kurtz particle foam...
TRANSCRIPT
ProduKT -Thema
Particle Foam Materials – Our World KURTZ Particle Foam Machines
ProduKT -Thema
32
Our competitive lead in technology
optimizes quality, costs and delivery service
in our customers‘ production process.
Our Vision
Our Mission We produce and deliver plants, machines, tools and components and render services for the particle foam processing industry.
The requirements of our customers are the measure for our action.
Our worldwide network guarantees local service to our partners on a long-term basis.
We are a member of a strong, diversified group of companies and draw from this extensive synergy potentials.
As a division of a family business, we place as much emphasis on an appropriate increase of our own capital and its interest, as we do on long-term development and the safeguarding of jobs. Therefore, we pay special attention that all business divisions achieve above-average longterm profitability.
It pays off:Process Development by KURTZ
According to the Kurtz Group‘s vision, Kurtz SeRviceS optimizes the quality, costs and delivery time in your pro-duction process.
This means, we make our know-how available to you as our partner to achieve your production aims. As only the highest availability of plants and process mastering pro-
Kurtz SeRviceS is always focused on the complete plant. Use the opportunity and let our experts carry out a comprehensive valu-
ation of your production facility. An analysis of relevant processes as well as the diagnosis of weak points considerably increases
the efficiency and productivity of your plant. Our experts will be pleased to assist you in securing the best production conditions in
your plant and in realising determined improvement potential.
vide the most decisive advantage in a highly-competitive market.
it is not the investment costs that determine the profitabil-ity of a plant. Using our specific know-how, for example, we can analyse the influence of life cycle costs on the value of a plant.
Total Support
Technical consulting
engineering
Technical Support
Know-How Transfer
Spare Parts and Repairs
Optimization and Modernization
Staff Qualificationcost Analysis
Steam installation
Upgrade Potential
Spare Parts
Maintenance Strategy
Material Transport
Material Flow
Process
Programme Flow
control System
Pre-expanderFill injector
Steam Quality
Water Quality
vacuum
energy consumption
Machine condition
Hydraulics
Mould condition
Mould Maintenance
Mould change
Design andEngineering(incl. acquisition)
Installation and Commissioning
Operation(incl. unscheduled repairs)
Preventive Maintenance
Modernization and Upgrade
54 54
The pre-expander forms the basis for the process-ing of expandable polystyrene (ePS). KURTZ pre-expanders are the result of the logical implementa-tion of physical processes in machine technology, intensive exchange of the experiences of users and recommendations of raw material manufacturers.
The systems can be adapted to suit all requirements with maximum economic efficiency and reliable quality.
KURTZ pre-expanders guarantee a high degree of automation, reliable controls and reproducibility as well as an evenly expanded product. ease of opera-tion involves distinct economic advantages.
The demands of processors for shortest cycles and interim storage periods and compliance with the legal requirements in specific countries have led to the development of materials which cool more quickly and are low in pentanes, with a pentane content of just 3 - 4 %. KURTZ recognized this trend very early on and developed the right machinery to satisfy these requirements.
The First Step to SuccessHigh-Performance KURTZ Pre-expanders
KURTZ offers the processors of thermoplastic foams a full range of pre-expanders:
The product range comprises continuous and batch pre-expanders for block and shape moulding produc-tion, laboratory pre-expanders for research and devel-opment and HP pre-expanders for density adjustment of ePP.
The expansion vessel volume ranges from 0.15 m³ to 7 m³. With a bead density of 15 g/l a throughput volume of approx. 85 – 3,500 kg/h is achieved.
The new Tex 1000 batch pre-expander stands out by its low energy consumption at above-average throughputs and a precise process control. The beads are of a highly consistent quality and the density is distributed very evenly. The large discharge opening combined with the tilting mechanism of the pre-ex-pander tank allows fast material discharge. The new ventilation of the pre-expander tank accel-erates the media flow during the cycle. This leads to considerably shorter cycle times and energy savings at the same time.
Pre-ExpandingePS is pre-expanded as expandable beads are fed into the pre-expander. Hot water vapour as a medium first sof-tens the polystyrene beads, and the blowing agent thus released in them is activated. Pre-expansion involves vaporization and thus the swelling of the beads.
