www.wittmann-group.com
Techniques – Markets – Trends Volume 9 – 2/2015
Always perfectly staged:
WITTMANN auxiliary equipment
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 3/2015 of “WITTMANN innovations” will appear at the beginning of the third quarter 2015.
WITTMANN innovations (Volume 9 – 2/2015)
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
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
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• 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• Thenewtemperaturecontrollersofthe
TEMPROplusCseries3/2007• COOLMAXcoolingunits2/2008• Temperaturecontroller“guarding”injectionmoldingmachines3/2008• TemperaturecontrollerswithDUOcooling4/2008• Variothermaltempering1/2009• TEMPROplusC1802/2009• TEMPROdirectC120[C250]3/2009• WFC:WaterFlowControl4/2009• TEMPROplusC1801/2010• TEMPRO:Universalbenchmark2/2010• BFMOLD®moldcooling3/2010• TEMPROplusD4/2010• Online-thermography1/2011• TemperingandinjectionmoldingatFuchs&Sohn2/2011• TEMPROplusDintheautomotivesector1/2012• Oscilloscopefunction2/2012• Compacttemperaturecontroller4/2012• Qualityassurancethroughtheoptimaltemperingprocess1/2013• TheStarlingerspecialsolution2/2013• NewWITTMANNtemperingandflowcontrolequipment4/2013• TEMPROusesheatwaste1/2014• CleansolutionatDELPHI4/2014• Blumusingaspecialsolution1/2015
Injection Molding• Injectionmoldingonestopshop4/2008• MetalinjectionmoldingatIndo-US
MIM4/2008• Costoptimization:EcoPower1/2009• ITassistedservices1/2009• Waterinjectionforall-plasticparts2/2009• TheKronaIndústriaequipment2/2009• Micro-parts:Microsystem503/2009• Multi-componentprocessatwolfcraft4/2009• Processdataacquisition:partnershipwithWilleSystem4/2009• Thenewall-electricEcoPower 4/2009• ThomasDudleyandWITTMANNBATTENFELD1/2010• IMLwithTMXpress1/2010• AIRMOULD®andAQUAMOULD®Mobile1/2010• DesignMoldedPlasticsandtheirmold-ingmachines2/2010• StadelmannreliesonWilleandWITT-MANNBATTENFELD2/2010• ThenewMicroPower3/2010• AQUAMOULD®andprojectileinjec-tiontechnology3/2010• Newbenchmark:MacroPower4/2010• STELLAreliesonWITTMANNBATTENFELDmachines4/2010• 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
WITTMANN innovations – 2/2015 3
Editorial
DearReader,
WearelookingforwardtoApril22and23withgreatpleasure.Onthesedays,wewouldinviteyoutoagainvisitourmachinemanufacturingplantinKottingbrunn,wheretheMacroPower Days2015willtakeplace.Asthenamealreadyimplies,thespeechesandpresentationsofthiseventwillfocusprimarilyonourMacroPowerseriesoflargemachines.Weareofferingourguestsanopportunitytotakealookatseveninjectionmoldinglineswithclampingforcesrangingfrom400to1,600t,andtogatherinformationaboutadvancedprocesstechnologies.TheothermodelsfromourPowerSerieswillalsobeavailableforviewing.
Well-knownexpertsfromindustry,scientificresearchandteachingwillholdpresentationsonhighlytopicalsub-jectssuchasIndustry 4.0,manufacturingof“organosheets”,injection-moldedintegralfoam,andnumerousotherapplicationsfromvariousbranchesofindustry.Inshort,aprogramawaitsyouwhichcoverstheentirebandwidthofapplicationoptionsforourMacroPowermodels.
Univ.-Prof.FriedrichBleicher,HeadoftheInstituteforProductionTechnologyatTUVienna,willholdtheopeningspeechabout“Industry 4.0fortheplasticsindustry“,dealingwithadevelopmentwhichisvitalfortheCentralEuropeanindustryandforeconomicpolicies.Industry 4.0standsforpoolingalltrendswhichaimtoimplementcomprehensivenetworkingofallinformationandcommunicationtechnolo-giesinanInternetofobjects,servicesanddata.Thefacilitiesforquick,flexibleresponsetocustomers’demands(includ-ingcost-efficientproductionofsmallbatches)willbefurtherimproved,thuspreservingthecompetitivenessofcountrieswithhighwagelevels.
