in partnersHip WitH inDustrY KraussMaffei is a premium ... · Our Injection Moulding Machinery Division supplies machinery and systems from 35 to 4,000 tonnes for standard applications

Our service fOr cOst-cOmpetitive alternatives

Complete refurbishing for injection moulding machines

in partnersHip WitH inDustrY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Whatever you aim to achieve in plastics or rubber

processing, KraussMaffei is your partner. We are

the only company with intensive expertise across

the three main engineering fields. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

ready for any challenge

Our Injection Moulding Machinery Division

supplies machinery and systems from 35 to 4,000

tonnes for standard applications and for all

processing variants, together with fully automated

solutions. We have a strong customer base in all the

relevant industries worldwide.

Our Reaction Process Machinery Division supplies

machines and complete systems for processing

polyurethanes and other reactive materials.

Completing our product portfolio, Automotive

Component Systems supplies foam moulds, cutters

and routers. Our customer base is wide, with a

focus on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems for compounding, for pipe,

profile and sheet extrusion, physical foaming, and

the production of technical rubbers and inter-

mediates for tire production. Machinery from the

company’s range – from single extruders to

complete extrusion lines – is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, furniture and packaging.

people for plastics

We are the “people for plastics”. We are your

partners from the first exploratory discussion,

through development to commissioning, servicing

and operating your system, and final disposal. At all

times, you are assured of outstanding competence

in planning and engineering, as well as reliable and

fast spare parts, service and support.

adding value for customers

We put our expertise to work for your success.

With machine ranges engineered for modular-

ity, we can deliver application-specific solutions

based on our wide range of standard modules and

specially engineered solutions. This strategy offers

customers technical and cost advantages.

close to customers around the world

As an international company, KraussMaffei has a

presence in all the major markets for the plastics

and rubber processing industries and employs over

3,000 people worldwide. Our sales and service

network keeps us close to all our customers around

the world.

Life ScienceConstructionWhite goodsAutomotive Electrical / electronics

Electrical / electronics Packaging

Reduce your costs, but not your expectations – with KraussMaffei Service

KraussMaffei Service is there with fast, professional help wherever you are in the world. KraussMaffei Service is your expert and reliable partner at all times, but especially for retrofitting, refurbishing and improving the performance of injection moulding machines and for implementing energy-saving measures.

If you are buying or selling a used injection moulding machine, we can offer cost-competitive solutions for a wide range of retrofit and upgrade options. We will modernize your machine to your requirements and to conform with current safety standards. We give a 12-month factory guarantee on all completely overhauled injection moulding machines. And we’re always available for consulting and application engineering.

Page 4 Completely overhauled injection moulding machines

You get a good deal when you buy a second-hand

KraussMaffei machine that has been completely

overhauled by our experts. You get KraussMaffei

quality and service at an excellent price.

always a good investment

KraussMaffei Service (KHS) specializes in

overhauling, upgrading and remarketing previously-

owned KraussMaffei injection moulding machines.

Our engineering expertise, experience and attention

to detail are your guarantee for highest quality.

We give a twelve-month factory guarantee on every

fully-overhauled injection moulding machine we

sell. Your investment is safe and you can expect it

to pay dividends, because you can be sure of

maximum operational availability and a machine

that is an excellent match to your requirements.

customized solutions

You may be buying a second-hand injection moulding

machine, but you are getting first-class know-how.

KraussMaffei is one of the world’s leading suppliers

of advanced plastics processing machinery. When

it comes to used machines, we bring our expertise

to bear on adapting and upgrading machines and

their control systems so that you get a customized,

application specific machine. For maximum efficiency

and minimum costs, we’ve developed modular

retrofit packages. The choice is yours; you can opt

for anything from a limited, step-by-step retrofit to a

complete modernization. We naturally offer the same

retrofit options for older KraussMaffei machines you

have already installed. If you are considering a move

into new markets and new production challenges, you

can call on our teams for expert advice and for any

machine adaptations that may be necessary to realize

your new project.

