10. flat blow molded parts with improived properties (chuck - mkp

Flat blow molded parts with

Kautex Open House 2012

Flat blow molded parts with

improved properties (flying knives)

Chuck FlammerVice President Sales NAKautex Machines, Inc.

The Idea

Agenda

The Application

www.kautex-group.com

The Result

The Impact

The Idea

� In late 1990’s – early 2000’s,

thermoformed shells, welded

together to make fuel tanks

threatened blow molded tanks.

� Fuel tank manufacturers liked the

idea of an “open mold” approach

of placing items inside of cut


of placing items inside of cut

parisons.

� Blow molding came back with

ideas to accomplish this without

losing the round parison.

The Idea

� Engineers worked on the

idea of spreading and

separating the parison

into 2 halves.

� They came up with better

ideas for splitting the

parisons for fuel tanks.


parisons for fuel tanks.

� Kautex saw the

advantages of this

technology for the

production of flat panels

using “Flying Knives”.

The Idea

� Process advantages with Flying Knives

� Weight savings� By starting with a “flat” parison, plastic does not

freeze off while in contact with the mold and thin the outside edges

� Machine monitors the parison length every cycle� Parison is held in same position, minimizing

gravity effects

� Cycle time savingsMaximum wall thickness is controlled better


� Cycle time savings� Maximum wall thickness is controlled better� Warpage is minimized due to manipulation of

parison on spreaders� Clamp can close on parison rapidly� Faster pushout than on competitor machines� Reverse controlled air flushing removes hot air

with cooler air

The Idea

� Process advantages with Flying Knives

� Labor savings� Faster cycle time allows for more parts to be

produced with the same labor force� Head tooling changes less often

� Masterbatch savings� Using a dual entry head, the outside can

use the masterbatch and the inside can use the regrind with color


the regrind with color

The Application

� Large part injection molder in Chicago area

� Used large injection molders to mold “halves” and then weld together

� Outsourced molding to conventional 2D blow molding shop

� Needed to improve internal costs and appearance of parts by blow molding versus


appearance of parts by blow molding versus injection/welding

� Wanted to bring molding “in-house” to further decrease costs

� How could Kautex decrease costs (increase ROI)?

The Application


The Application

� Kautex had used this technology in the

production of automotive flat panel parts on a

smaller scale

� Suncast went to visit the customer to see the

production and acknowledge proof-of-concept


� Suncast was able to see the advantages of what

Kautex could do compared to what their

outsourced supplier was able to achieve

The Application

� For nearly 28 years, Suncast injection molded all products

� Decided to step out of comfort zone and blow mold products

� Partnered with outside supplier to begin

� Expanded facility in Batavia

� Purchased Kautex machines


� Purchased Kautex machines

� Totally out of box new product ideas

� Had an aggressive time line: First machine arrived January 17, 2011; production

June 6; 2011-with their own employees.

The Application

� KBS 241 Machine

� AKK 40L/600 accumulator head

� Dual Q120mm extruders

� Special parison spreaders and

pre-pinch

� Suncast runs 24/7 operation


� Suncast runs 24/7 operation

� Machines change molds over in

~40 minutes

� Currently running 50 molds, will

be 100+ by end of 2012

The Application

� Raised roof 12 feet

� Expanded infrastructure: power, water, compressed air

� New technology


� Partnered with Kautex-leader in blow molding equipment

� They have unique grinding rooms, article take out, and installation

The Application


The Result

� Weight Savings

� Double digit percentage in weight savings on parts

� Cycle time savings

� 35% decrease in cycle time

� Labor savings

� Half the number of machines needed because of faster cycle time


� Half the number of machines needed because of faster cycle time

� Masterbatch savings

� This is in the next plans for Suncast

The Impact – what the customer has said

� Owner could have invested in the outside supplier

� Chose to invest in current work force and the community in Batavia

� Return in loyalty, dedication, hard work, and team commitment is beyond

words

� They know that their future is blow molding!

� Historical interaction with other suppliers, then Kautex showed up at the door. WOW!!!


Historical interaction with other suppliers, then Kautex showed up at the door. WOW!!!

� They forged a real team; at all levels of both organizations

� They have been asked if at any point they thought they had gone in the wrong direction-NEVER!!!

� They have the best machines; the best service; the best partnership.

� Kautex ROCKS!!

Thank you very much for your attention.Thank you very much for your attention!Any questions?


10. flat blow molded parts with improived properties (chuck - mkp

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