ThecompaniesoftheWITTMANNGrouphavetheuniqueexpertiseattheirdisposaltointegrateallinjectionmoldingcomponents,i.e.thecompleteautomationsystemandfullrangeofperipheralequipment.Thisgivesusadeci-sivecompetitiveadvantageoverothercompaniesoftheinjec-tionmoldingequipmentindustry.Withourintegrationsolu-tioncalledWITTMANN 4.0wearealreadyofferingnowwhatas,forexample,beendescribedbytheFraunhoferInstituteasthegreatestchallengeinconnectionwithIndustry 4.0:thedefinitionofcommunicationstandards,includingguaranteedsafetyofdataandaccess.WithWITTMANN 4.0 wehaveal-readyreachedagoalwhichmanyothersareonlyjuststartingslowlytopursue.WewouldinviteyoutogatherinformationaboutthepotentialofWITTMANN 4.0attheMacroPower DaysoftheWITTMANNGroup!
Yourscordially,MichaelWittmann
Michael Wittmann
ContentAutomation Thus productivity occurs
Sonny Morneaultvisits Alliance Precision Plastics in Spindale, North Carolina.Page 6
InjectionMolding
Resource saving production
News
Gabriele Hopfon Fushima, a Spanish molder working for the world market …Page 8
Jimmy Teowrites about auto-mation systems at Greenland Plastics in Singapore.Page 4
EntireSystems
Best molding quality
We present: the WITTMANN BATTENFELD QuickLook app.Page 12
We provide insight into WITTMANN Kunststoffgeräte GmbH in Vienna, Austria.Page 13
… and on Tielke in Germany, the all-round injec-tion molder and toolmaker.Page 10
Highly integrated workcells
Portrait
WITTMANN innovations – 2/20154
Automation for a smooth process run
OneofthesecretsbehindGreenland’ssuccessisthattheirautomationcomponentshavebeenconsistentlystate-of-art.ThisphilosophyledtotheacquisitionofaWITTMANNW818servorobotwithfullyautomaticdownstreamequip-mentdeliveredfromWITTMANNBATTENFELDSingapore.
A well-established Singapore plastics processor usesautomation systems provided by the local WITTMANN branch –and achieves a remarkable increase in productivity.Jimmy Teo
GreenlandPlastics,locatedinSingapore,isaspecialtyproducerofPVC(Polyvinyl
Chloride),PE(Polyethlene)andABSparts(AcrylonitrileButadieneSty-rene),andalsoprocesseshalogenfree(HF)material.
GreenlandoperatestwoproductionplantsinSoutheastAsia,oneproduc-tionplantinSingapore,andtheotheroneinMalaysia.Thehighlycom-petitivecompanyiswellpositionedtomeetanyneedsandexpectationsofitscustomers.
Inthefirstinstance,GreenlandPlasticsishighlyspecializedintheextrusionindustry,especiallyintheextrusionofpipes,industrialhoses,cabletrunkingandprofiles,renderingOEMservicesforcustomrequirements.Withalmost40yearsofextrusionandinjectionprocessexperience,Greenlandiswidelyknownandhighlyrespectedforexcellentqualityandabsolutereliability.
The highest degree of accuracy … over and over again
Automation
Jimmy Teo, Man-aging Director of WITTMANN BATTENFELD Singapore and Chia Mui King, Managing Direc-tor of Greenland Plastics Singapore. The handshake marked the seal-ing of a further automation project, allocated to WITTMANN BATTENFELD Singapore.
Hexagon screw nuts that are inserted into the mold, and finished molded parts, manufactured at Greenland Plastics (S) Pte. Ltd. in Singapore.
WITTMANN innovations – 2/2015 5
Afterthehexagonscrewnuts,producedatGreen-land,havebeenorientedbymeansofacustomizedbowlfeeder,theW818robotreliablypicksandplacestheinsertsintothemold,workingwithabsoluteprecisionandrepeatedaccuracy.Thankstoitsprocessconsis-tency,theWITTMANNautomationsolutionincreasesproductivitythroughasignificantreductionofcycletimes,anditcontributestoimprovingthehighqual-itystandards.Theautomationprocesscanbeoperatedwithoutanyinterruptionforverylongperiods,perhapsevenforyears.