During intermediate storage the propellant gas is diffused from the expanded styrene granules and air penetrates. This “packed air“ is further processed in a shape mould-ing machine or block mould .
ePS may also be subject to a second expansion process to achieve lower particle densities. expandable poly-propylene (ePP) is expanded to low densities using so called HP pre-expanders.
Tex 1000 - low energy
consumption with
above-average
throughputs
Pre-expansion Process Flow
Batch pre-expansion
unit including raw ma-
terial feeding station,
weighing unit and fluid
bed
Gas diffusion in the bead
The bead expands completely only after steam diffusion
pentane vapourpentane diffusion
exce
ss p
enta
ne
exce
ss s
team
cell membrane 1- 8 µm
Pre-exPanders Pre-exPanders
steamsteam diffusion
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shaPe moulding machines
KURTZ Shape Moulding Machines Optimal Solutions for Any Application
Process Flow in Mouldings Production
Particle foam materials offer a wide range of possibili-ties with a broad spectrum of applications. The pre-expanded beads can be further processed either into ePS blocks on so called block moulds or into mould-ings made of ePS, ePP, ePe or co-polymers on shape moulding machines.
As a supplier of complete systems, KURTZ is, of course, pleased to be able to offer both kinds of plants. The shape moulding machine gives the product its final shape. The pre-expanded and intermediately stored material is transported into the mould. Hot water vapour - as medium - plastifies the beads and forces them to expand. Then the individual beads get in direct contact and fuse together to form a moulding.
all, also requires a high level of development in the machine design. This includes the reliability of function, flexibility in use, energy efficiency, short cycle times,
minimization of down times and, not least, the possibility of including efficient handling and material flow systems.
A major advantage of KURTZ is the wide-ranging know-how throughout the complete manufacturing process.
Our engineering departments can design complete factory layouts, which include both simple expansion machines and also the full range of associated supply systems and logis-
tics and handling concepts.
There are two possibilities to optain the perfect shape moulding machine for relevant applications and their technical requirements and batch sizes.
The machine manufacturer can either offer multiple machine types.- or there is the KURTZ solutionoffering three machine lines as standard:
A comprehensive range of shapemoulding machines provides the tailor-made solution for all appli-cations. KURTZ offers the most economically efficient machinery for every requirement – from large-scale series production to the flexible manufacture of a wide variety of small scale products.
KURTZ shape moulding machines are the international technological yardstick for the processing of expand-able thermoplastic foams. They allow pro-cessors to keep their options open for all important aspects of the process in the future. Our customers include well-known processors from the packaging, construction and automotive industries in all the major markets of the world.
Where generally special machines are expected, KURTZ meets the requirements with its diversified and thought-out standard elements.
High-tech production is not only based on material specification and the moulding’s design, but, above
shape moulding machine
for the processing of expandable
polystyrene.
KURTZ N-LiNe shape moulding machines are a solid basic model for ePS shape moulding production. The N-Line series is available in sizes S, M and L covering moulding areas of up to 2.5 m². When designing the N-LiNe shape moulding machines, the main focus was put on their functionality and a solid construction.
N-LINE - The BasisFor ePS Processing
N-LiNe shape moulding machines are predominantly designed for the market outside europe where most of the raw material is being processed. The shape mould-ings are generally not very complicated and are pro-duced in large numbers.
ce-conformity by the machine manufacturer is not required in these countries.
Maximum freedom for EPS processorsCost-effective version for
EPS packagings
High-end technology for highest demands
98 9
A-Line
A-LINE - New Benchmarks in ePS Processing
shape moulding machine
for the processing of
expandable polypropylene
(ePP) and polystyrene (ePS)
shape moulding machine
for the processing of
expandable polystyrene (ePS)
Dual Density Functionhigh density - bearing loadlow density - gentle packaging
In-Mould Skinning skinned surface
Skin Mouldinglaminated surfaces one-sided /
double-sided with foldback
Insert Mouldingfoaming in of structured parts
SQM/EQM - order-related
energy quantity monitor
Central docking position
for media supply
Machines of the TOP-LiNe series can doubtlessly be named “kings of shape moulding machines“They are the peak in shape moulding production and are used for applications where normal ePS processing reaches its limits as well as for ePP processing.
