wittmann innovations

www.wittmann-group.com

Techniques – Markets – Trends Volume 9 – 4/2015

Quarterly magazine of WITTMANN Kunststoffgeräte GmbH and WITTMANN BATTENFELD GmbH. Appears to meet the informa- tional demands of staff and customers. Editorial office: WITTMANN Kunststoffgeräte GmbH, Lichtblaustrasse 10, 1220 Vienna;tel. +43-1 250 39-204, fax +43-1 250 39-439; [email protected]; http://www.wittmann-group.comIssue 1/2016 of “WITTMANN innovations” will appear at the beginning of the first quarter 2016.

WITTMANN innovations (Volume 9 – 4/2015)

www.wittmann-group.com

Techniques – Markets – Trends Volume 9 – 4/2015

Articles that appeared in WITTMANN innovations so far

Automation• Productionandqualitycontrolinmedi-

calengineering1/2007• Thehandlingoflargestructuralfoamparts2/2007• ThenewR8robotcontrol3/2007• High-end:Theproductionofseatadjustmentrods1/2008• Driveengineeringforrobots1/2008• Automatingtheproductionoftrans-ponderpins2/2008• Automatedremotecontrolkeys3/2008• AutomationatCarclo,UK4/2008• Theflexibleautomationcell1/2009• ThecultivationofgrowthwithWITT-MANNrobots2/2009• Brudertoywheelproduction4/2009• PalletproductionatUtz,Poland1/2010• EcoModeforefficientrobots2/2010• Automatedoillevelsensors2/2010• Automatingrotationwelding3/2010• ThenewR8.2robotcontrol4/2010• Linearrobotsinthecleanroom1/2011• Super-fastpartremoval2/2011• Automationofcupsandlids3/2011• Superiormulti-componentparts4/2011• Automatinginsertmolding1/2012• Theexpertautomationoflids2/2012• LSRpartsatSilcotech,Switzerland:Qualitythroughautomation3/2012• Zero-rejectproduction4/2012• SmallestpartsatJENOPTIK2/2013• TheSchrambergautomation3/2013• TheBusch-Jaegerautomation1/2014• AutomatingIn-MoldDecoration2/2014• AutomationatPortEriePlastics3/2014• AutomatingSTARPLASTIK4/2014• JonesPlasticandWITTMANN1/2015• RobotsatGreeland/Singapore2/2015• SEBtandemrobots(F)3/2015• TheSacelautomation(I)3/2015

Conveying/Drying/Entire Systems• CentralsystematBOSCH1/2007• Qualitycontrolofdryers1/2007• Kromberg&Schubert'ssystem2/2007• Costefficientmaterialdrying2/2007• FEEDMAXforthecleanroom3/2007• ThenewDRYMAXED803/2007• Focusonmaterialfeeding1/2008• NetworkcontrolatArge20002/2008• Changingparameterswhenconveying

differentmaterials2/2008• Optimizingaconveyingsystem3/2008• Dryerswithenergyrating3/2008• TheMetchemcentralsystem4/2008• AuxiliariesatDelphiinChina1/2009• LISICOSMETICS'centralsystem2/2009• Perfectplanningofcentralsystemsavoidsdowntime3/2009• TestingenergyclaimsatFKT4/2009• ThenewFEEDMAXB1001/2010• GreinerissavingenergybyusingWITTMANNdryers2/2010• TheA.C.S.conveyingsystem3/2010• FEEDMAXPrimusconveyor4/2010• ThenewDRYMAXAton2/2011• TheBKFconveyingsystem2/2011• WDKunststofftechnikanditscentralsystem4/2011• PETprocessorusesaWITTMANNconveyingsystem1/2012• ThePLASTICOMsystem2/2012• TheNICOMATICsystem3/2012• Savingenergyinmaterialdrying4/2012• TheBespakmaterialhandling2/2013• VisionTechnicalMolding:Prescriptionforefficiency3/2013• WPCinjectionmolding1/2014• NewPollmanncentralsystem2/2014• TheHELLAMexicosystem3/2014• TheProcopisystem,France4/2014• TheSLMmaterialmanagement4/2014• SlovenianproducerreliesontheWITTMANNGroup1/2015• EntiresolutionanAlliancePrecisionPlastics,USA2/2015• OurSpanishcustomerFushima2/2015• InjectionMoldingatTielke2/2015• TheWiBaQuickLookApp2/2015• FRANKplasticcentralsystem3/2015

Granulation• Inlinerecyclingofsprues1/2007• GiantgranulatorMCP1002/2007• ThenewMASgranulator3/2007• Challengingrecyclingprocess1/2008• TheMC70-80atCentrex2/2008• GiboPlastenforcesrecycling2/2009• MCgranulatorswithAFauger4/2009• Grindingofferrite1/2010• Grindingcriticalmaterial3/2010• TheTMPCONVERTsolution1/2011• InlinerecyclingwithMinor23/2011• Granulatorsunderthepress2/2012• Largesolutionsforlargeparts1/2013

Blending• ThenewGRAVIMAXseries2/2007• Blendereconomics3/2007• GRAVIMAX14Vblender3/2009• Theartofblendingregrind3/2011• Dosingonthehighestlevel1/2013• Precisionforsaferailtraffic4/2013

In-Mold Labeling• IMLstackmoldsystems3/2007• TheWITTMANN2+2stackmold

1/2008• ATMd.o.o.inSerbiagrowswithWITTMANNsystems3/2009• QuadrangularIMLdesignatPLASTIPAKinCanada4/2010• TeaPlastinAlbaniawantstobecometheNumberOneinIML3/2012• EcoPower:fourfoldIML1/2013• IMLasamultifacetedprocess4/2013

News From The Subsidiaries• Australia2/2008, 2/2013• Austria2+3/2008, 1/2010, 3/2011,

4/2012, 3/2013, 2/2015, 3/2015• Benelux3/2008,2/2009• Brazil3/2007,1/2009• Bulgaria2/2009• Canada1/2007,1+2/2008,3/2009• China2/2010• Colombia2/2012• CzechRepublic/Slovakia4/2009,3/2014• Denmark1/2009, 1/2013• Finland4/2008+1/2012• France2/2007,3/2008• Germany1/2007, 3/2012, 4/2013,3/2014• GreatBritain2/2009,2/2010• Greece2/2014• Guatemala1/2013• Hungary1/2008• India2/2008,3/2010, 2/2012• Israel1/2012• Italy4/2008, 1/2010, 4/2011• Mexico3/2007,3/2009, 1+2/2011• Poland2/2013, 3/2013• Russia4/2012• Slovenia/Croatia1/2010• SoutheastAsia2/2007• SouthKorea3/2010• Spain3/2007• Sweden2/2009• Switzerland1/2008, 2/2012• Taiwan4/2009• Turkey3/2008, 2+4/2011• USA2/2008,3/2009, 1/2011, 4/2013, 4/2014

Temperature Control• Advantagesofpulsedcooling1/2007• Comparingwatertooil2/2007• ThenewTEMPROplusCseries3/2007• COOLMAXcoolingunits2/2008• Temperaturecontroller“guarding”

injectionmoldingmachines3/2008• TEMPROwithDUOcooling4/2008• Variothermaltempering1/2009• TEMPROplusC1802/2009• TEMPROdirectC120[C250]3/2009• WFC:WaterFlowControl4/2009• TEMPROplusC1801/2010• TEMPRO:Universalbenchmark2/2010• BFMOLD®moldcooling3/2010• TEMPROplusD4/2010• Online-thermography1/2011• TemperingatFuchs&Sohn2/2011• TEMPROplusDintheautomotivesector1/2012• Oscilloscopefunction2/2012• Compacttemperaturecontroller4/2012• Optimaltempering=quality1/2013• TheStarlingerspecialsolution2/2013• NewWITTMANNequipment4/2013• TEMPROusesheatwaste1/2014• CleansolutionatDELPHI4/2014• Blumusingaspecialsolution1/2015

Injection Molding• Injectionmoldingonestopshop4/2008• MetalinjectionmoldingatIndo-US