ChiaMuiKing,GreenlandManagingDirectorcom-mentsonthis:“ThankstotheWITTMANNrobot,wehaveachievedasignificantreductionofthemoldopeningtimesthatapproximatelymountupto70to80%.Wehaveincreasedourproductivity;weproducedmoregoodsandworkedoffmoreservicesusingthesameamountoflaborandcapital.Forus,itisnotreallyabout
cuttingcosts,butsimplyabout‘doingthingsright’and‘doingtherightthings’toachievemaximumefficiencyandvalue.”
Service and responsiveness
“WerecognizeandappreciatetheservicedepartmentofWITTMANNBATTENFELDSingaporeasextremelycooperativeandknowledgeable.Theyalwaysrespondimmediately,andthisisthereasonwhywehavechosenWITTMANNBATTENFELDSingaporeasourpreferred
automationpartner.Additionally,ourtechnicaldepart-menthasbenefittedsomuchfromtheircustomizedtrainingprogram,”saysChiaMuiKing.Movingforwardandachievinghigherproductivitythroughautomation,GreenlandPlasticshasmadeanagreementwithWITT-MANNBATTENFELDSingaporetoundertaketheirfutureautomationprojectswiththem.•
Automation
Jimmy Teois ManagingDirector of WITT-MANN BATTEN-FELD (Singapore) Pte. Ltd.
Greenland custom-ized end-of-arm tooling (EOAT), designed by WITT-MANN BATTEN-FELD Singapore.
WITTMANN innovations – 2/20156
Entire Systems
AlliancePrecisionPlastics,headquarteredinRochester,NY,isacustominjectionmolding,molddesign,moldbuilding,and
contractassemblycompany.Whatbeganasalocaltoolmakingshopin
1953hasgrownintoapowerfulproductionmoldingcompany,withover90injectionmold-ingmachinesspreadoverfourmainlocationsintheUSandMexico.ThemostrecentlocationcametoAllianceinearly2012viatheacquisi-tionofcertainassetsofMoldingDynamics,Inc.,locatedinSpindale,NC.Withthisacquisitioncametheawardofamajornewprojectbyalead-ingappliancemanufacturer,andaresultingneedforanewlineofmoldingmachinesandauxilia-riestosupportit.“WehadastrongcustomerbaseintheSouth-
easternUS,andsawtheSpindalefacilityasagreatfitforustobetterservicethatregionforbothnewandexistingcustomers,”saysJoeWilliams,VicePresidentofOperationsatAlliance.“Itwasanincrediblysmoothacquisitionandcombinationofcorporatecultures.ThetransactionbroughttoAl-liancethechancetohireanumberoftalentedandhard-workingpeopleinNorthCarolinatojoinourteam.ThatcombinationhasallowedAlliancetoexpandboththeirbusinessopportunitiesandtheirphysicalplant.”
OneofthoseopportunitieswastobidonalargenewprojectbeingofferedbyanexistingSpindalecustomer.Toaccommodatethenewworkcells,AlliancealsoneededtoexpandtheirSpindalefacility.
Asaresult,AlliancePrecisionPlasticsbeganconstructionona17,500sq.ft.additiontotheexistingplant.Thenewspaceisprimarilyforwarehouseuse,leavingmoreroomontheexistingfloorforthenewworkcells.
ThisadditionwasstartedinJuly2014andincludes5dockdoorsformoreefficientshippingandloading,aswellasincreasedcapacity.Itwascompletedandmovedintobytheendof2014.
A new work cell
Uponwinningtheprojectandplanningtheexpansion,Alliancewentoutlookingfortheequipmentnecessarytobuildthenewworkcellsnecessarytosupportit.Thenewprojectwasacomplexonethatrequiredmachinesthatof-
After winning a bid for a complex new molding project, Alliance Precision Plastics needed additional new equip-ment that was customizable, easy to integrate, and quickly delivered. By pro-viding one-stop shopping, WITTMANN BATTENFELD was able to meet all of their needs and meet them faster than the competition.Sonny Morneault
Alliance Precision Plastics: Workcell integration, automation and service
WITTMANN innovations – 2/2015 7
Entire Systems
feredflexibility,customization,andafastturnaround,andworkingwithWITTMANNBATTENFELDmadesense.“WehadworkedwithWITTMANNBATTENFELDbeforeonacustomspoolautomationprojectbackafewyearsagoandwehadsomegreatfeedbackfromouremployeesontheeaseofuseandqualityoftheWITTMANNrobots,”
Small picture above: View of injection molding machines from WITTMANN BATTENFELD at the Alliance Preci-sion Plastics plant in Spindale, NC, USA.Picture left (from left to right): Joe Minor (WITT-MANN BATTEN-FELD IMM Region-al Sales Manager), Joseph Williams (Vice President of Operations for Alliance Preci-sion Plastics), Joe Varone (Regional Sales Manager of WITTMANN BATTENFELD Robots and Auto-mation), Dave Wyscarver (WITT- MANN BATTEN-FELD Regional Sales Rep).