Fields of application•EPPprocessing(operatingpressureupto5bar)• dualdensityfunction• in-mouldskinning• skinmoulding• insertmoulding
Main advantages•KURTZsteamingsystemswithvalvesets developed by KURTZ • shortestcycletimes• lowestenergyconsumption• additionalenergysavingsbyfreesteamchamberdesign• longermaintenanceintervals• bestaccessibility•SQM/EQM,D-Logandfurtherperipheral equipment reproducibly prove energy efficiency
„HyPo drive“ servo hydraulicsAs an option to standard hydraulics, servo hydraulics can be delivered, combining the ad-vantages of both electrics and hydraulics. This means an increase of productivity of up to 20 %. More advantages:• noconstantnumberof revolutionswhich means considerably reduced noise level• unlimitedmoulddesign• constantspeedoverthewholeway• permanentlyevenforceduringmovements (crack filling, demoulding, ejection, ...)• reducedelectricalenergyrequirement
Shape moulding machines of the A-LiNe series are de-signed for a maximum operating pressure of 1.5 bar.The machines can be equipped with every common han-dling option.
KURTZ A-LiNe shape moulding machines are available in 4 sizes (S – XL) covering a moulding area of up to 3.2 m².
They are characterised mainly by their central docking station. The fixed and movable machine side can be equipped with a number of different steam chambers.
TOP-LINE - for Highest Demands in Processing ePS & ePP Par ticle Foam Materials
Following mould types can be used with KURTZ A-LiNe shape moulding machines:
• originalKURTZmoulds
• mouldsofcompetitorsinoriginaldimensions
• monoblockmoulds
• Eco-LTHandLTHmoulds
in this way A-LiNe shape moulding machines offer maxi-mum freedom to the ePS processors. They can also be extended by options like SQM/eQM and D-Log.
shaPe moulding machines shaPe moulding machines
1110
Unconventionality Is Our StrengthKURTZ Technology also for individual Solutions
KURTZ shape moulding machines are extremely flex-ible and ideal for individual configuration. However, there are certain applications which demand special solutions. KURTZ offers a wide range of special machines which are especially designed to meet the customers‘ requirements.
When, for example, manufacturing sun visors or bicy-cle helmets, certain insert parts have to be placed into the mould by hand. in order to ensure that operatives can do this quickly, easily and safely, the technology known as shuttle technology has been developed. This makes it possible to 1.) insert, 2.) weld and 3.) laminate the parts in question in a single automated process. New developments in the area of headrests or side impact cushions in car manufacture open up further areas of application for ePP.
The trend here is also in the direction of foaming and laminating in a single cycle. For this purpose KURTZ offers a special machinery concept with a thermo-form-ing unit integrated into the shape moulding machine.
Shape mould-
ing machine,
bed and roller
version, for the
manufacture of
insulating panels
Shape moulding machine for
particularly energy-efficient moulding
Plant for the manufacture of covings
using the in-Mould Skinning technology
Manufacturers of icF parts (insulating concrete Forms, elements used in housing construction) have particular requirements of these machines. Maximum throughput of shape mouldings with plastic or metal inserts are achieved on shuttle machines with, e.g. 3 cavities.
instead of a shuttle, the rotation technology uses a rotating steam chamber with option for positioning in-serts. This saves space and gives shorter cycle times.
The bed and roller version is used by KURTZ for mounting surfaces larger than 2.5 m and very heavy moulds. The moving steam chamber moves along a machine bed; guide rails are not used.
For demanding and complex mouldings with inserts, the Rotax technology was developed. Two identical and horizontally rotatable mould halves are mounted on the fixed side. The counter part is fixed on a con-ventional and horizontally movable press frame. While a moulding is foamed inside, the operator or a robot can remove finished mouldings from the outside and can equip the mould with inserts for the next cycle. compared to traditional processes, this technology considerably reduces the cycle times in all fields of ap-plication.
The transfer technology uses several moulds for the manufacture of a shape moulding. The beads are fed into a hot mould and sintered together with the as-sistance of steam. After a brief period in which the pressure of the foam is reduced, they are “transferred” to the cold mould. contact of the moulding with the relatively cold mould walls cools the foam further and stabilises it to such an extent that the moulding can be removed. This enables high productivity in combination with low energy consumption. The options for inserts and lamination open up further areas of application.