MIM4/2008• Costoptimization:EcoPower1/2009• ITassistedservices1/2009• Thewaterinjectionprocess2/2009• TheKronaIndústriaequipment2/2009• Micro-parts:Microsystem503/2009• Multi-componentprocessatwolfcraft4/2009• Processdataacquisition:partnershipwithWilleSystem4/2009• Thenewall-electricEcoPower 4/2009• TheThomasDudleycompany1/2010• IMLwithTMXpress1/2010• AIRMOULD®andAQUAMOULD®Mobile1/2010• DesignMoldedPlasticsandtheirmold-ingmachines2/2010• StadelmannreliesonWilleandWITT-MANNBATTENFELD2/2010• ThenewMicroPower3/2010• AQUAMOULD®andprojectileinjec-tiontechnology3/2010• Newbenchmark:MacroPower4/2010• TheSTELLAcompany4/2010• TheServoDrivetechnology1/2011• The75thmachineforKrona1/2011• PackagingspecialistTMXpress2/2011• WAVIN(CzechRep.)andWITT-MANNBATTENFELD3/2011• SANITmoldingasuccess3/2011• WEPPLER'smoldingmachines4/2011• MacroPowerproducingcableties1/2012• TheCELLMOULD®process2/2012• The43ESMINmachines3/2012• Remoteconnectivity3/2012• Foamedhigh-qualityparts4/2012• LECHNER'MacroPower4/2012• MacroPoweratGTLINE1/2013• Praiseforthestandardmachine!1/2013• VerticalmachinesatElectricfil2/2013• BECK'smoldingtechnology2/2013• ESCHAusingHMmachines3/2013• HofferPlastics'HMmachines3/2013• GuppyusingtheEcoPower3/2013• TheBackhaussuccess4/2013• Incapsulation:cleanandsafe4/2013• Multi-componentparts1/2014• Successthroughversatility1/2014• ThetriedandtestedatPhilips2/2014• Light-weightfoamedparts2/2014• TheKRESZ&FIEDLERSystems3/2014• SMEmolderAutenrieth3/2014• TopmicropartsfromKüngAG3/2014• Openingupefficiencyreserves4/2014• HiQShaping4/2014• ServoPowersavesenergy1/2015• Bestqualityathünersdorff1/2015• TheGripItFixingssuccessstory1/2015• GerresheimersysteminChina2/2015• MicroPoweratTessy(USA)3/2015• MoldingatInterplex(China)3/2015

WITTMANN innovations – 4/2015 3

Editorial

DearReader,

Therewasnosummerholidayoff-seasoninthenewsthisyear.Overthelastfewmonths,thenewspaperswereover-flowingwithreportsabouttherefugeecrisis,stockexchangeturbulences,speculationsaboutanincreaseofinterestratesintheU.S.,andsuccessiverecordheatwavesinlargepartsofEurope.Regardlessofalltheseturbulences,theeconomicdevelopmentofourcompanyhascontinuedonahighlevel(eventhoughanumberofthresholdcountrieshavetempo-rarilyoptedoutasdriversofgrowth).Sowelookforwardtothefallandwintermonthswithconfidence,andinparticulartothisyear’sFakumatobeheldfrom13to17OctoberinFriedrichshafen.Totallycommittedtoourtraditionalmottoworld of innovation,weareonceagainpresentingnumerousnovelties.

Asthisyear’sfairhighlight,wewillhaveournewservo-hydraulicSmartPower350injectionmoldingmachineondis-play,whichsimultaneouslyconstitutesoneofthehighlightsofourcorporatehistory.ThiscompletesourSmartPowerseries,whichalsocomprisesthesmallersizesof180and240.

Today,thecompletePowerSeries,whichwestartedtodevelopalittlemorethansevenyearsago,includestheEcoPower,MicroPower,MacroPowerandfinallySmartPowermachineseries.Allmodelscombinedcovertheentireclamp-ingforcerangefrom5tto1,600t.Proudly–andrightfullyso–wecannowsaythattheWITTMANNGroupisabletoofferitscustomersthemostmodernmachineryavailableonthemarketforthepurposesoftheplasticsprocessingindustry.

Nolessinnovativearethemanynoveltiesfromtheseg-mentsofautomationandperipheralequipmentwewillalsoshowattheFakuma.Wehaveequippedourmedium-sizedrobotserieswithrotaryservoaxes,afeaturewhichgivesthemevengreatercompactnessandacceleratestheirmove-mentsevenfurther.Infuture,robotscanalsobefittedasanoptionwithweighingstationstoenableimmediateweightcontrolofremovedparts.Intheareaoftemperaturecontrol-ling,weareintroducingtheFLOWCONplus,anintelligentflowcontrollerwhichisalsoavailableasastand-aloneversion.CompletelynewaswellaretheJunior3CompactgranulatormodelandtheFEEDMAXB203netmaterialloader.

Allofthis–andmuchmore–willbeonshowatourbooth1204inhallB1.Youarecordiallyinvitedtomakeuseofthisopportunitytogatherfirst-handinformation.IspeakforourentireFakumateambysayingthatitisalwaysagreatpleasureforustowelcomeyouatourbooth(oratoneofourproductionfacilities).

Yourscordially,MichaelWittmann

Michael Wittmann

ContentInjectionMolding

Quality in the automotive field

From the idea to the part

… and DieterWiegelmann, Germany.Page 6

Gabriele Hopfon RT-CAD,Austria, …Page 4

IML

New Hungarian subsidiaryNew Polish subsidiaryOpen House in FranceNew premises in TaiwanOur agent in Vietnam

Making more from less

News P. 16P. 16P. 17P. 18P. 19

Production of cups

Flow Control The new FLOWCON plus

Blending The path to better blending

Automation Expertise in South Korea

Handling of bike parts

Kasper JohannesHagemannon OneSeal,Denmark.Page 8

Arieh Zoharon AMRAZ, Israel.Page 9

WalterLichtenbergeron the new water flow controller.Page 10

Jonathan FowlerandNicholas Paradisoon how it works.Page 12

Chong Geun Kimon PETRA and MGS.Page 14

Ravi Sonion SMIPL, India.Page 15

WITTMANN innovations – 4/20154

The RT-CAD company based in Uttendorf, Upper Austria, develops, designs and manufactures technically complex plastic parts. Since the beginning of 2014, RT-CAD has been usinga MacroPower 1500/8800 from WITTMANNBATTENFELD to produce large-sized parts.Gabriele Hopf

RolandTiefenböckestablishedRT-CADin1997asacompanydesigningplasticparts.In1999,theproductionofprototypeswasaddedtoitsrangeof

serviceswiththeacquisitionofitsfirstFDMmachineforrapidprototyping.Onlyoneyearlater,RolandTiefenböckconcludedacooperationcontractwithMoldflow,sothathewasabletoofferhiscustomersmanufacturingsimulationaswell.Sincethen,RT-CADhasalsobeenoperatingasadistributionpartnerfortheMoldflowsimulationsoftwareinAustria,andhasbeencooperatinginthismattersince2011withWESTCAM,whichhastakenoverthedistributionofMoldflowinAustria.Theintroductionoftherapidproto-typingandsimulationbusinesswasfollowedbyafurtherextensionoftheserviceportfoliowithvacuuminjectionmoldingin2001,andthefoundationofthecompany’sownmoldmakingshopin2003–alogicalconsequencefortheprofessionalmoldmakerRolandTiefenböck.

In2008,thecompany’sfirstinjectionmoldingmachinewentintooperation,only2yearslater,productionbeganinanewmanufacturinghallandthengrewfurtherovertheyears.Today,RT-CADrunsitsproductionplantwith48employeesand13injectionmoldingmachinesrangingfrom50to1,500tinclampingforceandoperatingin3shiftstomaketechnicallycomplexpartsforwell-knowncustomersfromthetwo-wheelindustry,theelectricalindustry,weldingtechnologyandthefurnitureindustry,withthetwofirst-namedsectorscontributingabout80%ofthecompany’ssales.Amongitsproductsarepartsformetalsubstitution,light-weightcomponents,hybridpartsandpartsinmulti-componentandIMLtechnology.