saysAlanKearns,GeneralManageratAlliance’sSpindalefacility.“WehaveagreatrelationshipwithWITTMANNBATTENFELD’ssalesrepsintheareaandtheypitchedusaturnkeylinewitheverythingweneeded.Wehadacustomerandothermoldershighlyrecommendthemtous.Theintegrationoftheworkcell,thesinglesourcing,andthefast
Sonny Morneaultis National Sales Manager of WITTMANN BATTENFELD, Inc. in Torrington, CT, USA.
deliverytimewereallbigsellingpointsforusthatWITT-MANNBATTENFELDcouldachieve,sowepulledthetrig-ger.”Asaresult,Alliancepurchasedseveninjectionmoldingmachines(aTM500,2HM150s,2HM90s,anHM65,andanHMMC300two-shotmachine),4robots(2W833sand2W831s),5granulators(4SJMinor2sandanML33),
3dryers(2DRYMAXAtonF70-200-Msand1DRYMAXE30-70-M),3loaders(3FEEDMAXS3Primuses),2pickers(W702s),5TCUs(TEMPRObasicC200s)andasilo.
Withallofthisequipmentcomingfromasinglesource,Alliancehadallofitdeliveredtotheminthreemonthstime,somethingthatwasimportanttothemwiththeirneedtogetthenewprojectunderwayassoonaspossible.Themachinesandrobotswereintuitivetoprogramandsetup,aswellasbackedbyWITTMANNBATTENFELD’sstel-larcustomerserviceandsupportteam.Theeaseofintegrationwaskeyfortheproject,withalloftherobots,materialhandlingsystemsandinjectionmoldingmachinescommunicatingandworkingtogetherseamlessly.TheplantpersonnelatAlli-ancepraisethesimplicityofthecontrollersandthecontrolsystems,andappreciatetheconsistencyofthemacrosstheentireworkcell.“Asgoodastheequipmenthasbeen,theser-
vicehasbeenanevenbiggeraddedvalueforus,”saysKearns.“Theyhaveknowledgeable,helpfulsalesrepresentativesandindependentserviceprovidersthatarebasedrightinourbackyard,whichmakesourliveseasierandhelpsourequip-mentrunevenbetter.”
A custom solution
Oneofthenewmachinesneededtomoldachal-lengingpartfortheapplianceindustrythatrequiredacustombuild.Theapplicationwasatthecruxoftheworkcell,andwasnecessarytomoldthebasecomponentofthefinishedcomplexappliancepart.AllianceworkedcloselywiththeengineersatWITT-MANNBATTENFELDandtheybuiltacustomtwo-shotmachineprovidingthesolutionthatwasneededattheworkcell'sfrontend.“WereallyleanedonWITTMANNBATTEN-
FELDforhelpwiththetwoshotmachine.”saysKearns.“Themoldsizerequiredabigmachineandtheshotsizesdemandedsomethingdifferent.Whatweendedupwithwasanearlycompletelycustommachinethatfitourapplicationperfectlyandpro-videduswiththesolutionweneeded.”
“WehavethoroughlyenjoyedworkingwithAlliancehereinSpindale,”saysJoeVarone,Re-gionalSalesManager–RobotsatWITTMANNBATTENFELD.“JoeMinor(RegionalSalesMan-
ager–MoldingMachines),DaveWyscarver(RegionalSalesRepresentative)andmyselfhavebeenheremanytimesandknowthecaliberofcompanytheyare.We’reproudtohaveafullWITTMANNBATTENFELDworkcellupandrunningintheirfacilityandexcitedforthemtoreapthebenefitsourequipmenthastooffer.”•
WITTMANN innovations – 2/20158
Injection Molding
Fushima, a well-known maker of toothbrushes and many other personal hygiene products located on the north coast of Spain, has been relying for many years on injection molding machines from WITTMANN BATTENFELD.Gabriele Hopf
Top-quality toothbrushes with WITTMANN BATTENFELD injection molding machines
Installation of the EcoPower ma-chines at Fushima.