individual financing plans

A fully-overhauled KraussMaffei injection

moulding machine keeps start-up costs for your

new production project as low as possible. Even

more so, because you have the possibility to

various financing plans to suit your budget, from

leasing and leasing with an option to purchase to

a balance-of-purchase-price scheme.

the right partner

If you’re planning a new project and looking for

a fair partner to buy your used machine, contact

KraussMaffei. We’ll inspect your machine and

make you a fair offer. If you want us to, we’ll also

handle disassembly and transport for you.

all tHe services YOu neeD

Previously-owned injection moulding machines – the cheaper alternative, an investment with a secure future

Page 5Complete service portfolio

Your advantages at a glance:

· Refurbish and retrofit a machine to your requirements, whether it’s a machine you already own or a secondhand machine you’re planning to buy.

· Implement energy-saving measures

· Buy and sell used injection moulding machines

· 12 months factory guarantee for fully-overhauled injection moulding machines

· Upgrade to state-of-the-art – satisfies current safety criteria, with CE marking and the latest machine control system

· Consulting and advice on the right technology for your specific applications

· Assembly and commissioning

· Training and documentation

transparent tecHnOlOGY

Meet the machine: take a tour of a fully overhauled and upgraded injection moulding machine (KM 3200-13000 A)

Aluminium enclosure· with window panels and

hydraulic operation· easier control and at the

same time highest safety

Position - controlled clamping unit with proportional valves (behind machine)· integrated electronics· individually adjustable

Guideway supported sliding-shoe· eliminates platen tilt· less wear on mould· less wear on tiebars

Ultrasonic potentiomheter· fast, precise, maintenance-free· low wear

MC control system· user-friendly· real-time display of

all operating data· extensive quality controls· links to Ethernet systems· display screen close to mould

Plasticizing with shut-off nozzle· fast and precise

closure of nozzle

Ultrasonic potentiometer· fast, precise, maintenance-free· less wear and tear

Closed loop pump control· controlled by pressure and throughput· regenerative pump drives (option)· automatic demand-driven response· energy saving

Lower noise levels · +/– 76 dbA

Injection unit· directly electronically

controlled valves

Control cabinet· good ergonomics· control reserves for later

installation of other options

Options Robot interface · Entry to automated production

Wear protection for the plasticizing unit· up to six times longer service life· long-term consistent product quality

Quick-change mould fixing system· ideal for frequent mould changes

Modular hydraulics concept· parallel machine movements· pressure accumulator for fast

injection up to 600 mm/s

Electric-motor screw drive· plasticizing in parallel with

all machine movements

Teleservice interface


The clamp units of KraussMaffei injection

moulding machines offer a number of decisive

benefits for your production and from the

beginning on its easy to use.

no-tilt mould fixing platen

Massive, projecting sliding shoes support the

moving platen as it moves across the machine bed.

Together with the four tiebars, they are capable of

countering every tilting moment, so that even very

heavy moulds will remain absolutely parallel dur-

ing opening and closing. The benefit for you: no

mould wear and no wear on the guide elements.

High-precision position control

Opening and closing movements are tightly

controlled. The end positions “Mould lock” (as

the mould closes) and “Mould open” (as the

mould opens) are repeated with absolute preci-

sion, no matter how heavy the mould and how

fast it is moving. This precision guarantees that

the mould securing process and parts removal

(optimized for time and stroke) are both smooth

and precise.

sensitive mould securing

Mould securing is the most critical phase in the

cycle. In engineering our injection moulding

machines, special attention was paid to getting the

locking phase perfect, in order to give fullest

protection to delicate mould contours. On

adjustable stroke sections, it is possible to program

and call up several different mould closing speeds

and pressure limits independently of each other.

clamp unit

Reliable, precise and flexible

Fixed platen: core pulls and mould-

master valves with proportional valve

closed-loop control

Moving platen: core pulls and ejector

valves with proportional valve

closed-loop control

Proportional valve closed-loop control

for the clamp block

Page 9Clamp unit

flexible for part removal equipment

Parts handling equipment is generally positioned

at right angles to the injection moulding machine,

with parts transport on the operator or

non-operator side. The KraussMaffei clamping

system allows handling equipment to be installed

in the machine’s longitudinal axis as well. There

is ample space for the installation of linear or

6-axis robots.

safety covers

Large window panels give a clear view of the mov-

ing mould and machine components. The front

and rear panels can be opened separately. These

doors give access to the ejector area. The housing is

designed to allow easy connection of the hoses and

cables supplying the mould.

ready for special tasks

Standard machines are not capable of meeting the

requirements of highly specialized applications.