An ambitious company

Ingeographicalterms,RT-CADismainlyactiveinAustria,GermanyandIndia,whereitsuppliespartstothecountry’ssecondlargestmotorcyclemanufacturer.

Forthetwo-wheelsector,RT-CADsuppliesaboveallcladdingcomponentsandtechnicalpartsconnectedwiththemotorinthemotorcyclesegmentoftheAustrianmanufacturerKTM,includingmassproductionaswellasproductsmadeofextremelyhard-wearingmaterialsformo-torracing.

RolandTiefenböckseesthekeytosuccessprimarilyinconsistencyfromtheinitialproductideaallthewaythroughproductdevelopment,engineering,manufacturingsimula-

Sophisticated plastic parts – from the idea to series production

InjectionMolding

Cladding com-ponents for KTM motor cycles, manufactured using the IML technology (back injection molding of foil).

(Photo: RT-CAD)

Cladding compo-nents in different designs.

(Photo: RT-CAD)

Side mirror for the KTM X-Bow – product develop-ment and mold making took place at RT-CAD.

(Photo: RT-CAD)


InjectionMolding

tion,prototypingmoldmakingtoseriesproduction.Aboveall,thesimulationwithMoldflowsoftwareandthecom-pany’sownengineeringexpertisecreatesubstantialaddedvalueforcustomersbyavoidingerrorsinthepreliminarystages.

Apartfromthecladdingpartsandtechnicalcompo-nentsformotorcyclesalreadymentioned,afewexamplesofproductsdevelopedandmanufacturedatRT-CADareACinvertersforphotovoltaicsystemsdeliveredtoFronius,“Macao”chairsforWiesnerHager,forwhichthecompanyactuallywonthereddotDesignAward,displayscreensforthehousingfrontpanelsofweldingequipmentorpushbut-tonsforcigarettevendingmachines,withthespecialfeatureofhavingthebrandlogosinsertmoldedwitha2mmlayeroftransparentplastic.

Forhisinjectionmoldingmachines,RolandTiefenböckrequiresabovealleasymaintenance,user-friendlinessandalongservicelife,inadditiontoafavorableprice/performanceratio.Goodtechnicalsupportisalsoimportantforhim.

The MacroPower 1500/8800

WhatheappreciatesabouttheMacroPower1500/8800deliveredlastyear–currentlythelargestinjectionmoldingmachineoperatingatRT-CAD–isthegoodaccessibility,easylateralmoldinsertion,thema-chine’scompactdesignanditsoutstandinguser-friendlinessviathemodernB6Pcontrolsystem.RolandTiefenböckcomments:“Themenuover-viewofthecontrolsystemfollowsalogicalconcept,andthecontrolsystemcanbe

integratedintotheexistingnetworkwithoutanyproblems.Thegraphicdisplayprovidesaclearoverview.”AdditionalvitalfeaturesforTiefenböckarethemachine’slownoiselevelanditslowenergyconsumption,duetotheefficientservodrive.“OurpowerconsumptionhardlychangedatallfollowingtheinstallationoftheMacroPower”,saysRolandTiefenböck.

TheMacroPowerinstalledatRT-CADisamachinewith15,000KNclampingforcewithspecialequipmentforprocessingflame-retardantplasticmaterialsandaWFCsystemfullyintegratedintothecontrolsystem,whichenablesflowratesandtemperaturesoftheindividualcool-ingcircuitstobedisplayedandmonitoreddirectlyonthemachine.

ThisparticularMacroPowerisacompleteproductioncellincludingfullyintegratedtemperaturecontrollers,aW843servorobotfromWITTMANNandaprotectiveenclosure.

AnotherpositiveaspectfromRolandTiefenböck’spointofviewisthepossibilitytopurchaseeverythingfromasinglesourceatWITTMANN–fromthemachinetotheautomationsystemandthecompleterangeofperipheralequipment.•

Moldflow software simulation of a plastic part.

(Photo: WESTCAM)

Bernd Aigner, WITTMANN BATTENFELD Sales (left), and Roland Tiefenböck, Managing Director of RT-CAD in front of the MacroPower 1500/8800 with examples of parts produced on this machine (includ-ing the award-winning Macao chairs for Wiesner Hager).

The tail bracket for the KTM motor-cycle is a prime example of substi-tuting plastic for metal.


InjectionMolding

otherindustriesarebeingsuppliedaswell,suchasthesani-taryindustry,thehouseholdappliancessector,themedicaltechnology,packaging,agriculturalandtelecommunicationsindustries.

Thecompany’scustomerbaseincludesautomotivesupplierssuchasKostal,AckermannandGerhardi,andthemilkingmachinemanufacturerGeaFarm.ThemarketrangesfromGermanyandEuropetoNorthAmericaandArgentina.

TheDieterWiegelmannGmbHwasestablishedbyDieterWie-gelmannasamodelconstruc-

tionandmoldmakingcompanyin1980.Sincethen,prototypingisacorecom-petenceofthiscompany.Aluminumisthematerialmostfrequentlyusedinprototypeconstruction.

OneofWiegelmann’sstrengthsisthemachiningandassemblyofagreatvarietyofaluminumalloys.Butdepend-ingonrequirements,thecompanyalsoproducesmoldsmadeofsteelforseriesproduction.

In2007,MarcWiegelmannsuccee-dedhisfatherasManagingPartner.Theextensionofactivitiestoinjectionmoldingofplasticpartstookplaceafterhehadtakenoverthecompany.Initially,thisinvolvedonlysamplingfromtestrunsofthemolds,butitwasn’tlongbeforethisactivitywasextendedfurther.Today,thecompany’smainfocusliesontheproductionofplasticpartswithbatchesrangingfrom500to10,000unitsormore.

Mostoftheproductsgotoautomotivesuppliers,withproductiontargetingprimarilythepremiumsegmentoftheautomobileindustry.ProductsfromWiegelmanncanbefound,forexample,invehiclesoftheAudi,Mercedes,Fer-rariandBugattibrands.Apartfromtheautomotiveindustry,

Dieter Wiegelmann GmbH, based in Olsberg-Bruchhausen, North Rhine-Westphalia, has made a name for itself in Ger-many and beyond its national borders as a problem solver in the area of complex plastics applications. Since last year, a MacroPower 1500 and a hydraulic HM 240 equipped with the CELLMOULD® pack-age have been in operation to complement the machinery of this successful medium-sized enterprise. Closeness to customers, flexibility and high quality standards make Wiegelmann an ideal partner for sophisticated solutions.Gabriele Hopf

Machines and processes for highestquality automotive parts

Picture left:Pressure generator from WITTMANN BATTENFELD for the AIRMOULD® gas injection process and the CELLMOULD® structured foam process.Picture right:WITTMANN conveying system at Wiegelmann in Olsberg-Bruch-hausen, Germany.

Assembly work on an Audi radiator grille, manufac-tured at Wiegel-mann.


InjectionMolding

asafamily-friendlycompany.Tocounteractthegeneralshortageofskilledworkers,Wiegelmannalsotrainsyoungpeopleinmoldmaking,plasticsprocessingandproductdesign.

Thecompany’smachineryincludesspottingpresses,high-qualitymillingmachines,erodingmachines,adeepholedrillingmachine,opticalmeasuringdevicesand9injectionmoldingmachines,ofwhich4areusedforseriesproductionand5fortestingpurposes.Partsrangingfrom

10to7,000ginweightareinjection-moldedfromallcommonlyavailablematerials.

ForWiegelmann,themostim-portantfeaturesofinjectionmold-ingmachinesaretopquality,andmonitoringandrecordingsystemstoensurethetraceabilityrequiredbytheautomotiveindustry.Othersignificantaspectsaregoodenergyconsumptionvaluesinproductionandstate-of-the-artprocesstechnologies.

Wiegelmann andWITTMANN BATTENFELD

WITTMANNBATTENFELDsucceeded2014inplacingatWiegel-mannaMacroPower1500/8800withaWITTMANNW843robotandServoPowerdrive,andahydraulicHM240/1330,aswellasanWITTMANNmaterialdryingsystem.