– Fushima has 14 BATTENFELD machines installed on its production floor located in Guarnizo in the North of Spain.
Photos: Fushima
WITTMANN innovations – 2/2015 9
manualtoothbrushes.About40%ofthecompany’ssalesarerealizedoutsideofSpain.Fushimatoothbrushescanbefoundin55countriesworldwide.
Fushima’ssuccessisbasedonhighqualitystandardsandinnovation.TheDINISO9001certifiedcompanyregardsoutstandingachievementsinresearchanddevelopmentasoneofitsmainstrengths.“Alothaschangedinthetooth-brushsectoroverthelastdecades,”saysRaúlCimiano,ManagingDirectorofFushima.“Whiletoothbrushesweremadeofjustonematerialinthepast,today’shigh-qualitytoothbrushesconsistofseveraldifferentmaterials.Thisequallyappliestoothertypesofbrushes.”Agreatvarietyofmaterialsareusedintoothbrushproduction,including,forinstance,polypropylene,TPE,polyethylene,polystyrene,andABS.AccordingtoCimiano,itisalsoaspecialchal-lengetocreateaproductwhichdistinguishesitselffromothersonthemarketandisprofitableatthesametime.Tothisend,Fushimahasseveraldepartmentsengagedintest-ingnewmaterials,creatingnewprocesses,etc.
Fushima relies on WITTMANN BATTENFELD
Toliveuptoitsphilosophyofofferingitscustomersworld-classserviceandthebestpossibleproductstoendcustomers,Fushimaalsoneedsthebestpossibleproduc-tionequipmentthatisexistingonthemarket.Intheareaofinjectionmoldingmachineryandprocesstechnologies,FushimahasreliedonBATTENFELDmachinesformanyyears.
“BATTENFELDmachinesarereliable.Wehavehardlyanydowntimesorproductionfaults,”saysRaúlCimiano.Whatismore,WITTMANNBATTENFELD’sexcellentcustomerserviceandafter-salessupportisalsoappreciatedhere.Atotalof14BATTENFELDmachinesarecurrentlyinstalledatFushima,withclampingforcesrangingfrom50to180t.Untilmostrecently,thecompanyusedmainlyhydraulicmachines.
In2014,Fushimainvestedintwomachinesfromtheall-electricEcoPowerseries,eachwith180tclampingforce,andanEcoPower110.RaúlCimianoisimpressedbythecleanness,thelowsoundlevel,andespeciallybytheenergyefficiencyofthesemachines:“Wehavemea-suredenergysavingsofupto40%comparedtoconven-tionalmachines.”•
Injection Molding
Fushima,basedinGuarnizo,Cantabria,hasmadeanameforitselfasamanufactureroftoothbrushesandhairbrushesfarbeyonditsnationalborders.The
company,foundedbyLaureanoSalcinesGómezin1945,hasmorethan100employeesand,today,itrealizes11millionEurosinannualsales.Ona13,000m²productionfloor,72millionpiecesaremanufactured.Apartfromtoothbrushesandhairbrushes,theyalsomolddentalcareproductssuchasflossandinterdentalbrushes,aswellascosmeticbrushes,make-upmirrors,manicureutensils,barrettesandmore.Fushima’smainproductlineistoothbrushes,particularly
Gabriele Hopfis the Marketing Manager of WITT- MANN BATTEN-FELD in Kotting-brunn, Lower Austria.
From left to right: Daniel Lopez Virto, Fushima; Ignacio Puyuelo and Damian Hernandez, WITTMANN BATTENFELD Spain; Raúl Cimiano, Managing Director of Fushima; Loic Rolin, WITTMANN BATTENFELD Spain; Georg Tinschert, Man-aging Director of WITTMANN BATTENFELD. In the background the EcoPower 110 that Fushima has bought most recently. The pic-ture was taken in Barcelona at the Equiplast 2014.
Pictures left:High-quality den-tal products and brushes made by Fushima.