Because KraussMaffei standard machines are engi-

neered to a modular design, even highly specialized

machines can based on standard modules, while

simultaneously incorporating special hardware and

software features. Here are just three examples of

many: Rotating or swivel components especially for

multicomponent moulding; special machine versions

for injection compression moulding and bolt-on

equipment, eg, for gas or water assisted injection;

easy integration of part removal robots.

A fully modernized and upgraded clamp unit


Completely modernized injection unit from an A Series machine

Refurbishing and upgrading the injection and

plasticizing unit is a good investment for more

performance, better wear protection and less

stress on the material.

plasticizing units can be matched to the

material and the process

Finely scaled performance and appropriate screw

diameters make it possible to achieve a very close

match between raw material/process/product and

plasticizing performance. For more specialized

applications, our range of machines also includes

metering and injection equipment for standard,

multicomponent and special machines.

matching the screw to the material

We supply a very wide range of standard screws.

In addition, we offer special screw concepts for

high-quality, cost-competitive processing of even

the most difficult materials. A hallmark of all our

screws is an excellent price/performance ratio.

Improving screw design is an important focus of

our R&D effort as we aim to boost screw

performance for processing of all types of plastic,

increase throughput, reduce melt temperatures and

improve mixing and homogenization.

macHine upDates

Retrofits and refurbishing cost a fraction of the price of a new machine

Our plasticizing units – your benefits

· High availability

· Competitive prices

· Refurbishing, test and inspection of old plasticizing units

· Manufactured to the highest standards

· Fast response through direct contact to KHS

Page 11Machine updates

extra wear protection where necessary

Formulations containing additives or fillers to improve

processing, or end product properties, frequently

cause problems for the processing machinery,

including abrasion and/or corrosion of the screw, the

barrel and the non-return valve. KraussMaffei offers

the option of special wear protection for these parts

that minimizes the problem.

Wear protection for constant quality and

lower manufacturing costs

Wear is not merely a maintenance problem. Worn

machine components affect process stability.

Wear on plasticizing unit components impacts on

the process, increasing the reject rate and even

bringing processing to a halt. The right wear

protection is a critical factor in achieving

consistent quality and keeping costs under

control.

configurations with two or more injection

units and bolt-on units

To make multicomponent and/or multicolour

products, standard machines are equipped with

additional plasticizing units. In a KraussMaffei

multicomponent machine, each plasticizing unit

operates completely independently to ensure optimal

plasticizing and homogenization for each material/

colour. The whole process is synchronized by the

process controller. The additional units can be

positioned above or to either side of the main unit in

”L” and ”V” positions. Other arrangements are also

possible, depending on machine size and product.

Whatever the task, KraussMaffei has the expertise

and the hardware and software to configure the right

solution.

Application-specific solutions – for example

plasticizing unit with shut-off nozzle

Second injection unit in L position on the

non-operator side of the main unit for

a second material in multicomponent

moulding

Enhanced wear protection on a high-performance

screw – the arrow marks the start of the wear

protection layer


Whether you’re looking for lower energy

consumption, faster movement times, faster

acceleration and deceleration, or constant

reproducible quality over long production runs

– the pumps for the hydraulics in KraussMaffei

injection moulding machines are designed to

deliver all these benefits.

intelligent pump drives for minimal energy

consumption (option)

The regenerative pump drive consumes up to 40%

less energy, especially when running at less than the

rated load. This is because no more than the required

oil volume and pressure is delivered at each stage of

each operation. Actual values are measured in the

pumps and adjusted instantly. This keeps energy

consumption to a minimum.