TheHM240wassuppliedwiththeequipmentpackagesfortheWITT-MANNBATTENFELDAIRMOULD©internalgaspressureprocessandtheCELLMOULD©structuredfoamprocess,whichenabletheproductionoflight-weightpartswithlowwarp-ageandwithoutsinkmarks,andwithhighrigidityaswell.

MelanieWiegelmann,whoassiststhecompany’smanagementandisalsoresponsibleforqualitymanage-ment,appreciatesthetechnologicallymaturefeaturesoftheWITTMANNBATTENFELDmachinesaswellastheflexibilityandcompetenceofthemachinemanufacturer’sstaff.“TheWITTMANNBATTEN-FELDassociateshaveshownahighlevelofproblem-solvingcompetence”,

Wiegelmanncomments.WiegelmannalsoappreciatestheoptionofferedbyWITTMANNBATTENFELDtoacquireeverythingfromasinglesource,fromthemachine,auto-mationandperipheralequipmenttoultra-modernprocesstechnology.

FrankKarwinski,ManagerofPlasticsTechnologyatWiegelmann,isimpressedprimarilybytheMacroPower’scompactnessanditsenergyefficiency,whichresultsfromtheuseoflatestservodrivetechnology.•

Pooling of competences

Wiegelmannseesitselfasaproblemsolverforitscustomersand,besidesitstopqualitystandards,standsoutprimarilybyitsflexibilityandshortleadtimes.Fromconsultingandproductdevelopmenttomoldmakingandfinallyproduction,Wiegelmannprovidesitscustomerswitheverythingfromasinglesource.Italsoofferscomponentassembly,whichisgaininginimportance.Someofthechar-

acteristicscustomersappreciateaboutWiegelmannaretheshortcommunicationchannelsandresponsetimes,aswellasthecompany’shighinnovationpotential.

In2014,Wiegelmannrealized6.5millionEurosinsaleswithaworkforceofabout70.ThecompanyiscertifiedaccordingtoDINISO9001andDINISO14001standards.ItalsofulfillsmostoftherequirementsfortheTS16949standard–whichisimportantfortheautomo-tiveindustry.Moreover,Wiegelmannhasbeencertified

From left to right: Frank Karwinski, Manager of Plas-tics Technology at Wiegelmann, Marc Wiegelmann, Managing Partner of Wiegelmann, Melanie Wiegel-mann, Manage-ment Assistant and Quality Management Of-ficer at Wiegel-mann, and Frank Höher, WITTMANN BATTENFELD Sales, in front of the MacroPower 1500/8800

Gabriele Hopfis the Marketing Manager of WITT-MANN BATTEN-FELD in Kotting-brunn, Lower Austria.

Removal of a ra-diator grille from the MacroPower 1500/8800 by a WITTMANN W843 robot.


OneSeals’sProductionManager,JensVelschou,givesanoverviewofworkingwiththenewsystem:“Withthispro-ductionunit,anditsuniqueWITTMANNBATTENFELDone-stop-shoppingoptionsandperipheralequipment,wewereabletoachieveanumberofadvantages:compactspacesavingdesign,higherprecision,andabrilliantlyperformingcontrolsystem.”AndMoldingOperatorErwinCastilloadds:“Wereallyachieveasignificantlybettercontinuityandstabil-ityoftheproductionprocess.”ProductionManagerJens

Velschoucontinues:“TheHMServoPowermachineisclean,flexible,precise,andtheexecutionofthelinearguidesguaranteesagentleoperation.Themachine’snoiselevelislow,anditisoperatingextremelyenergy-efficient.Thehighenergyefficiencyofthesystemalsoresultsinamuchlowerconsump-tionofcoolingwater.”

Asked,ifOneSealthusisgettingbetterproductsforevenlessmoney,JensVelschouagrees:“Yes,absolutely!TheWindows™basedB6Pcontrolsystemprovidesuswithalmostunlimitedpossibilitiestoadjustthefunctionsofthemachine.Thecontrolsystemalsoclearlydocumentsoursuperiorproductionqual-ity,somethingthatisveryimportanttous.”

A strong basis

OneSealvaluestheversatilityinWITTMANNBATTENFELDmachinerange,whichgenerallyoffersawiderangeofstandardfeatures,andalsogreatscopeforcustomization.

Forexample,thelatestOneSealWITTMANNBATTENFELDHMmachinewassuppliedwithfurtherOneSealspecifications,includingthecolorvarnishing.

OneSealalsonotesthatthemainte-nancecostsforthenewHMServoPowerinjectionmoldingmachinefromWITTMANNBATTENFELDwillremainverylowfortheentirelifetimeofthemachine.•For further information please visitthe OneSeal website: www.oneseal.com

Today,thesuccess-fulDanishOneSealcompanyisrepre-

sentedallovertheworld,workingwithagentsanddistributorsonsixconti-nentsandinmorethan30countries.

TheCompany’sproductsareallmadeinDenmark.TheOneSealHighSecurityContainerBoltSealsaremadeofmetal,over-mold-edwithplasticmaterial.Themanufacturingtakesplaceinaproductionhallespeciallydedicatedtothisproduct,usingalineofWITTMANNBATTEN-FELDinjectionmoldingmachines.

OneSeal’sspecialhigh-valuemodelofHighSecu-rityContainerBoltSealsisprovidedwithahigh-tech-nologylaserengravement.Thisengravementafter-wardsisover-moldedwithplasticmaterialinordertoprotectthesealagainsttampering.

OneSealinvestedinitsveryfirstBATTENFELDmachinesomeeigh-teenyearsagoinordertoachievethisover-moldingtask.Severalmoresimilarmachinesfollowedinsubse-quentyears.

OneSealtheninvestedinequip-mentfromtheWITTMANNGroup–acompletenewproductioncell.ThecompanypurchasedaWITTMANNBATTENFELDHM65/210injectionmoldingmachine,equippedwithServoPowertechnologyandtheadvancedB6Pcontrolsystem.Theproductioncellwasalsosup-pliedwithaFEEDMAXS3materialloader,aDOSIMAXMCBasicdosingunit,andwithaWP80spruepicker,allfromtheWITTMANNGroup.

InjectionMolding

OneSeal ApS, based in Kokkedal, about 20 km north of Copenhagen, Denmark, was founded in the year 1974 by Michael Remark. The OneSeal company is a longtime customer of WITTMANN BATTENFELD and has becomeone of the world’s leading manufacturers of High Security Container Bolt Seals.Kasper Johannes Hagemann

OneSeal – making more from less

OneSeal Produc-tion Manager Jens Velschou (left) and Operator Erwin Castillo in front of the newly purchased HM injection molding machine. In the background, some more equipment from the WITT-MANN Group can be seen (sprue picker, loader).

One of OneSeal’s Container Bolt Seals, a worldwide bestseller in the container logistics business.

Kasper JohannesHagemannis Service and Sales Consultant working for the Danish Agent of the WITTMANN Group: Wiba Tech ApS in Fredens-borg, Danmark.

A view of the One-Seal production hall in Kokkedal, Denmark. – All WITTMANN BATTENFELD machines were de-livered in the color that was chosen by OneSeal as an option.


IML

accurately,providingafulldatadisplayanddatalogging.Qualityassuredproductionisthentransferredtoanaccu-mulationsectionwhereaWITTMANNW818robotstacksthecupsonaconveyorbelt.

Thewholesystemwasveryeasilyinstalled,runningverysmoothlyfromthebeginning.EitanBenShalom,theHeadoftheAMRAZIMLDepartment,expresseshisentiresatisfactionabouttheWITTMANNIMLsystembysimplysaying:“It’sourbestproductionline.”AndheemphasizestheremarkablesupportandserviceprovidedbyA.ZOHAR,thelocalWITTMANNGroupagent.

Recently,AMRAZandWITTMANNagreedtoextendtheirbusinesscooperation–installingfurtherIMLsystemsinthefuture.•For further information please visitthe AMRAZ website: www.amraz.co.il

Since1939AMRAZhasbeenatthefore-frontoftheIsraeliplasticsindustry.Thecompanyspecializesinplasticspackaging,

usingawiderangeofthermoplasticrawmateri-alsandanextensivearrayofadvancedproduc-tionmethods.