Photos: Fushima
WITTMANN innovations – 2/201510
Injection Molding
InJune2014,AntonTielkeGmbHcel-ebratedits75thanniversary.ThecompanywasestablishedbyAntonTielkein1939,
beginningwiththeproductionofhardwarecomponentsmadeofironandothermetals,primarilyforcustomersfromtheautomotiveandaircraftindustries.Thefamily-ownedenterprisewithaworkforceof25employeeshasnowbeensuccessfullyengagedinplas-ticsprocessingformorethan50years,mak-ingplasticpartsfromallcommonlyavailablethermoplasticresinsandthermoplasticelastomers,withpartweightsrangingfrom0.1to1,400g.Tielke’smaincustomerbaseincludesheatingandsanitaryinstallation,electricalgoodsandbuildingconstructionindustries,butalsoafewselectautomotivecustomers.ItsmainmarketisGermanyandneighboringforeigncountries.
Inadditiontocustomizedproductsmadetocustomers’specifications,thecompanymanufacturesquiteasizeableproductrangeofitsown.Forexample,itproducescapsandstopperstocoversensitivedrillingsandtubesandtoprotectthreadingagainstmoisture,dust,soilinganddamage.Thesepartsareextremelyresistanttoacids,alkali,alcohol,grease,solventsandheat.Tielkealsomakesthedi-rectgreenTMbrandplantsystem,acombinationofplantcon-tainerswithbreathable,water-permeablepotcovers,whichareprimarilyusedfornurseryandhedgeplantsorhigh-stemtrees,and–equippedwithanintegratedwatertank–astransportcontainersandstandsforChristmastrees.
A conscientious all-rounder
Tielkeofferseverythingfromasinglesource,fromprototypingtoseriesproduction.Italsooperatesitsownmold-makingshop.Highqualitystandardsand,aboveall,closenesstocustomersarevital,long-termsuccessfactors
Anton Tielke GmbH & Co. KG in Attendorn, North Rhine-Westphalia, Germany, is firmly committed to protecting the environment and saving resources in manufacturing its products. This is why the first all-electric machine from WITT-MANN BATTENFELD’s EcoPower series, which was delivered at the beginning of June, is greatly appreciated, in particular for its energy efficiency and cleanness.Gabriele Hopf
Resource-saving production at Tielke using WITTMANN BATTENFELD equipment
From left to right: Dipl.-Ing. Ingo Rüggeberg, Man-aging Partner and Ralf Dingerkus, Authorized Repre-sentative of Anton Tielke GmbH & Co. KG, and Frank Höher, Sales Representative of WITTMANN BATTENFELD, in front of the EcoPower 55/130 delivered in 2014.
Picture above:The innovative directgreen™ plant system, consisting of a plant container and a breathable, water-permeable pot cover.Picture right:Prototypes of parts that are used in forest enterprises at young trees to prevent damage caused by game animals.
Photos: Tielke
WITTMANN innovations – 2/2015 11
resourcesaremajorconcernsforthecompany’smajoritystakeholderandManagingPartner,Dipl.-Ing.IngoRügge-berg,andareconsequentlyacentralguidingprincipleofitscorporatephilosophy.Therefore,investmentsinmodern,energy-efficientproductionequipmentaremadeonaregu-
larbasis,too.Anenergyconsultantwascalledin2013
forjointpreparationofaconcepttofurtherimprovethecompany’sbalanceofenergy.“Lastyearwerealizeda10%increaseinsalescomparedtotheprecedingyear,withpowerconsumptionremainingonthesamelevel,”IngoRüggebergexplainsproudly.Andthisiswhytheoutstandingattributesofthenewlyacquiredall-electricEcoPower55fromWITTMANNBATTENFELDaregreatlyap-preciatedatTielke.
Atfirst,IngoRüggebergcouldhardlybelievethatsuchamachineastheall-electricEcoPowercouldoperatewithoutcoolingandalmostwithoutlubricant,sinceitrequiresoilonlyforitstogglesystem.TheEcoPower55/130,equippedwithaTEMPROplusDtemperaturecontrollerfromWITTMANN,cameafterahydrau-licmachinewithaServoPowerdriveandWITTMANNspruepicker,whichhadjustbeendeliveredinthefallofthepreviousyear,andwhosecompactnessandhighenergyefficiencywerewelcomedwithgreatenthusiasmatTielke.