KURTZ also offers solutions for the manufacture of floor heating panels with sound insulation and two den-sities, also based on the transfer technology.
Rotax machine for the production of
ePP parts with inserts
Machine for the production of icF
components (insulating concrete
Forms)
Machine for the production of
skin-moulded fish boxes
Machine for the production
of lost-foam parts
Machine for the production
of ePP parts with inserts
cusTom-madecusTom-made
1312
Lightweight, Inexpensive & Flexible:The KURTZ ePS Pallet coated With Foil on Both Sides
EPS pallet with KURTZ
know-how: Foaming and
film coating on all sides
in one single process,
with a weight of only 3.5
kg bearing a load of up to
1,000 kg.
Production of Roller Shutter Casingscustomer-Specific High-Tech Solution
Lately, KURTZ was confronted with the topic of produc-ing ePS roller shutter casings. conventionally, they are produced with driven mono-block moulds. Afters studying all aspects of this project, KURTZ came to the conclusion that the production with a new KURTZ shape moulding machine specifically developed for this purpose was more profitable than common production methods.
various models that differ in insulation thickness, height, roller shutter diameter and geometry can be realised
with only a few moulds. The insulation thickness can be adjusted infinitely and fully automaticly on the outside of the roller shutter casing. The total concept consisting of special machine and moulds is much more favourable than all other production methods and guarantees a short ROi.
We developed a vertical machine type K761 v, with steam chamber dimensions of 700 x 6100 mm.The lower steam chamber is in “shuttle“ design which moves to an ergonomic position for the operator when inserting the parts. Armouring iron and aluminium bands are put into the mould before filling in order to receive a product that does not have to be reworked af-terwards. Simultaneously to the insertion process, the finished product is put on a table docked on the shuttle. The finished roller shutter casings can also be stacked and palletised automatically by means of subsequent KURTZ linear handling systems.
Today, ePS pallets with film coating are a sensible
alternative to all conventional pallets made of timber,
pressboard or by injection moulding.
They combine a number of positive properties in only
one product and particularly air freight can no longer
be imagined without them.
Alongside the great savings in weight of up to 15 kg
per pallet, simple cleaning with water, easy handling
without the risk of injuries and the additional cushion-
ing and insulation properties, the resistance to abra-
sion necessary for air transport is also guaranteed.
Specifically for the production of these pallets, KURTZ
has developed a unique manufacturing process per-
mitting production of the complete pallet in only one
machine.
KURTZ ePS pallets are made in sandwich construc-
tion comprising an ePS core and a PS film coating on
all sides. After the ePS core has been foamed and
when the mould is still hot, the core is directly covered
with film and fused with its entire surface by means of
steam. in this way the ePS core and film form a solid
connection. A trimming of protruding films is normally
unnecessary. compared to other ePS pallets, up to 2.5
kg of film per pallet can be saved with the same dy-
namic loading capacity!
it is also a fact that amongst all ePS pallets on the
market, the KURTZ pallet stands out with currently
lowest manufacturing costs. For the 1,200 x 1,000 mm
pallet sizes iSO certifications for 500 kg and 1,000 kg
dynamic load were obtained.
As a result of varied experience, KURTZ is in a position
to develop tailor-made pallets according to most differ-
ent customer requirements.
ePS roller shutter casings with
armouring iron and aluminium
bands
Technology
14
Right Mould Design for 24” ICF Block
no cooling
no cross steaming
parting line
No crack filling possible !
0 75.000 150.000 225.000 300.000
14
Technologies + Processes
TechnologiesKnow-How to Do With The Foaming Process
Technologies + Processes
Schematic portrayal of the
transfer technology
As a competent partner in the supply of complete plants for the processing of particle foam materials, we have built up quite a lot of process knowledge in the course of 30 years. This is why our machines do not look like ordinary production tools, but optimisation of the process-ing is at the centre of attention. Many procedures have been developed by KURTZ in the course of the years and patents applied for or legal protection of utility patents provided.
An example of a milestone here is the LTH process patented by KURTZ. it has established itself as a particularly economical process for the production of large quantities of mouldings.
This technology works without great volumes which have to be filled with steam and air or evacuated. Steam chamber configurations known up to now are no longer needed. The cooling water no longer comes into contact with the particle foam material.