fast response time

Characteristic of the pressure- and flow-controlled

pumps is the very fast response that enables rapid

accelerations and decelerations or small pressure

variations, eg, in the holding pressure phase.

parallel machine movements cut cycle times

Options available for our standard machines include

the clamping unit open/close stroke to operate in

parallel with the ejector stroke/core-pulling. They are

also engineered to ensure completely independent

movements of the clamping unit (including ejector and

core-pull) and the injection unit (stroke and

plasticizing). KraussMaffei development engineers have

made full use of all the mechanical and control options

to reduce cycle times in a successful drive to produce

an outstandingly fast and efficient machine.

HYDraulics

Precision control, fast response, flexible for upgrades

The customer wanted to save energy, so we upgraded the machine

to use this regenerative pump drive.

The hydraulic drive in a completely overhauled

injection moulding machine.

Page 13Hydraulics

reliable proportional valves

Digital set values for operating speeds and pressures

are entered in the microprocessor controller. These

values are used to control the proportional valves.

The electrically operated valves with an additional

internal closed-loop monitoring system guarantee

high reproducibility and long-term consistent

maintenance of the set values. The result is consistent

production cycles and high product quality.

effective soundproofing cuts

noise levels (option)

The drive unit can be enclosed in soundproofed

covers, capable of reducing sound emission levels

to approx. 76 dBA. Cover panels can be detached

and lifted off individually to allow access for

service and maintenance work and easy access to

all hydraulic components.

extra, high-performance control

for injection and plasticizing

Machines can be fitted with an extra proportional

valve for the injection phase. Pressure and speed

for injection and plasticizing can then be adjusted

with ultimate precision by closed-loop control.

Normally, injection pressure is simply generated by

the machine‘s hydraulic drive pump. If required, an

additional pressure accumulator can be installed to

deliver even higher injection speeds.

Closed-loop control close to the consumer

for highest precision and dynamic control of

injection pressure, back and holding pressure.

Modular concept for ejector, core pulls and

cascades regulated via the operator display.

Clamp unit block with variable-delivery

pumps and integrated safety systems.


cOmpOnents anD prOcesses

Special solutions – a ready response to innovative technologies and new market prospects

KraussMaffei supplies proven modules and

innovative processes that let you retrofit your

machines, at a relatively low cost, ready

to enter markets where you see new business

opportunities.

Bolt-on units: low-cost entry into

multicomponent injection moulding technology

KraussMaffei makes it easy for you to move into

the growth market of multicomponent moulding.

You can add a bolt-on injection unit to an already-

installed injection moulding machine. It’s the easiest

and lowest cost approach to starting 2-component

(2C) moulding : KraussMaffei bolt-on units can also

be integrated in machines from other manufactur-

ers – we’ll handle the retrofit for you. An existing

2C machine can naturally be retrofitted with a

third injection unit for 3C moulding. And we’re the

experts in fitting a lot of machine into a little space.

To keep the footprint of your 2C machine the same,

we offer a V-version bolt-on unit. “V” stands for

vertical and this unit is mounted vertically above the

fixed platen. The L-version needs more space, it’s

mounted horizontally at 90° to the main injection

unit. Connection and disconnection is so simple, that

bolt-on units can be switched from one machine to

another if required.

Decoform: innovative one-step production

technology for premium quality decor elements

In the fast-changing automotive market, the

development time for new models shortens year by

year. Models and brands are now largely

differentiated not by technology, but by fittings,

comfort features and customer choice. This means

that the design and quality of the passenger compart-

ment play an ever more important role in purchase

decisions. In a fiercely competitive market with costs

under immense pressure, the challenge is to produce

high quality moulded parts at low unit cost. The

Standard machines can be fitted with one or more

additional injection units to create, for example,

a 3-colour machine

View from the top of an overhauled

KM 3000-13000 A

Independent bolt-on unit horizontal position

Independent bolt-on unit vertical position

Linear robot

Page 15Components and processes

results can be seen in the rapid advance in produc-

tion technologies for each new generation of cars.