A long lasting partnership
Thecooperationbetweenthetwocom-paniesdatesbacktotheverybeginningofplasticsprocessingatTielke.Tielke’sproductionofthermoplasticsstartedoffwithaBSKM10VPfrom1957,builtattheformerBATTENFELDplantinMeinerz-hagen,Germany.
Today,BATTENFELDmachinesfromthePlusseries,togglemachinesfromtheTMseriesandmachinesfromthehydraulicHMseriesareoperatingattheAttendornfacilityinadditiontotheEcoPower55andHM
110ServoPower,withclampingforcesrangingfrom25to500t.Apartfromthemachines’technicalcapabilities,theirqualityandenergyefficiency,thecostsalsoplayavitalpartforTielke,withthemainemphasisbeingnotsomuchontheacquisitioncosts,butprimarilyonthemachines’totallifecyclecosts.Theavailabilityoftechnicalsupportisthusamajorconsideration.
IngoRüggebergandhislong-standingauthorizedrepre-sentativeRalfDingerkusareparticularlyappreciativeofthepersonalcontacttothecompanyandtheexcellentsupportprovidedbythesalesteam.“Mutualtrustandcontinuityinourpartnershipsarethetopprioritiesforus,”saysIngoRüggeberg.“AndthesefactorsareanabsolutegivenatWITTMANNBATTENFELDinadditiontothehighqualityandtechnologicalmaturityoftheirmachines.”•
Injection Molding
forthecompany,whichhasbeencertifiedaccordingtoDINISO9001.Tielkealsotakesprideinitscertificationasan“energy-conscious”company,implementedbyICGZertifi-zierungGmbHatthebeginningof2014,sincethelong-termprotectionoftheenvironmentandsavingofnatural
Tielke currently has 10 BATTEN-FELD machines (WITTMANN BATTENFELD respectively) on its production floor.
Molds produced at the in-house mold-making shop.
Photo: Tielke
A further example of Tielke’s own products: closure elements, made of plastics.
Photo: Tielke
WITTMANN innovations – 2/201512
AstatusrequestoninjectionmoldingmachinesfromWITT-MANNBATTENFELDandonWITTMANNrobotsisnowpossibleviaSmartphoneeasilyandatanytime.
TheWiBa QuickLookappdevelopedforthispurposeiscurrentlyavailablefreeofchargeviatheAppleiOSappstoreandviaGooglePlayasanAndroidapp.
Ineachcase,thenewapplinksupwiththelatestsoftwareversionsofWITTMANNR8.3robotsandWITT-MANNBATTENFELDUNILOGB6controlsystems.Inthisway,theproductiondataandconditionofthemostimportantequipmentthatisoperatinginagivenproductioncellcanbecheckedquicklyandeasilywiththehelpofWiBa QuickLook.
PrerequisitesfortheuseoftheWiBa QuickLookapparethesoftwareversions8.21.00forR8robotcontrolsystemsandV07.2forUNILOGB6machinecontrolsystems.Furthermore,theconnectionofthecontrolsystemstotheWIFIsystemoftheinjectionmoldingplantmustbeensured,sothattherobotsandprocessingmachinescanbereachedbytheapp.Dependingonthemodel,theminimumrequirementfortheSmartphoneitselfistheinstallationofeitheriOS7orAndroid4.
Functions of WiBa QuickLook
ThevolumeofinformationwhichQuickLookappuserscanaccesshasbeendeliberatelykeptmanageable.Userscarryingoutacheckwillbe
givenaquick,well-foundedover-viewofthemostimportantcurrentparametersettingsinagivenproduc-tioncell–thosewhichconcerntheinjectionmoldingmachineandanyoneorseveralrobotsinvolved.Toretrievespecialdetailinformationortoadjusttheparametersettingsintheproductionequipment,usersarestillrequiredtogodirectlytotherelevantprocessingmachinesandhandlingdevices.
Asalways,specialcarehasalsobeentakentomakehandlingoftheappextremelyuser-friendly.Color-codedoperatingstatesinthelistsofequipmentgiveaquickoverview.Theclose-upviewsfortheindividualcomponentsprovideaccesstothe
productiondataandalarms(ifany),aswellasuser-definedprogramval-ues.Severalcomponentsofaproduc-tioncellcanbegroupedforascreenview,andthelistsofproductionequipmentcanbesortedmanually.Agridviewisavailableasanalternative,whichprovidestheoptiontosortthecomponentsautomaticallyaccordingtostatus.