AMRAZprovidesitsclientswithcompletetechnologicalsolutionsandoffersthemostadvancedproductionmethods,suchasthinfilminjectionmolding,technicalinjectionmolding,co-extrusion,extrusionofmulti-layerfoilsandmulti-colorstripedfoils,hotfill,in-moldlabeling(IML)andmuchmore.AMRAZgivesclientser-vicethroughouttheentireproductionprocess,fromdesignandtheengineeringprocess,topackaging,palletizing,storing,shippingandlogistics.Thecompany’swidecustomerbaseincludesleadinglocalandinternationalbrands,suchasCoca-Cola,Pepsi,Nestlé,Uni-lever,Danone,Yoplait,Ikea,KeterPlastics,Jaffora-Tavori,Prigat,MeiEden,Neviot,Osem,Tnuva,Strauss,andmanymore.TheAMRAZheadquartersarelocatedinRishonleZion,thelocationofoneoftheIsraeliplants.

The WITTMANN IML system at AMRAZ

AMRAZisthelargestIML-basedpackagingsupplierinIsrael.Mostofthecompany’sIMLsystemsareproducingpartsforthefoodindustry.

Lastyear,AMRAZpurchaseditsfirstIMLsystemfromWITTMANN,averysophisticatedsystemthatisabletoproducecomplexparts.Thissystemisproducingauniquemilkshakecupwithabanderolelabel.Attheendoftheprocessthecup’stopissealedwithanalumi-numlid.

TheIMLlabelisinsertedbyahorizontalWITTMANNW837robotthatalsoremovesthecupsfroma4-cavitymold.Atiltingarmtakesthefourcupsfromthehorizontalrobotandpresentsthemtoatransferrobotwhichthenplacesthecupsontherotarytableofthealuminumlidseal-ingmachine.

Aconveyorthentransfersthecupsfromthelidsealingmachinetoa5-cameravisioncontrolstation.There,thesealingischeckedbymeansofspeciallygenerated360°3D-monitoredpictures.Thevisionsystemevaluatestheaccuracyofthebanderolelabelpositioning,andalsochecksifthelabelshavedefects,andifthesealinghasbeendone

With two plants in Israel and one in Romania, AMRAZ keeps itsposition at the forefront of technological developments, marketing itsproducts in over twenty countries around the globe. Now the highlyrespected manufacturer has just started-up a WITTMANN IML systemin order to produce a food packaging item for the drinks industry.Arieh Zohar

AMRAZ is delighted with its first WITTMANN IML system

Eitan Ben Shalom, Head of theAMRAZ IML Department (left), and Ya’akovi Schlosberg, the local Service Engi-neer of A. ZOHAR Ltd., in front of the AMRAZ IML system.

Picture left:View of the vision system display installed at AMRAZ, showing the inspection of the produced parts.Picture right:Finished cups, stacked on a con-veyor belt using a WITTMANN W818 robot.

Arieh Zoharis the Director of A. ZOHAR Ltd., the Is-raeli Agent of the WITTMANN Group based in Zichron Ya’akov, Israel.


Flow Control

At this year’s Fakuma trade fair in Friedrichshafen, WITTMANN will be intro-ducing FLOWCON plus, a new, intelligent flow controller. This sets newstandards in terms of process safety, process documentation and reproducibility when it comes to injection molding high-quality plastic components.Walter Lichtenberger

WITTMANNKunststoffgeräteGmbH,basedinVienna,hasfor40yearsbeentheundisputednumberoneinthedevelopmentandmanufac-

tureofwaterdistributionsystemsforplasticsprocessing,havingsoldmorethan600,000flowcontrollers.Withtheirlatestinnovationinthiskeyareaofinjectionmolding,thecompanywillbepresentingthefirstexampleofanewgenerationofintelligentflowcontrollers–FLOWCONplus.

A new ap-proach to flow control

Withitspropor-tionalvalveandzero-wearflowmeasurement,theWITTMANNFLOWCONplusintelligentwaterflowcontrollerensuresconstantflowandaconstanttemperature,allachievedinreproduciblefashionthroughthewholeperiodofmanufacture.

Theequipmentachievespermanentmonitoringoftheamountoffluidpassingthroughacoolingduct,whichgivesitadecisiveadvantage.

Disruptivefactors,suchasconstric-tionofcoolingductsorfluctuationsinpressurearedetectedandtheflowiscontrolledproportionallyusingsteppermo-torsinsteadoftheoldmanualregulatingvalves.ThesesteppermotorsoperatethefineadjustmentvalvesoftheFLOWCONsystem.

Thispreventsirregularitiesinthetemperatureandimprovesthesafetyoftheprocess,whichultimatelycontributestoasuperiorqualityofcomponents.Thisisallaccomplishedwithcomprehensivereproducibility,sincealloftheprocessdatacanbesavedandveryeasilycalledupforsubsequentproductionruns.

Thecompactdesignoftheequipmentmeansitcanbemounteddirectlyontheclampingplateoftheinjectionmoldingmachine.Thisalsoavoidstheneedforlonghose

connectionstothetoolingandconcomitanthighpressurelosses.FLOWCONalsomakesitpossibletoconnect4×12circuitstogetherbymeansofdatacables.

The FLOWCON plus offerssustainability and flexibility

ThehousingcomponentsforFLOWCONplusaremadeofhigh-qualityplasticcapableofwithstandingtempera-turesofupto120°Candallowwaterdistributionequip-menttobeusedastemperaturecontrolunits.Inthisway,theflowcanbematchedtothedimensionsofthecoolingducts,whilepermanentmonitoringofmultiplecircuitsistakingplace.

Auniformdistributionofheatovertheentiresur-faceofthecavityistherebyobtained,whichguaran-

teesthatthepartsremainlargelyundistortedinthemanufacturingprocess.

IfFLOWCONplusisusedinconjunctionwithaWITTMANNtemperaturecontrol

unitfromtheTEMPRObasicC120range–whichallowsforaflowof

280litersperminute–itensuresthatthereisturbulenceinthetoolducts,makingitpossibletoprovidetheoptimumdis-sipationofheat.

WhilstFLOWCONplusisversatileinitsapplications,theidealsolutionistouseitinconjunc-tionwithaWITT-MANNBATTEN-FELDinjectionmoldingma-chine,whichallowsallWITTMANNperipherals

tobefullyinte-gratedintothecontrolsystem.Forthestand-aloneversionsoftheequipment,

WITTMANNprovidesaremotecontrolsystemwithatouchscreendisplay,whichisconnectedtoFLOWCONplusviaaserialport.Andlastbutnotleast,thevalvesoftheFLOWCONpluscaneitherbeusedassimplecontrolvalveswithflowmonitoringorcanbeusedforclosed-loopcontroloftooltemperaturesinconjunc-tionwithtemperaturesensorinthereturnchannel.•

The new FLOWCON plus has arrived!

The newest de- velopment in flow control for injection molding pro-cesses: FLOWCON plus, the intel-ligent flow control-ler from WITT-MANN, shown here with the cover partially open.

WalterLichtenbergeris Temperature Control Depart-ment Manager of WITTMANN Kunststoffgeräte GmbH in Vienna.


The new FLOWCON plus has arrived! When the new FLOWCON plus from WITTMANN is mounted closed to the mold using solid mounting angles on the mounting plate of the injection mold-ing machine, the losses in tempera-ture and pressure are minimized.


Withtherisingcostofraw

materials,andtighterdemandsforproductconsistency,manyprocessorsstrugglewithblendingtheirresinrecipes.Re-introducingregrindintothefinalproductisbecomingmoreandmorecommon,drivenbyenvironmentalmandatesandcostsavings.

Herearefiveblendingtipstohelpprocessorskeeptheirmaterialandlaborcostsdownandaidinmanufacturingamoreconsistentandcompliantfinalproduct.