The LTH method leads the energy directly into the foam. The savings in consumption which can be achieved with this innovative modular process are up to 35 % in water, even up to 70 % in air and steam.
The skin moulding system used by KURTZ is one of the leading refining processes for ePS and ePP mouldings. Shape mouldings can be foamed and coated with film in one working step inside the same machine.
Bicycle helmet
in-mould technology with insert
Motor block
lost-foam pattern
Transport packaging
dual density technology
The KURTZ dual density technology gives mouldings a higher density at certain points and thus higher strength. This is necessary, for example, for mouldings for specific transportation tasks.
With the in-mould skinning technology of KURTZ the surface of the ePS moulding is refined. The advantage is that a smooth, welded surface is produced in one work-ing step. This technology opens up a variety of new markets. Ornamental battens for ceilings, seedling trays, ice-cream packaging are only a few of the examples.
comparison of energy
consumption with
differing technologies
comparison of costs in differing
methods
ICF production
Mould design for
24“ blocks
The so-called lost-foam method or casting with lost-foam models in sand free of binder is being used to an in-creasing degree all over the world. The particular know-how in this method is in the design of the moulds. They are equipped with a number of integrated steam cham-bers, with each individual steam chamber having a separate regulation for steam, air and water.
This technology is mainly used in the automotive industry, e.g. for the production of cylinder heads, brake disks, crankshaft housings, oil pump housings and intake manifolds.
K1016 Tv3 shape moulding machine with
transfer technology
1716
Shape Moulding ApplicationsWe Give Shape to ideas
aPPlicaTions
ePS mouldings are used as packaging for food and drinks or technical products. They protect and insulate. Seed-ling trays made of this versatile material offer advan-tages. in the building industry, sound insulation and floor heating panels but also decoration elements are used. complete houses are built of so-called icF elements or are insulated with ePS sheets - a positive contribu-tion to climate protection. in the leisure-time industry, for example, bicycle helmets or fun-boards are made of the all-rounder ePS.
Similar kinds of particle foam materials of polyethylene (ePe), polypropylene (ePP) or co-polymers open exten-sive possibilities of application with regard to increased heat resistance, form resilience and insulation character-istics - for example in use in the automotive area as SiP’s for side impact protection or as bumper cores.
Technical mouldings can be used as reusable packaging for all shock-sensitive components, as construction parts in high-tech devices or as insulation material for boilers, for example.
aPPlicaTions
1918
EPS Block MouldsNew Steam for Top Quality Blocks
vario block mould
visualization
The processing window in terms of weight gain, required steam quantity and stabilisation phase is becoming smaller and smaller.
The Monoflex is the solution for the flexible block production. Also in a vertical finish, but with a mov-able side wall, it provides variable block dimensions. Thanks to the generous design of the side wall drive, 100 % recycling material can be used.
As a special solution the vario block mould is avail-able in horizontal version according to customer requirements.
Blocks produced on KURTZ block moulds excel thanks to a homogeneous distribution of weight, good block fusion and low residual moisture. in combination with short cycle times, KURTZ blocks are guarantors for the fact that the processors can secure an important competitive advantage on their markets thanks to the outstanding quality of their products and also their economical production.
By request, KURTZ can also plan and deliver the required peripheral equipment designed to meet the customer‘s production capacity.
Monoflex
vertical block mould with
movable side
KURTZ block moulds stand out due to their high pro-ductivity, reliability and quality. in this way the processor can cope with the ever increasing prices of raw mate-rial and energy on the market.
The control concept of KURTZ block moulds was funda-mentally revised to make the operation more user-friend-ly and to make full use of the block moulds potentials.
The control is realised on a colour touch panel with an integrated PLc. A high-performance cPU allows a pre-cise steam pressure regulation and thus reproducible sequences and blocks. The simplified menu navigation allows for an intuitive operation and quick access to numerous sub-functions on the one hand and provides a multitude of survey information on the other hand. The parameter settings for the moulding process offer new possibilities and are directly visualised by a graph-ic illustration. Since the operator can freely and flexibly set programme sequences, steaming possibilities are unlimited.
