wittmann innovations
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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; bernhard.grabner@wittmann-group.com; 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)
WITTMANN innovations – 4/2015 5
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.
WITTMANN innovations – 4/20156
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.
WITTMANN innovations – 4/2015 7
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.
WITTMANN innovations – 4/20158
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.
WITTMANN innovations – 4/2015 9
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.
WITTMANN innovations – 4/201510
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 injec- tion 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.
WITTMANN innovations – 4/2015 11
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.
WITTMANN innovations – 4/201512
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.
WITTMANN innovations – 4/2015 13
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.
WITTMANN innovations – 4/201514
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.
WITTMANN innovations – 4/2015 15
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.
WITTMANN innovations – 4/201516
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 com- pany, 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.•
WITTMANN innovations – 4/2015 17
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 …
WITTMANN innovations – 4/201518
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.”•
WITTMANN innovations – 4/2015 19
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 2069info.us@wittmann-group.comwww.wittmann-group.com
WITTMANN ROBOT(KUNSHAN) CO. LTD.No. 1 Wittmann Rd.DianShanHu TownKunshan City, Jiangsu Province215245 CHINAtel.: +86 512 5748 3388fax: +86 512 5749 3199info@wittmann-group.cnwww.wittmann-group.com
WITTMANNKUNSTSTOFFGERÄTE GMBHLichtblaustrasse 101220 Vienna, AUSTRIAtel.: +43 1 250 39-0fax: +43 1 259 71-70info.at@wittmann-group.comwww.wittmann-group.com
WITTMANNBATTENFELD GMBHWiener Neustädter Strasse 812542 Kottingbrunn, AUSTRIATel : +43 2252 404-0Fax: +43 2252 404-1062info@wittmann-group.comwww.wittmann-group.com
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