TheelaboratedfunctionsoftheWiBa QuickLookappmakeiteasytoaddcomponentsbysimplyenteringtheirIPaddresses.
And,lastbutnotleast,thesettingsofequipmentshownbytheappcanbeveryeasilypassedontothirdpar-tiessimplybyusingtheemailfunctionoftheSmartphone.•
News
The WiBa QuickLook app from WITTMANN BATTENFELDprovides a very simple way to check the status ofinjection molding machines and robots via Smartphone.
Molding machine and robot status requests
– List view; status colors are identical with LED colors of WITTMANN W8 pro appliances; green stands for auto-matic operation, blue for non-auto- matic operation, red for safety criteria not complied with.
– Overview page on calling up an appliance in the automatic opera-tion mode.
– Addition of a new appliance; entry of IP address.(from left to right)
WiBa QuickLook app, now avail-able free of charge from the Apple app store or from Google Play.
WITTMANN innovations – 2/2015 13
Molding machine and robot status requests WITTMANN Kunststoffgeräte GmbH, Vienna
This picture shows most of the employees of WITTMANN Kunststoffgeräte GmbH. About 320 staff members are currently employed in Vienna.
Portrait
In 1976, WITTMANN Kunststoffgeräte GmbH was established in Vienna.Its corporate history, which now consists of almost 40 years, is characterizedby continuous growth based on the constant pursuit of innovation.
InVienna,WITTMANNKunststoff-geräteGmbHhasdedicateditself
toallaspectsofautomationandalltypesofperipheralequipmentusedinplasticsprocessing.ThecompanyconstitutestheWITTMANNGroup’sprimarydevelopmentandcompetencecenterforbasicrobotmodels,includ-ingalloptionsandspecializedvariants,andalsofortemperaturecontrollers,dryairdryers,materialloadersandgravimetricmeteringdevices.
TheplantinViennaisalsoanimportantproductionplant.HeretherobotseriesW832toW873aremanu-factured,aswellasIMLequipment,thetemperaturecontrollersoftheTEMPROplusDseries,coolingwaterflowcontrollersandvariousinjectionmoldingtechnologyproducts.
TheglobalpresenceoftheWITT-MANNGroup,andespeciallyitsproductionfacilitiesintheUSAandinChina,allowstheVienneseplanttoconcentrateontheEuropeanmarket.Fromhere,thismarketisprimarilysuppliedwithrobots,temperaturecon-trollersandrelevantinjectionmoldingtechnologyproducts,withthelargestproportionofsalestraditionallybeingrealizedinGermany.
A location withdevelopment potential
AmajorindicatoroftheVienneseproductionfacility’spotentialfordevelopmentisthefactthatin2014itrealizedanabsolutelyremarkable13%increaseinsalescomparedtothepreviousyear.
About320employeesareworkingforWITTMANNatpresentinthethreeVienneseplants.InWolkersdorf,notfarfromVienna,yetanothernew
buildingiscurrentlyunderconstruc-tiondestinedfortheMaterialHandlingDepartmentandisexpectedtobereadyforoccupationinthefallofthisyear.
In2015,WITTMANNKunststoff-geräteGmbHwillcelebratethe40thanniversaryofitsfoundation.Itiscertainlyanoccasionforreflectingonthepastsuccessstoryofthiscompany,whichhasultimatelyledtoitbecomingtheonlysupplierofcompleteinjectionmoldingsolutionsworldwide.•
The main building of WITTMANN Kunststoffgeräte GmbH. The Viennese facility simultaneously functions as corpo-rate headquarters of the WITTMANN Group. Here, all information is brought together from the subsidiar-ies and representa-tive offices around the world.
BP00000034 – 1502
WITTMANNBATTENFELD INC.1 Technology Park DriveTorrington, CT 06790USAtel.: +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 ViennaAUSTRIAtel.: +43 1 250 39-0fax: +43 1 259 [email protected]
WITTMANNBATTENFELD GMBHWiener Neustädter Strasse 812542 KottingbrunnAUSTRIATel : +43 2252 404-0Fax: +43 2252 [email protected]