센터장 장자순), 경북대 첨단디스플레이 제조공정 및 장비연구센터(센터장 박이순)와 지난 9월 17일 인터불고 엑스코에서 '지역 LED 융합산업 육성을 위한 혁신 네트워킹 구축'에 대한 전략적 업무협약을 체결했다.

이번 업무협약으로 세 기관은 기업 공동지원 시스템 구축, 인력 및 연구개발장비 등의 활용 지원, 기술정보 및 학술정보 교류 등을 통해 지역 LED 관련 융합산업 육성 및 발전을 위한 활동에 협력할 방침이다. 특히 R&D 역량을 보유한 나노부품실용화센터와 다양한 기술산업화 경험을 보유한 두 대학 연구센터의 상호협력을 통해 LED 융합산업 전반에 걸친 다양한 시너지효과를 얻을 수 있을 것으로 기대하고 있다.

이와 함께 이들 기관들은 9월 16, 17일 양일간 엑스코에서 'CIGS 박막 태양전지 사용화기술 세미나'와 'LED-산업전문가 초청 세미나'를 잇따라 열어 관련 산업 동향을 파악할 수 있는 기회를 제공했다. 장자순 영남대 LED-IT 융합산업화 연구센터장은 “LED산업은 2007년 140억달러 시장규모에서 급속히 발전해 2015년에는 1천억달러 시장 규모로 성장할 것”이라며 “지역의 LED 융합산업 분야 연구기관들이 합심해 세계 LED 시장에서 대구경북지역이 중심축이 될 수 있도록 하겠다”고 말했다.

<박찬균 기자>

월간 플라스틱코리아 - 2009년 10월호 커버스트리

구독신청 문의

전화 : 02-711-3422

tag : PC, 휴대폰, 실리콘, LCD, 반도체, LED, 넷북, 엘이디, 다우코닝, 리드프레임, BLU, 발광다이오드, 그린에너지, 히로세코리아, 연호전자, 정진넥스텍, 한국잔자공업, 에이치와이티씨, HYTC

LOADER WITH SEE-THROUGH BODY PROVIDES ACCURATE, BRIDGE-FREE RESIN DISC

2009-09-19T16:42:36Z

LOADER WITH SEE-THROUGH BODY PROVIDES ACCURATE, BRIDGE-FREE RESIN DISCHARGE AND IS EASY TO DEPLOY AND CLEAN OUT

GlassVu™ GVL Motorized Vacuum Loader from Maguire Is Self-Contained System Whose Clear Center Section Gives Full View of Loading for Easy Setup and Monitoring

ASTON, PENNSYLVANIA, U.S.A., August 20, 2009: A motorized vacuum loader unique for its cylindrical shape and wrap-around see-through section makes it easy for plastics processors to set up and monitor the loading of resin pellets and regrind, and provides fast, free-flowing evacuation of these materials, it was announced today by Maguire Products, Inc.

The GlassVu™ GVL loader is a self-contained unit of modular design, with an onboard motor at the top and a built-in microprocessor control at the base. A slanted hinged lid at top provides easy access for cleanout and filter changing. The cylindrical body of the loader has a center section of borosilicate glass. The cylinder shape extends all the way down to the discharge area, eliminating the conventional cone-shaped bottom, whose narrow section can cause agglomeration or bridging of material.

Located at the base of the loader body, the discharge assembly efficiently controls the flow of materials with a pneumatically driven, positive-seal discharge valve that prevents vacuum leaks associated with flapper valves. The material drops into a hopper through a mechanical, counterbalanced level switch, which automatically returns to its normal position once material is evacuated.

“The discharge section of the GlassVu GVL loader is designed to break up bridging of material and provide fast, flawless evacuation,” said Frank Kavanagh, national sales manager. “Use of a mechanical level switch avoids false readings and frequent adjustments encountered with electronic level sensors because of dust or static electricity.”

The discharge area design also makes possible flush mounting of the loader onto a hopper by means of a mounting flange at the base of the loader. For mounting directly onto a processing machine, Maguire supplies a glass hopper, which is contained within a sturdy frame that supports the loader. The hopper pivots out of the frame for easy draining of residual material.

Other user-friendly features cited by Kavanagh include a rotating inlet that allows 360-degree access for hoses, a patented blowback system that cleans the entire surface of the filter with one blast, and a handle for easy portability.