Step 1 –Blend it up close

Theclosertheblenderistotheprocessingmachine,themorehomogeneousthemixtureofmaterials.Separationcanoccurwhentheblendhastobeconveyedgreatdistanc-esbeforereachingthefeedthroatofthemachine.Thisisthecasewhenblendingmaterialswithdifferentbulkdensitiesandisespeciallytruewhenblendingregrindwithvirginmaterial,asthebulkdensityandsizeoftheregrindcanvarygreatly.Theinconsistencyinbulkdensitycausesthesmaller,lighterpelletstoseparatefromthelarger,heavierpellets,resultinginuneven“layering”ofmaterialonthefeedthroat.

Itisidealtoblenddirectlyonthefeedthroatorabovethefeedthroatonamezzanine.Iftheblendermustbelocatedremotelythenplaceitbesidethemachineorascloseaspos-sible.Also,agood-qualitylow-speed,high-torquegranula-torcanhelpbyprovidingamoreconsistentbulkdensityandregrindsizewithfewerfines.

Step 2 – Say no to static

Staticbuild-upisablender’sworstenemy.Staticwillcausematerialtosticktothewallsofthemixingcham-ber,resultingininconsistentbatches.Withlowadditive

percentages,evenahandfulofpelletshungupinamixingbowlcanhaveadramaticeffectonthefinishedproduct.Withpropergroundingofvacuumreceiversandblenders,andusinggood-qualitygroundedhose,staticbuild-upcanbegreatlyreduced.

Staticringsonthewallsofthemixingchamberarealsoessentialtoensuringpelletsfallbackintotheblendifstatic-chargedpelletscreepupthewall.Mixingchamberswithahemisphericalgeometryalsohelpeliminatedeadspotsandmaterialhang-up.

Step 3 – Pay attention to receivers

Thetypeofreceiverontheblenderhopperscanaffecttheaccuracyoftheblender.Volumetricandgravimetricblendersthatrelyontimeonlycanbeadverselyaffectedbyoutsideinfluences,suchaspressurechangesinthemate-rialhopper.

Aventuriorpressurecyclonestyleofseparatorreceivercreatesapositivepressureinthehopper.Thiswillforcematerialthroughthematerialhoppervalvemorerapidly,resultinginoverdosingmaterialduringthereceiver’sconveyingcycle.

Blending

Rising costs of resins and of additives, along with higher demandsfor quality and use of regrind, place a premium on proficient materialblending. Here are some steps to get you there.Nicholas Paradiso – Jonathan Fowler

5 quick steps toward better blending

Photo at left shows a WITT-MANN FEEDMAX material loader containing a blend that has been con-veyed 200 ft from the press. Notice that the mixture of white virgin material and blue colorant is uneven, as separation has occurred. The image on the right shows the same FEEDMAX loader with a blend that has been conveyed from beside the press, and the mixture is homo-geneous.


Agravity-styledischargevalveonavacuumreceiver,mosttypicallyaflap,cancreateanegativepressureinthematerialhopperiftheflapisleaking.Thiscanresultinunderdosingmaterialbecauseofaslightsuppressionofmaterialflowduetothevacuumcreatedinthehopperduringthereceiver’sconveyingcycle.

Vacuumreceiverswithpositivedischargevalveshelpeliminatethis,asthevalvecanpositivelycloseandsealwithcompressedair.

Step 4 – Thwart those bridges

Whenworkingwith“difficult”materialssuchasregrind,flake,orstickyadditives,thereisachancethematerialcanbridgeinthehopper.Bridgingmaterialswillhinderblenderperformancebecauseoflackofmaterialflow.Valvesizeiscrucialtohelptheflowofdifficultmaterials;uselargerhop-persiftheblenderisavailablewithdifferenthoppersizes.

Agitationofdifficultmaterialsisalsoanoptiontoenhancematerialflow.Bridgebreakerscanbeinstalledinsidematerialhoppers;theypulseaknife-styleactuatorwhenthedosingvalvepulses.

Step 5 – Learn to deal with regrind

Oneheadacheinblendingregrindiseitherrunningoutofitorhavingtoomuch.Itseemsthatnomatterhowhardyoutry,thereisnomagicblendingrecipethatwillkeepupwithyourregrindproductionwithoutrunningoutofregrindfive

minutesafteryouwalkaway.Onemethodtohelpelimi-natethisistouseanintermediateregrindbinbetweenthegranulatorandblender.Thiscanhelpbystoringsurgeduringhigh-regrindproductiontimesandprovidingmaterialduringlow-regrindproductiontimes.Anotherapproachistovarytherecipeontheblenderrelativetotheamountofregrindproduction.Doingthismanuallyisatime-consumingandte-dioustask.Useablenderthatwilladjusttherecipeautomati-callydependingonyourregrindcapacity.Thistypeofblender

usesalevelswitchtomonitortheregrindlevel.Thisswitchcanbemountedinanintermediatehopper,orintheblender’sregrindmaterialhopper.Theoperatorsetstwodifferentreci-pes.Forexample:ahigh-levelrecipemayhavearecipeof40%regrind,60%virgin,2%colorant(thecolorantisautomaticallycalculatedtorelativetothe100%ofvirgin-plus-regrindmate-rial).Aslongastheregrindlevelstaysabovethelevelswitch,thisrecipewillbeused.Iftheregrindleveldropsbelowtheswitch,asecondrecipecomesintoplay:Itmayhavearecipeof20%regrind,80%virgin,2%colorant.Thiswillallowtheregrindtobuildbackuptothelevelswitchagain.

Analyzingandadjustingyourmaterialblendingneedscangoalongwaytowardsreducingoperatorheadaches,down-time,andrejects,andproducingconsistent,high-qualitymoldedparts.Spendingsometimeupfrontonyourblendingprofileswillsaveyoutimeandmoneyinthelongrun.•Article originally appeared in

“Plastics Technology” (September 2014).

Blending

Jonathan Fowleris the Material Handling Systems Specialist for WITT- MANN BATTEN-FELD Inc. in Torrington, CT, USA.NicholasParadisofrom WITTMANN BATTENFELD Inc., is Lead Engineer for Material Han-dling & Auxiliaries

Picture left:Inside the WITT-MANN GRAVIMAX blender material hopper, there are no valves in the way that could af-fect material flow.Picture right:Sensor on the blender hopper of the WITTMANN GRAVIMAX moni-tors material level for automatic se-lection of a high/low regrind recipe.

Picture left:The mixing bowl of the WITTMANN GRAVIMAX blend-er is equipped with static rings on the walls of chamber. These rings ensure that as material climbs up the walls of the mixing bowl due to static, the pel-lets fall back into the mixture.Picture right:Pneumatic mate-rial discharge shut-off valve of the FEEDMAX loader models. When a load cycle starts, this air cyl-inder is actuated, and the discharge bell is forced to make a perfect vacuum seal.


Thispro-ject–justoneexampleofthemanyPETRAcanaccomplishforitsKoreancustomers–demonstratesvividlythepotentialforsavingsthatcanbemadewithwellthought-outautomationsystems.ItwillalsocertainlyspreadawarenessofWITTMANNGroup’spresenceinKorea.•

ThefiveemployeesatPETRAmakeupasmall,buttight-knit

team,andareallthemoreeffectivebecauseofit.Intheirfirstyearofbusiness,theymademorethanamillioneuros.Foritscus-tomers,PETRAishighlyregardedforthetotalreliabilityofitsproductsanditsgreatprice/per-formanceratio–andnotleastfortheirreadinesstotacklethemostvariedofassignments.

TheircustomersincludeNamdoMoldCorporation,HansungSolutec,FaureciaKoreaandWonilHydrau-lic,tonamejustafew.

Automation of a plastic frame

InordertoautomateanMGSinjectionmoldingmachine,PetrasuppliedaW853robot(alargepieceofkitwithaz-axis4mlong)andWITTMANNW832robot,bothofwhichareequippedwiththelatestR8.3robotcontrolsystem.

AspecialautomationsolutionwastobeimplementedforMGS.Theautomotivesuppliermanufacturesplasticframesforslidingsunroofsusinginjectionmold-ing.Thirty-twometalcomponentsinallneedtobeputinsidethecavityinordertomakethisplasticcomponent:6screwsforthestationarypartofthetooland24moremetalparts(nuts,bolts,clampsandpins)inthemovinghalf.