Block weighing device
with lifting unit
(stroke 1800 mm)
innovative and self-explanatory user interface of the blockmould
control for a simple and clear operation
Block printer
The vertical ecomat block mould with fixed dimensions has captured the market. Due the cleverly optimised ventilation and steaming technology it sets benchmarks in block processing.
blocK moulds
2120
Cutting Lines for EPS-Scheet CuttingQuick, Precise And economic
cuTTing lines cuTTing lines
in the field of sheet cutting, KURTZ provides all the cutting systems the world markets demand. KURTZ manages to give block processors decisive competitive advantages with innovative technologies
in view of cutting speed and throughput, the Proline cutting line is beyond competition and is currently one of the fastest plants on the market. The well-proven automatic KURTZ wire adjustment is not only used for sheet cutting but also for trimming and cross cutting.
Besides high cutting speeds, the long stroke tech-nology who was developed and patented by KURTZ provides for an outstanding surface quality in view of smoothness and reduces the picture-frame effect con-siderably. in this way the thickness tolerances of the cut sheets can be kept at a very low level. completely automatic waste disposal systems for the disposal of the trimmings produced in the cutting pro-cess not only increase the quality of the products but also ensure that the production systems present themselves in a flawless condition.
The plant control with graphic user interface enable simple and clear operation even of complex plants. if requested, an integration in a higher-level PPS system is possible as well as teleservice by means of an adapter.
Fully automatic cut-
ting line with a
cutting capacity
and precision way
beyond competition
Block turner
with centring
function
Cutting wire
adjustment
Hot wire cutting frame
with wire adjustment
Innovative and self-explan-
atory user interface of the
plant control for a simple and
clear operation
2322
handling sysTems
Handling SystemsFully Automatic Factory
Handling systems are used to rationalise work processes in the production of mouldings in such a way that produc-tion and removal of the mouldings from the machine is done semi or completely automatically as far as possible.
The profitability of the use of handling systems is primarily dependent on the location or the wage level in the region in question. Reduction of personnel costs is in the foreground.
The mouldings’ design, e.g. contour, surface quality, weight, integration of inserts or room height, has a great influence on the possibility of use of handling devices. Stackability and stacking capacity of the mouldings, vent-ing of the stacks and the stack heights must be taken into account in the run-up.
in block processing companies, very personnel-intensive manual work is frequently done. KURTZ machine con-cepts with intelligent handling systems help the proces-sors to recognise and set free rationalisation potentials in their company.
KURTZ provides processors with a wide range of highly specialised handling components for a state-of-the-art material flow concept tailor-made to match the require-ments.
Stacking table
Glueing station
Fully automatic sheet handling
handling sysTems
EPS shape moulding
machine for the production
of fish boxes in the skin-
moulding process with hand-
ling systems for foil insertion
as well as removing and
placing of the mouldings on
stacking tables
Block positioner and turner Removing, stacking, glueing and
packing of boxes
Sheet removal and handling
The most modern EPS proces-
sing plant in Northern Europe
EPS shape moulding plant
with KURTZ technology in
the US
KURTZ prepares ideal handling concepts and solutions in close cooperation with the customer. These concepts meet the customers‘ structural conditions and requi-rements, no matter if it is a fully-automatic block or shape moulding plant.
KURTZ handling and automation concepts guarantee a short ROi for the customer.
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EngineeringTotal competence in the Foaming Process
Processing of ePS, ePe and ePP provides attractive possibilities of diversification even for “material outsiders“. KURTZ engineering realises complete production solu-tions for professionals and starters for maximum produc-tivity, flexibility and profitability at any location in the world they desire.
KURTZ engineering includes project analysis, consul-tancy, planning, cost calculation, system construction, installation and commissioning, training of personnel, application technique support and service on site.
KURTZ complete solutions provide all the professional benefits which make processing of thermoplastic foams competitive: minimisation of investment costs, technology saving energy and personnel, tailor-made and universal
1 Pre-expander
2 Fluid bed dryer
3 Storage silo
4 Shape moulding machine
5 Block mould
6 Universal removing device
7 Stacking table
8 Glueing station
9 Removing conveyor
10 Transport cart
11 Mixing and dosing unit
12 Block storage
13 cutting line
14 Pre-breaker with mill
15 Dust separator
16 Filter station
17 extruder
18Feed water treatment for steam boiler
19 Steam boiler
20 Steam pressure red. valve
21 Steam accumulator
22 Water cooling plant
23 Water pressure tank
24 condensate return
25 compressor
26 Air receiver
27 central vacuum
Components
complete plant for the
manufacture of shape mouldings
processing of raw materials, and flexibility due to mould receivers independent of the system. Just-in-time pro-duction, profitability even in small series, forward-looking recycling etc. Tell us the products you would like to manu-facture and we will draw up the professional complete solution for you.