The GVL-10 model, with capacity of 10 lb. (4.5 kg), is only 29 in. (74 cm) high and 8 in. (20 cm) in diameter. An optional cabled pendant is available for controlling the unit from a distance on the shop floor. The unit is sold with Maguire’s five-year warranty on all components except wear items such as filters.

투명 이송로더 - 정확하고, 브리징이 없는 수지의 배출을 제공하며 이송과 크리닝이 쉽다.

맥과이어의 글래스뷰(GlassVu™) GVL 모터 진공 로더는 명확한 중심부에서 셋업이 용이하고 모니터하기 쉽도록 완벽한 시야를 제공해 주는 자체 이송시스템입니다.

원통형과 투명함이 특징인 이 진공 로더는 성형시 수지와 재생재의 이송을 설정하고 모니터하기 쉽게 만들어 주며, 이 원료들의 신속하고, 자유로운 흐름성을 제공해 주는데, 맥과이어에 의해 오늘 발표되었습니다.

이 GlassVu™ GVL 로더는 윗부분에 자체 모니터와 베이스에는 내장 마이크로프로세서 제어기가 있는, 모듈식 디자인의 자체 이송 유니트입니다. 윗부분의 비스듬한 힌지가 있는 커버에로 청소와 필터 교환이 손쉽게 접근할 수 있습니다. 이 로더의 원통형 몸체에는 특수 유리로 되어 있는 중심부가 있습니다. 이 원통형은, 원료 덩어리나 브리지가 생길수 있는 밑이 좁아지는 재래식 원뿔형 바닥을 없애, 배출부까지 계속 이어집니다.

로더 본체 베이스에 있는, 플래퍼 밸브로 에어 누공을 막아주는 공급밸브는, 견고하게 씰링되어 있고 공압으로 작동하여 원료의 흐름을 효율적으로 제어합니다. 원료는 일단 원료가 빠져나가면 자동으로 원위치로 돌아가는, 기계식의 레벨스위치를 통과해 호퍼로 떨어지게 됩니다.

“이 GlassVu GVL 로더의 공급부는 원료의 브리지를 없애고 빠르고, 문제없는 배출이 되도록 디자인 되어 있다”고 광역 세일즈 매니저, 프랭크 캐버너는 말합니다. “기계식 레벨스위치를 사용하여 분진이나 정전기로 인한 전자식 센서로 인해 생길수 있는 오작동과 자주자주 조정해야 하는 불편을 피할 수 있습니다.”

공급부 디자인은 로더 베이스의 플랜지를 이용해 로더를 호퍼와 같은 높이로 장착할 수 있도록 되어 있습니다. 성형기에 직접 장착하기 위해, 맥과이어에서는 글라스 호퍼를 제공하는데, 이것은 로더를 지지하는 견고한 프레임 내에 들어 있습니다. 이 호퍼는 잔류된 원료를 쉽게 드레인시키기 위해 프레임 밖으로 선회합니다.

캐버너가 제시한 사용자 친화적인 특징들에는, 전체 필터 표면을 단번에 청소하는 특허된 블로우 백 시스템인, 360도에서 접근이 가능한 회전구, 그리고 간편한 휴대를 위한 손잡이 등이 있습니다.

10 파운드 (4.5kg) 용량의, 이 GVL-10 모델은, 높이가 29 인치 (74 cm) 직경이 8인치(20 cm) 밖에 되지 않습니다. 현장에서 원격으로 각 유니트를 제어하려면 옵션인 케이블로 된 펜던트를 이용할 수 있습니다. 이 유니트는 필터 등의 소모품을 제외한 모든 부품에 대해 맥과이어의 5년 보증기간으로 공급됩니다.

사진 첨부: 맥과이어의 GlassVu GVL 자동 이송로더

tag : 칼라믹서, Maguire, 믹서기, 로더, 멕과이어, Loader

Wittmann Battenfeld at the Fakuma 2009:

2009-09-19T16:29:11Z

Wittmann Battenfeld at the Fakuma 2009:

Here it is - the new all-electric EcoPower series

Energy and cost savings is the motto these days. With the first presentation of its new all-electric EcoPower machine series, Wittmann Battenfeld is right on target. From 13 -17 October, visitors to the Fakuma in Friedrichshafen will be able to experience this novelty first hand at the booth of the Wittmann group (hall B1, booth 1204). In addition to this exhibition highlight, a high-speed packaging line and a multi-component application will be shown.