The same methods can be used to gain quality and

cost advantages in aircraft and train interiors and

seats, and in the furniture industry.

KraussMaffei offers DecoForm and DecoPress

machines where the proven quality of our engi-

neering and our high-performance components are

the answer to cost-competitive production of high-

quality decor parts. Modular and upgradeable,

they are also ready for the future.

in-mould decoration instead of laminating:

faster, better, cheaper

In-mould decoration – injecting a polymer backing

onto a film or fabric insert in the mould – has

proved most successful when the mould is

equipped with hot runners and needle shut-off

nozzles. These are independently controlled to

avoid damaging the insert material through high

melt temperatures and pressure, shear forces and

shifting. In-mould decoration delivers powerful

technical and economic benefits. It involves fewer

process steps. It’s more environmentally friendly,

firstly because no adhesive means no solvents are

used. Secondly, it’s possible to use regrind in the

substrate material and, thirdly, for high

recyclability the same type of polymer can be

used for the décor film and the substrate. Unit

manufacturing costs for IMD can be substantially

lower (between 15 and 30%) than for conventional

laminating processes.

tandem and stack moulding

These production processes can both be

integrated. They both offer potential for extremely

cost-competitive and economic production.

Hydraulic station with pressure accumulator

for DecoForm and DecoPress applications

Microprocessor controller

micrOprOcessOr cOntrOller

Intelligent, easy-to-use and upgradeable

Control comfort with state-of-the art technology

Perfect process control requires a microprocessor-

based control system, capable of providing

intelligent functions, easy to operate and

error-resistant.

fast and accurate display of processes,

values and graphics

KraussMaffei‘s microprocessor controller is

standard on all our injection moulding machine

ranges, including our multicomponent, thermoset

and special purpose machines. It’s easy to use and

ensures state-of-the-art process control with fast

signal processing for exact reproducibility of set

values within the tightest tolerances. The fast,

multitasking operating system displays actual

values, graphics, etc. in real time, stores set and

actual values and provides easy connectivity to a

PC environment.

simplified touch-key screen for easy,

errorfree machine operation

The number of push buttons and soft keys on the

control panel has been reduced to a minimum, so

that access to the control menus and parameters

has never been simpler or the error risk lower. Even

where functions have been expanded, the enhanced

display format makes for a more compact

presentation without loss of functionality. Motor

and heating are switched on/off using separate

buttons on the operator panel.

colour stn flat-panel display

Controller operation is fully supported by PC display

technology, such as windows, scroll bars and buttons.

Plain text information is toned down, the emphasis is

on easy to understand symbols and pictographs. The

net result is a quicker and surer grasp even of com-

plex interactions and processes. This approach makes

it easier to understand and/or change the production

status currently being displayed. More information

on a page also means less paging. The total number

of pages has been reduced significantly. Parameters

can be tagged, so that pressing the help key will

then invoke an on-line explanation, eg, of functional

operation, setting ranges, etc.

Page 16

Page 17Scope of activities - refurbishing, retrofits and upgrades

scOpe Of activities –

refurBisHinG, retrOfits anD upGraDes

What we can do for you – products and services from KraussMaffei Service

With KraussMaffei Service and the KHS team

your first point of contact, you can be sure of

outstanding support, quality workmanship and

competitive prices. Contact us for upgrades and

retrofits, complete overhauls, modifications and

performance enhancement – or if you want to buy

or sell a used machine. Here is a list of our main

products and services for your injection moulding

machines:

· Retrofits and upgrades

· Overhauling machines

· Performance enhancement

· Modifications for special applications

· Energy consulting

· Implementation of energy-saving measures

· Upgrade and refurbish hydraulic screw drives

· Automation solutions

· Planning application-specific special machines

· Purchase and sale of used machines

· Machine recalculation for design and

process engineering

· Bolt-on units for all machine sizes and brands

· Refurbishing plasticizing units

· Redesign of shut-off nozzles

· Modernizing control systems

· Loan machines for temporary

production bottlenecks

· Expert moving service for machines and

complete production plants

· Cycle-time optimization by integrating electric

screw drives and up-to-date control systems

· Preassembly of components

... and more

Your KHS customer service team

Rely on us for a fast and competent response to

all your service needs anywhere in the world.