Insertionofalltheseparts,whichwaspreviouslydonemanually,wasnowtobeaccomplishedbyrobot.Apartfromthesavingsinpersonnelcosts(forthreeoperators),theobjectivesetwastoreducecycletimesbyathird(from300secondsto200).

Nowthattheautomationfortheproductionoftheplasticframesisrunningsmoothly,ithasactuallyreducedcycletimesdowntoanoutstanding160seconds–almosthalvingthetimeneeded.Theinsertionofthe32metalpartsishandledbyaWITTMANNW853robot.

Automation

In Yongin, south of Seoul, is the headquarters of PETRA Corp. Ltd.,representatives for the WITTMANN Group in South Korea.Founded as recently as 2014, the company already counts manyrenowned Korean industrial concerns among its customers.Chong Geun Kim

South Korean automation expertise

Picture left:Finished injection molded com-ponent: plastic frames for a slid-ing sun roof.Pictures right:Views of the WITTMANN robot installed for the production of frames at MGS.

View of an open injection molding machine: Prior to installation of the WITTMANN robot at automo-tive component manufacturer MGS, metal parts had to be inserted into the cavity by hand.

Chong Geun Kimis the CEO at PETRA Corp. Ltd, the WITTMANN Group’s represen-tatives in Korea, based in Yongin.


Automation

Choosing WITTMANNas automation partner

SMIPLINDIAoperatesstrongTechnicalProcessEngineeringandProjectManagementTeamswhostrictlyfollowwell-definedSuzukicorporatepurchaseandengineeringguidelines.Final-izingcontractswithanysupplierrequiresseveralprocessstepsintermsofthetechnicalevalua-tionsrequiredthroughthewholetransaction.TheWITTMANNGroupperformedexceptionallywellthroughoutthisprocess.SMIPLEngineeringTeamnotedthatWITTMANNkeyfeaturessuchasdetachablecontrollers,SoftTorque,orQuickEdithadsignificantimpactinday-to-dayoperations.TheSMIPLteamalsoappreciatedtheEcoModeenergysavingfunctionthatcomesasastandardwithWITTMANN

robots,aswellasthedepictionoftheso-calledSafetyAreasontherobotcontrols.Inaddition,WITTMANNcommittedtodevelopingacontrollerlanguageinJapaneseexclusivelyforSMIPL.ItwasalsonoteworthythatmostallmanufacturersofautomotiveplasticspartsinIndiaarenowusingWITTMANNproductstoenhancetheirproductivity,afactorincludedintheSMIPLdecision,togetherwiththeincreasinglyglobalpresenceoftheWITTMANNGroup.

Perfect installation, easy startup

ThelocalWITTMANNteamprovidedexemplaryinstal-lationworkandsubsequenttraining,incorporatingalltheSMIPLinstallationguidelines.TheWITTMANNEndofArmTooling(EOAT)workedfaultlesslyfromthefirststroke;pick-ingupproductswithouttheneedforasingleadjustment.•

SuzukiMotorcycleIndiaPrivateLimited(SMIPL)be-cameestablishedinIndiain

2005,andhasgrownitsbusinesseversince,producingscootersandbikesforthelocalandinter-nationalmarkets.Recently,SMIPLhasmadethedecisiontoacquireseveralWITTMANNrobotsequippedwithspecialEOAT(EndofArmTooling)togetherwithdownstreamequipmentsuchasbeltconveyors.

SMIPL,buildingmotorcyclesinGurgaon(Haryana),hasad-optedtheproprietarycompany’smanufacturingphilosophyofproducinghighvalueproducts.

ThelocallybuiltSuzukimodelsofscooters(withthebrandnamesLet’s,SwishandAccess)andbikes(namedGixxer,Hayate,andInazuma)havefoundwideacceptance.StrongmarketdemandhasledSMIPLtoexpandtheproductionwithinashortspaceoftime.Thecompanymanufacturedapproximately100,000unitsmoremotorcyclesin2014–comparedwiththepreviousyear.ThethennewLet’sandGixxermodelsplayedakeypartinachievingrecordproductionnumbers.

The Suzuki purchase criteria

ThoughWITTMANNisalreadystronglyinvolvedintheIndianauto-motivesector–beingasuppliertoalmostallautomotiveplasticspartsmanufacturers–aseparateapproachwasneededinrelationtotheSMIPLmotorcyclebusinessandthemeritsoftheWITTMANNproductrange.

SoSMIPLisquiteopenforbestoftechnologyandma-chineryavailablegloballywiththeirlocalsupportonourcapitalequipmentpurchaseprocess.

WITTMANN BATTENFELD India, based in Chennai, is very proud to have equipped motor scooter and bike manufacturer Suzuki Motorcycle India Private Limited (SMIPL) in Gurgaon with an automation solution consisting of several WITTMANN robots, and with additional downstream equipment, including conveying solutions. The Japanese giant now occupies a prominent place on the customer list of the WITTMANN Group’s Indian subsidiary.Ravi Soni

Suzuki Motorcycle buys equipment fromWITTMANN BATTENFELD

Ravi Soni (left) with key members of the SMIPL Plas-tics Engineering Team.

The WITTMANN robot control now is available also with Japanese as an operating language.

Ravi Soniis the North India Sales Manager of WITTMANN BATTENFELD India Pvt Ltd in Chennai.

Suzuki bike, manu-factured by SMIPL in Gurgaon.


News

The new WITTMANN BATTENFELD subsidiary in Hungary

Withtheseparationofsalesandserviceactivitiesfromthe

WITTMANNproductionplantinMosonmagyaróvárandtheirreloca-tiontoBudaörsnearBudapest,theWITTMANNGroupisnowlocatedgeographicallywithineasyreachforcustomersfromallpartsofthecountry.

Thenew,enlargedsalesandser-viceorganizationwithaworkforceof14staffmemberswillnowtakecareofalltaskswithcustomercontact,includingprojectplanning,customersupport,repairsandsparepartsservice.

Theorganizationhasbeencom-pletelyrestructuredtoenableittoprovidecustomerswithoptimalsupportfromacentrallocationinHungary.ThemanagementofthenewsalessubsidiaryliesinthehandsofZsoltRápolti,whohasdistributedtheproductsoftheWITTMANNGroupinHungarysuccessfullyasaregionalsalesmansince2012.

ThismovealsoenablestheWITTMANNproductioncom-panyunderthemanagementofThomasWITT-MANNtopro-

ceedwiththenecessaryextensionsofproductioncapacityandbuildingstoaccommodatetheproductionstart-upoftheEcoPowermachineseriesand

theongoingproductionoftherobotserieswithupto12kgloadcapacityandtheTEMPRObasictemperaturecontrollers.

ThemembersoftheManagementBoardandSalesManagementoftheWITTMANNGroupareconfidentthatthenewsalesorganizationinHungarywillensureevenbettersup-porttothelocalcustomersandwishZsoltRápoltiandhisteameverypos-siblesuccess.•

From the beginning of September this year, the WITTMANN Groupis present in Hungary with a new sales and service subsidiary.The new company will be domiciled in Budaörs, near Budapest.

Zsolt Rápolti, Man-aging Director of the new Hungar-ian subsidiary.

The new house of WITTMANN BATTENFELD Kft., the new sales and service subsidiary in Budaörs, not far from Budapest.

OnJanuary1st2016,BAT-TENFELDPolskabased

inGrodziskMazowiecki(about30kmsouthwest-erlyofWarsaw)willbecomeWITMANNBATTENFELDPolska.

ThenewPolishsubsidiarythatisthuscreatedwilloffertheentireproductrangeoftheWITTMANNGrouptotheveryactivePolishindustry.Forsometimenow,ManagingDirec-torBogdanZabrzewskiisintenselybusytoadapthimselfandhisteamtotheforthcomingdutiesandrespon-sibilitiesandtorespectivelyadjustthestructureofthecompany.ThePolishrepresentationwasalwayscharacter-

The WITTMANN Group reorganizing Polish activities

Picture left:The premises of BATTENFELD Polska, the pro-spective WITT- MANN BATTEN- FELD Polska company, in Grodzisk Mazowiecki.Picture right:Managing Director Bogdan Zabrzewski.

izedbybeingveryclosetothecus-tomer.Inordertofurtherunderlinethisaspect,thePolishsalesteamwastrengthenedcorrespondingly.Beyondthat,additionalserviceengineershavetakentheirpositionsinWrocław,Katowice,andPoznań.