Quality assurance is indispensable for the documentation of constant product quality. it demands a regular check of the steam, water, air and vacuum media and of the production materials being used.
This includes an incoming check of the raw materials and an optimal monitoring of the production data during pro-duction. The real-time recording of the process parame-ters during the production process documents the quality
of the products. By connecting the individual control units to a host computer, these measures are considerably facilitated, automated and freed from input errors.
Recycling material can be fed to the production circulation via the internal operational circulation through crushing, dedusting and feeding devices, resulting in savings of raw material.
Raw materials that can no longer be used can be pro-cessed further either mechanically or thermally.
Steam generator and compressor
Silo system Silo control unit
Block handling
complete plant for block processing
comPleTe soluTionscomPleTe soluTions
SeiTe
26 27
Filling SystemsMaximum ef ficiency
Alerts and error messagesMedia pressure screen
Filling sysTems Process moniToring & oPTimizaTion
The appropriate filling of the mould is an important step when producing mouldings of particle foams. The qual-ity of the moulding is substantially determined by the filling process. Density distribution and an even filling are of particular importance. The efficiency of the filling systems used has a significant influence on the resulting energy consumption. Total air consumption and the cooling of the mould walls are decisive in this connection. For a long time KURTZ has been providing cost-saving solutions to achieve the optimum filling process.
B-Jet, the filling injector with turnable upper part offers easy maintenance and reduces the times for the mould change. Furthermore it is pressure-tight and vacuum sealed.
When pressure filling with certified pressure tanks, coun-ter pressure filling to reduce the volume of the beads or low-pressure filling – the maximum admissible loading of material in the airflow is always the focal point.
The steaming of the filling injectors’ closing piston avoids fusion failures at the moulding. Large-dimen-sioned injectors allow maximum material throughput, also with big-size beads.
The filling injector B-Jet “TraceLess“ fills the cavity indi-rectly and thus protects filigree mould surfaces, mould decors or coatings from wearing. This reduces the costs for mould maintenance considerably and extends the mould’s lifetime. Another advantage of the B-Jet “Trace-Less“ filling injector is that there is no “plug“ at the moulding anymore and the plunger hardly leaves any traces.
in the production of particle foam products, process-ing plants are always subject to fluctuations in process energies. Monitoring physical values and supply media as well as recording measured data are great advan-tages for the processor. When the individual operation windows required for each processing plant are fixed, a safe operation as well as correct and constant process parameters can be proved.
At the same time, D-Log helps to cut wastes in produc-tion by displaying operation anomalies. Steam, air and water can be monitored regarding pressure and tem-perature. vacuum and material transport should also be checked for pressure. The results of this monitoring can be used to simply determine measures to improve the plant availability. Besides a visual display, D-Log can be used to switch off a plant in case the measured data are outside the defined range of tolerance.
The dramatic rise in the oil price led to a cost explosion in the particle foam industry.
The KURTZ SQM monitoring method can measure the steam consumption and evaluate the energy costs per cycle or check optimisation measures for single shape moulding machines with minimal effort. The KURTZ SQM
B-Jet - a generation of filling injectors with per-
fect installation and maintenance options
SQM: steam quantity monitoring directly at
the shape moulding machine via notebook
IMPOSSIBlE? No!
- The KURTZ B-Jet
“TraceLess“ can fill
around the corner with-
out leaving any traces.
does not require a common flow metre (vortex shedding device) with necessary settling sections. Some pressure and path sensors connected to the media block of the KURTZ shape moulding machine and an analyser unit are enough. The measured values are displayed on a laptop or machine terminal.
The extension, the KURTZ eQM measuring method, can additionally record air and electricity consumption. it contributes to a further optimisation of the processes and thus to a considerable reduction of energy consumption in particle foam processing.
ejection function and micro-injectors complete the pro-gramme range. Filling injectors from our competitors can also successfully be replaced by the more capable KURTZ design.