With a joint booth at the trade fair, the two companies of the Wittmann group underscore their common philosophy of “everything from a single source”. Applications from the automotive, electronics and packaging industries are on display. The premiere of the high-performance, energy-efficient all-electric EcoPower machine series will take center stage at this year’s show.

EcoPower - Energy-efficient, clean and compact

At the booth of the Wittmann group, the curtain will be raised for the first time on EcoPower, the new generation of all-electric machines.

With this new development, Wittmann Battenfeld is presenting impressive evidence of its more than 20 years of experience in the area of all-electric machines.

The EcoPower series scores above all with a compact, beltless injection unit and the clean design of its clamping units with direct drives. The braking energy of the drives, which is normally wasted or recovered by an elaborate process, is utilized inside the machine with the EcoPower.

To achieve maximum customer benefit, the EcoPower series comes in a modular design and is preconfigured. This enables the machines to be laid out for standard high-precision injection molding, as well as clean-room technology and high-speed applications.

The performance features just mentioned will be presented on an EcoPower 110/350, manufacturing a housing cover. The parts are removed and deposited on a conveyor belt by a Wittmann robot from the W821 series, which is fully integrated in the Unilog B6 machine control system.

With the new EcoPower series, temperature control devices and material dryers can be mechanically integrated directly into the machine frame, which saves extra costs for space.

Moreover, the entire peripheral equipment is set, visualized directly and data stored via the machine’s control system.

Multi-component technology for cost-efficient applications

On an HM MK 240/1330H/210S, Wittmann Battenfeld will demonstrate the production of a 2-component sealing element (JP Grosfilley) from PP/TPE for the BMW Mini Cooper within a cycle time of 30 seconds.

Thanks to the space-saving configuration of the injection units (horizontal, diagonal) the W823 Wittmann robot for the removal of finished parts can be mounted on top of the fixed platen.

In the ‘insider solution’ on display, the finished parts are deposited on a conveyor belt integrated in the machine frame. This significantly reduces the machine’s footprint, resulting in further cost cutting.

The operation of the robot is particularly user-friendly. In addition to a manual control device, the robot can be operated completely via the Unilog B6 machine control system.

This exhibit is also equipped with power factor correction, which achieves substantial cost savings through a combined reduction of reactive and effective power.

Wittmann Battenfeld offers a wide range of custom-made optional packages and combination possibilities for its multi-component series. Its know-how, which has been developed over many years, includes all process variants, such as multi-color, multi-component, assembly and sandwich injection molding.

TM Xpress - The high-speed solution for the packaging industry

The TM Xpress, presented for the first time in 2008, has met with a very positive response from the market. In combination with a Wittmann IML tool and Wittmann automation equipment, it stands as a synonym for the Wittmann group’s philosophy of “everything from a single source”.

To this year’s Fakuma, Wittmann Battenfeld is bringing a TM Xpress 210/1350 demonstrating the production of a bucket made of PP holding 1,180 ml. Insertion of the banderole label as well as removal and depositing of the finished buckets are handled by the IML automation equipment. The buckets will be manufactured in a 2-cavity mold within a cycle time of 5.8 seconds.

Battenfeld K4 - Security for all production data

Jointly with Wille System GmbH, Wittmann Battenfeld is now offering a modern database concept, which operates on a server for central data administration and is directly integrated in the Unilog B6 machine control system as well. Its structure, data format, menu system and tools are perfectly tailored to meet the stringent demands of the plastics processing industry.

From the machine’s parameter settings, quality assurance, maintenance data, primary and final costing, order-related time data collection, shop floor layout to innumerable evaluation options including open item management, a unique range of service tools has thus become available.

The entire machinery of a company, including machines at other locations and in other countries, can even be visualized and monitored from the B6-control system, regardless of the types and brands of injection molding machines.

All exhibits shown at the booth are connected to this process data collection tool. All data can be retrieved directly on the machine, at the service corner of the booth as well as at the booth of Wille GmbH (hall A1, booth 1401).

Of course, all exhibits are also connected to the Wittmann Battenfeld remote service network and their data can also be retrieved via Battenfeld K4. The proven web service will also be presented once again by means of a live connection.

Fig. 1: The new EcoPower 110/350 from Wittmann Battenfeld will manufacture a housing cover.

Fig. 2: An HM MK 240/1330H/210S will manufacture sealing elements for the BMW Mini Cooper.