Withmanpowerofnearly30,thesubsidiaryiswellpreparedtomeettheupcomingchallenge.Several

smallerstockswillbecreatedthatwillcontainservicepackagesfortheneedsoftheserviceengineers.Andtheheadquar-tersinGrodzisk

Mazowieckiwillhouseanextensivesparepartsstorage.ThemonthsofNovemberandDecember2015willstillbeusedforthespecializedtrainingoftheserviceteam.AndthecompletingtrainingforthesalesteamwillfollowupinJanuary2016.•


News

… to have a close look at the machinery in the exhibition hall …

What’s cooking at the French branch?On June 23rd, WITTMANNBATTENFELD France SAS heldthe first Open House event.

TheaimofthiseventwastoinvitetheWITTMANNGroupsub-

sidiariestodiscoverthenewFrenchplant,tomeetthepeopleworkingintheGranulatorsDepartment,andsubsequentlytogetanoverviewofthelatestchangesinregardtothegranu-latorsbusiness.Representativesof17subsidiariesfromEuropeandNorthAmericametinMoiransandhelpedmaketheeventarealsuccess.

Therewasatightprogram:presen-tationoftheFrenchteam,productupgradesandapricelistreview,alectureaboutMCgranulators,apresentationofsomecustomersuc-cessstories–andmanyconstructivediscussionsalsotookplace.

ThetimewasalsorighttounveilthelatestmemberoftheWITT-MANNgranulatorsfamily,thenewJunior3Compactgranulator.Thismachinewillbepresentedtothepublicatthe2015FakumaexhibitionOctober13–17.

Withregardtoautomation,theFrenchteamdemonstrateditscom-petencebyrunninganIMLside-entryrobotfortheautomationofa16-cavi-tiesmoldingprocess.ThisunitwasmanufacturedinMoiransandwashandlingtheproductionofsixroundlidsincludingtheirstackingintocard-boardboxes.

“Cooking for the future”

Attheendoftheevent,aspecialsurpriseawaitedthenumerousvisi-tors.AllwereinvitedtoparticipateinaFrenchcookingevent.Dressedaschefs,theguestsoftheOpenHousecookedtheirownmealtogether,usingaprofessionalkitchen,andassistedbyrealchefs.•

… and finally, also to explore one‘s own cooking skills.

The Open House event in Moirans offered many op-portunities to get in contact with each other …


WITTMANNTaiwanwasfoun-ded2007inTaichung.From

thebeginning,itwasthecompany’sdeclaredambitiontoprovidetheentireTaiwanesemarket–whichisademandingone–withrobotsandperipheralequipmentfromWITT-MANN.In2008,thecompanywasrenamedWITTMANNBATTEN-FELD(Taiwan)Co.LtdandfromthattimehasalsosoldtheWITTMANNBATTENFELDinjectionmoldingmachines.

Working in an active market

Presently,theTaiwanesemarketisbecomingmoreandmoreimportantfortheWITTMANNGroup.Partly,thisisduetothemanyTaiwanesecompaniesthatarerelocatingbacktoTaiwanfromChina.

Inaddition,thereisastrongandnoticeabletrendintheindustrytowardsmoreinvestment.Thereisalsohighdemandfornewproductionequipmentwithahigherdegreeofautomation.

Asaconsequence,thenewWITT-MANNBATTENFELDfacilitywascreated.ThebuildingislocatedintheTaichungIndustrialAreaandisperfectforadministration,salesandservice,stockholdingandtraining.Thenewpremisescover2,280square

News

The new location for WITTMANN BATTENFELD Taiwan

metersandthebuildingareaitselfcomprises1,400squaremetersoffloorspace.DavidChen,theDirec-torofWITTMANNBATTENFELDTaiwan,says:“Ourcurrentteamnow

In July 2015, the WITTMANN BATTENFELD subsidiary in Taiwanmoved to a brand new building located in the Taichung district.The new facility provides more space, offers more possibilitiesto expand business in the future, and is surrounded by a moreinteresting businesslike environment.

Exterior view of the new premises of WITTMANN BATTENFELD (Taiwan) Co. Ltd. …

… and some interi-or views. – The Tai-wanese subsidiary of the WITTMANN Group is located in the Taichung Industrial Area.

consistsoffourteenpeople–andallofuswereveryhappytomoveintothenewfacility.Itisreallyagreatsettingfortheexcitingworkwearedoinghere.”•


TheT.A.O.BANGKOKCORPORATIONhasawork-forceof76employeesworkinginThailandandVietnam.

Ithasextensiveexperienceinsupplyinghigh-qualityscreenprintinginkandplasticfilmtoseveralindustriesinbothcountries,coveringautomotive,electronics,packaging,textiles,andtoymanufacturing.

TheT.A.O.BANGKOKCORPORATIONalsorepresentsafullyautomaticscreenprintingline,highpressureformingmachines,padprintingmachinesfromGermany–andfromnowonalsotheentireproductportfoliooftheWITTMANNGroup.

Thestrategyfocusesonprovidingthebestsolutionsforcustomers.Shortresponsetimesandarapidservicecountamongthedailybusinesspractices.T.A.O.BANGKOKalsocreatesanespeciallycustomizedtrainingforcustom-ers,includingspecialdemands,andhelpinggenerallywithplantefficiency.

Good reputation in Vietnam

Economically,Vietnamhasbeenoneofthefastestgrowingcountriesfordecades.ThelocalT.A.O.BANG-KOKstaffworkscloselywiththeVietnamesecustom-ers,havingreachedafullunderstandingofcultureandattitude.

ManyimportantVietnamesecustomers–suchasLongThanhPlastic,tonamejustoneofthemostprominent–placegreatconfidenceintheBANGKOKCORPORA-TIONbecauseofthecompany’sperseverancewithregardtogoodserviceandthecultivationoflong-termbusinessrelationships.

BoththeT.A.O.BANGKOKmanagement,andtheWITTMANNGroup,arelookingforwardtoalong-lastingandfruitfulpartnership.•

News

Picture left:Chitlada Vichyastit, Market-ing Operation Manager (left), Apichart Angspatt, Managing Direc-tor and Head of Technical Service (in the middle); and Chanachai Osornphasop, Managing Director of T.A.O. BANGKOK (Vietnam) Ltd.Picture right:Headquarters of the T.A.O. BANGKOK COR-PORATION Ltd., in Samut Sakhon south of Bangkok, Thailand.

WITTMANN Group is represented in VietnamThe T.A.O. BANGKOK CORPORATION LTD. was founded in Thailandin the year 1994 where the company has its headquarters.The company also owns two branch offices in Vietnam – in Hanoiand in Ho Chi Minh City. This year, it became the Vietnameseagent for the WITTMANN Group.

The T.A.O. BANGKOK Vietnam office in Ho Chi Minh City.

BP00000034 – 1504

WITTMANNBATTENFELD INC.1 Technology Park DriveTorrington, CT 06790, USAtel.: +1 860 496 9603fax: +1 860 482 [email protected]

WITTMANN ROBOT(KUNSHAN) CO. LTD.No. 1 Wittmann Rd.DianShanHu TownKunshan City, Jiangsu Province215245 CHINAtel.: +86 512 5748 3388fax: +86 512 5749 [email protected]

WITTMANNKUNSTSTOFFGERÄTE GMBHLichtblaustrasse 101220 Vienna, AUSTRIAtel.: +43 1 250 39-0fax: +43 1 259 [email protected]

WITTMANNBATTENFELD GMBHWiener Neustädter Strasse 812542 Kottingbrunn, AUSTRIATel : +43 2252 404-0Fax: +43 2252 [email protected]

wittmann innovations

Documents