Whatever you need – from troubleshooting or

training to spares or repairs – we’re on the job.

We’re dedicated to supplying service quality on a

par with the outstanding quality of our machines

and systems. We offer far more than spare parts

and hotlines. We’ll work with you to choose the

best and most cost-effective solution for your

operation. We’ll help you test new applications

and we’ll plan customized service packages.

all-round service

Our service offering is broad. We’ll configure your

system, install and commission it, train your staff,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. You’ll find us fast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

If necessary, we’ll get a technician to you quickly.

Remote diagnosis, interfacing directly with your

machine’s control system, can be a practical

alternative. Spares for all important wear parts are

available at short notice. We’re continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution for your business.

customer trials and prototyping in our test lab

The Injection Moulding Division operates a test

lab fitted with the latest machinery and equipment.

We can run trials, produce prototype parts and

fine-tune processes on your behalf. We can work

with you to test and evaluate processes, machines

and equipment in order to identify the best

approach for a particular project. Our highly-

qualified application engineers are there to help you.

training with high hands-on content

Courses are held in our lab and training centre,

or, optionally, on your premises. We offer

clearly-structured basic and advanced training in

operation, process control and maintenance for

KraussMaffei injection moulding machines. On

request, we’ll plan and hold special courses on

topics of your choice. All participants spend a high

proportion of their training working hands-on

with original KraussMaffei machines.

A well-structured training program produces

skilled operators and technicians, which will posi-

tively impact your up-time and productivity.

service WOrlDWiDe

Service, support and spare parts – when you need them, where you need them

contact for training:

Rupert Gruber

Phone: +49 89 8899-3613

Fax: +49 89 8899-4173

[email protected]

Phone or mail KHS directly Phone or mail KHS directly

Apart from email you can contact our customer service

and spare parts team from anywhere in the world using

our service hotline or by post at this address:

Our service teams:Our service teams: On call around the worldOn call around the world

Team EuropeTeam Europe

Service Team Injection Moulding

Email: [email protected]

Spare Parts Team Injection Moulding


Team Asia/ Near EastTeam Asia/ Near East





Team America/SpainTeam America/Spain





Ralph Lindner Ralph Lindner

Phone: +49 89 8899-3246Phone: +49 89 8899-3246

[email protected]@kraussmaffei.com

servicehotlineservicehotline

Phone: +49 89 8899-3026Phone: +49 89 8899-3026Fax: +49 89 8899-2856Fax: +49 89 8899-2856europeeurope Phone:Phone: +49 89 8899-3172 +49 89 8899-3172 Fax: +49 89 8899-3399Fax: +49 89 8899-3399asia/near eastasia/near east Phone:Phone: +49 89 8899-4298 +49 89 8899-4298america/spainamerica/spain Phone:Phone: +49 89 8899-3801 +49 89 8899-3801

Kraussmaffei technologies GmbHKraussmaffei technologies GmbH

Hall 91 West/Dept. KS 13/KHSHall 91 West/Dept. KS 13/KHS

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Kraussmaffei technologies GmbH

Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2569 ··· Fax +49 89 8899-2877www.kraussmaffei.com/usedmachines

KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

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KraussMaffei Service is your efficient and reliable partner anywhere in the world. Our areas of special expertise include retrofits and complete overhauls, modifications and performance enhancement of injection moulding machines. We also buy and sell used machines. Our solutions and services are complete and cost-effective, for example, we’ll modernize a machine so that it exactly matches your requirements and conforms with current safety legislation. We give a 12-month factory guarantee on all completely overhauled injection moulding machines. And our expertise in process engineering, energy-saving, etc. is on call at any time.

Documents

in partnersHip WitH inDustrY KraussMaffei is a premium ... · Our Injection Moulding Machinery Division supplies machinery and systems from 35 to 4,000 tonnes for standard applications