Fig. 3: The IML application on display is a synonym for the Wittmann group’s philosophy of “everything from a single source”.

tag : IML, Battenfeld, 위트만, Wittmann, 비트만, Cooper, FAKUMA 2009, EcoPower, BMW Mini

Auxiliaries from WITTMANN . the key to success!

2009-09-19T16:12:31Z

Auxiliaries from WITTMANN . the key to success!

The main themes of the last shows . energy efficiency, productivity and flexibility . maintain their high profile again during the 20th anniversary year of the FAKUMA show. More than ever, are intelligent, flexible and efficient devices required for molding success. The WITTMANN Group demonstrates innovative new products for optimizing the process of plastics molding.

Numerous product presentations demonstrate the innovative power of our combined companies of WITTMANN and BATTENFELD. From October 13th to 17th, 2009 the WITTMANN Group introduces in Hall B1 Booth 1204 a brand new worldwide introduction, the new electric molding machine. From the AUXILIARIES product range, the following product news will be presented to the visitors of FAKUMA 2009:

1. Robot model W811 with B/C-Servo - Rotations
The market need for additional servo driven degrees of freedom even on smaller robot models is addressed now by WITTMANN with the introduction of the B/C servo axes for small robot models W811, as well as W821 and W831. The Servo-B-axis allows for an incremental rotation of end-of-arm tooling and C-wrist flip between 0°-270°, while the Servo-C-axis rotates the end-of-arm tooling between 0° and 180°. All intermediate positions of the respective axis of rotation can be programmed with an accuracy of 0,01°.

Servo robots with Servo-B/C combination provide as a standard 5 degrees of freedom and thus allow the implementation of complex curved path motions. The payload available for end-of-arm tooling and part ranges depending on the robot model from 3kg to 8kg. These additional servo axes rotations are now available starting from the small robot model W811 up to the largest robot W873. The optimum 5 or 6 axis servo control shown is linear axis for injection molding part removal on the main axis and then to add these curvilinear motions control in wrist rotations for special part removal requirements or value added work cell demands in pre- or post molding operations. Along the main axis motions the payload is not compromised within the work envelop.

2. Robot control R8 with conveyor belt synchronisation

The R8 robot control from WITTMANN combines ideally an easy-to-use and intuitive operation with unmatched performance.

Within up to 16,000 lines per program practically unlimited robot sequences can be realized. The multitasking ability of the control allows the arbitrary sequential or parallel execution of work cell programs. Furthermore, up to 12 numerical axes can be moved synchronized or separate from each other. Besides the standard functionality of TruePath for the precise curvilinear following of 3D motions, the completely revised PartTrack function on the R8control allows the synchronous following of objects on a moving conveyor belt.

The exact position of the object on the conveyor belt is recognized by a sensor and tracked precisely by means of an incremental encoder. Thereby objects can be picked up from a moving conveyor or parts can be placed inside a box placed on such conveyors. Practical for the setup is, to not require the conveyor belt to be in any specific angle to the robot axes, as any arbitrary orientation and surface angle can be assumed and followed.

3. Gravimetric Blender Gravimax 14V with Batch-to-Batch precision

The completely redeveloped gravimetric blender GRAVIMAX 14V represents a further evolution of its successful forerunner - GRAVIMAX 14R. The GRAVIMAX 14V presents itself in a totally revised design, whereas the online batch metering valves RTLS (“Real time live scale” for each batch weighing, compared with competitive models which average batch weights) have been maintained from the previous model. The new design incorporates highly precise wear-resistant stainless steel valves and knife gates instead of the previously used rubber pinch valves. The GRAVIMAX 14V model achieves a material throughput of up to 80 kg/h, and is now equipped as a standard with two weigh cells for higher metering precision and an innovative laser pointer, positioned outside the material flow and thus, is protected from abrasion and contamination. The new corner windows of each hopper provide a full view for material inspection and each detach quickly for simpler and easier cleaning access.

4. Temperature controller Tempro plusC 180 . water temperature control up to 180°C

Water has better heat transfer characteristics over oil. And oil is expensive, messy and problematic for handling and disposal. Based upon the demand of the TEMPRO plusC 160 (320F) water temperature controllers using magnetically coupled pumps and these water vs oil benefits, WITTMANN decided to expand its high temperature water line to 180°C (356F).

Shorter heat-up times, more precise control, higher flow rates and a uniform temperature distribution within the cavities are the main advantages of water as the heat transfer medium versus thermal oils. And the ecological advantage continues, as water is unproblematic in its handling and disposal.

WITTMANN’s new water temperature controller TEMPRO plusC 180 will be displayed. The high performing control system is based on the proven TEMPRO plus C series. The process tank and all pressure connections were adjusted to the higher pressure conditions of up to 13bar at 180°C. A high safety level is achieved through the default system pressure control.

5. Temperature controller Tempro directC 120 for highest cooling capacity

Especially for the temperature control of larger molds and molding machines, temperature controller model TEMPRO direct C 120 has been released. The new centrifugal pump provides in the performance range from 0,75kW to 4kW and depending on the pressure situation a flow rate of 200 to 250 l/min and thereby guarantee the optimized temperature control of large mold and cooling requirements.

The maximum process temperature is 120°C (250F). Through the direct cooling, and thus very high cooling capacity, the main application ranges in temperatures between 10°C (50F) and 60°C (140F). Contrary to competitve directly cooled temperature controllers, model TEMPRO directC 120 of WITTMANN is manufactured of non-corrosive material.

6. WFC . Trouble-free flow monitoring of medium temperatures up to 90°C

The WITTMANN WFC controlled water flow regulator offers optimized Multi-Channel Flow Monitoring, used in parallel connection between the temperature controller and the mold or other mold cell consumers. The flow rate acquisition and monitoring offers increased process safety and thereby a further increase in part quality.

Additionally to the existing water flow regulators, a touchless flow measurement has been integrated and combined with a display. The processor has now the option to adjust the desired flow rate, via the proven valves from the WITTMANN flow regulator series. After connection to the molding machine this rate can be monitored to stay within an adjustable window size. During development of the WITTMANN WFC, focus was put on the compactness of the unit as well as the possibility for mounting on the tie bars of smaller injection molding machines.

7. Vacuum loader Feedmax B208-CT with sight glass

Immediately after the introduction of the FEEDMAX B Series vacuum loaders for central material handling systems, WITTMANN received a favourable market response in many new orders. This enormous acceptance by processors is based on several superior features, not only facilitating the daily operation with loaders, but also guaranteeing highest availability. Easiest cleaning possibilities allow for a long-term and efficient usage of the units. The pneumatically operated discharge bell guarantees a uniform loading capacity over the entire life-time and the execution from stainless steel makes it ideal also for abrasive applications.

In the new optional models FEEDMAX B-CT (Clear Tube) the lower cylinder section is made of high-quality Pyrex glass and permits the simple visual control of the material level. The vacuum loader with the Clear-Tube option is available in sizes 8l, 11l and 25l and ideally complements the standard models with material volume ranging from 3l to 25l.

8. Dry air Dryer Drymax D60-50/50/50 with energy saving function
The WITTMANN compact dryers of series DRYMAX D allow further flexibility by connecting it either to 1-, 2- or 3-drying hoppers. DRYMAX resin dryers of series D are as a default equipped with two desiccant beds and provide the energy saving functions SmartReg and SmartFlow, counter air flow regeneration, as well as an intelligent material protection function. DRYMAX dryers can be usually operated without the need for return air coolers with process temperatures up to130°C. The up to 3 stainless steel drying hoppers control individually the drying temperature and dry air volume for optimized resin drying. An optimized air distributor and hopper geometry guarantee efficient plastic resin drying.

tag : Robot, Temperature, Fakuma, Wittmann, Dry, Drymax, Servo, Gravimetric, Gravimax, WFC, Feedmax

Preforms, closures, beverage crates &pallets

2009-09-19T16:05:52Z

Preforms, closures, beverage crates &pallets

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.

(Photo)Bewahrte Technologie macht die PETForm-Systeme zu zuverlassigen Leistungstragern fur die PET Preformherstellung

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.

In addition to the short cycles and constant shotweights, the outstanding characteristic of this EX machine is its reduced energy consumption. Once out of

(Photo)Verschlusskappen lassen sich mithiilfe der EX-Baureihe extrem schnell und effizient herstellen 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.

(Photo)Die MX-Baureihe ermoglicht die Herstellung von Flaschenkasten mit gleichbleibend hoher Leistungsdichte

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 userfriendly, 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 fastacting, 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 roundthe- clock operation, through to innovative, exclusive processes to reduce material costs.

tag : EX, Extruder, PET, KraussMaffei, Extrusion, 사출성형기, 압출성형기, 사출성형, 크라우스마파이, IMC, 압출기, 전동사출기, WPC, Preforms, Closures, Pallets, 프리폼, HPX