With more than 100 different designs KURTZ is in a position to provide the most suitable filling injector for every application.
D-log: Media monitoring
Order-related SQM/EQM En-
ergy Quantity Monitor
D-Log, SQM & EQMThe incorrupt Scouts
2928
ServiceWorld-Wide, 24 Hours, Unique!
The area of service and after-sales is a strategic factor with KURTZ. Our long-term objective in after-sales is ensuring the production properties of KURTZ machines for a long service life. Alongside repairs, assembly and maintenance, we are also at your side with tailor-made training programmes for your personnel as well as individual consultancy on system engineering for main-tenance, conservation of value and stock-keeping right down to assessment of the production systems.
As even very short machine down-times can mean high losses of turnover in our customers‘ high-per-formance production systems, we do not only offer reli-able and competent service, but also quick availability: 24 hours a day right round the world!
Quality and service have been an integral part for the KURTZ particle foam machine sector for quite a long time now. And the basis for the services be offer has been and will be the world-wide quality of our product and service range that aims to guarantee de confi-dence and business success of your customers as the users of our products and to secure them in the long term.
Spare PartsBroad Availabil ity
Remote maintenace Maintenance & repairs
The KURTZ spare parts service enables correct se-lection of the spare part needed from the catalogue without having detailed knowledge. The selection of articles contains the most frequent spare parts.
For parts comprising further sub-groups, a group hierarchy has been introduced. This classification of various spare parts makes it possible to localise the individual part of a larger construction group being looked for in the catalogue.
As further facilitation of finding spare parts, pictures, sketches and information on features of the articles have been included in the catalogue.The spare part catalogue is available online at: www.kurtz.de
During use, the navigation bar is a great help, as links to the corresponding pages of the catalogue have been deposited here behind the titles.
Online spare parts catalogue
service sPare ParTs
SeiTe
3130
1779
18
52
1860
18
9619
2119
6219
6819
71
1982
1983
1984
1985
1988
1990
19
9019
9319
9620
01
2003
2003
2006
20
06
2006
20
06
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2009
since 1779
The Kurtz Group
process model
The Kurtz Group
The Kurtz Group is comprised of several companies from different business sectors. The strategic management is positioned in Kurtz Holding GmbH & co. Beteiligungs KG., while the operational responsibility lies with the individual segments.
Our integrated management system directs all the pro-cesses and assures that the demanding quality require-ments of our customers are satisfied. We regard the protection and preservation of nature as a great respon-sibility. We continually investigate possibilities for making our own contribution to environmental protection.
A matrix organisation with the business segments PLAS-TicS, MeTALS, eLecTRONicS and SeRviceS ensures the greatest possible degree of flexibility and customer proximity.
Business Segments And Products
Worldwide More Than 850 People
Founded as iron hammer works in 1779 in Hasloch in Spessart, the Kurtz Group has developed into aninternationally operating conglomerate. Today, we are technological or world market leaders in many fields.
The corporate group is in the ownership of the sixth generation of the family.
The management can fall back on an advisory board consisting of excellent industry personalities.
Our control center:
The headquarters of the Kurtz Group are in Wiebelbach
– not far from the iron hammer works in Hasloch.
Where it all began:
The historical iron hammer works in Hasloch, Spessart,
remains in operation today as an industrial memorial.
Fine Traditions And A Bright Future
hisToryKurTz grouP & managemenT sysTem
Foundry products Stencil Printers Pre-expanders Know-How Transfer
Machining Soldering Systems Shape Moulding MachinesUsed Machines and Assembly Service
casting Machines Soldering Tools Block mouldsTotal Maintenance Quality Service
Sheet Metal Technology inspection Systems Sheet Processing innovation Support
Rework Systems engineering
Foun
datio
n of
the
iron
ham
mer
wor
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Has
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Foun
datio
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the
iron
foun
dry i
n Ha
sloch
Firs
t mac
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build
ing a
ctivit
ies
Foun
datio
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“MGM
Met
all-G
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rei-M
annh
eim“
Pate
nt re
gistra
tion
of th
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ctrica
l sold
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iron
New
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foun
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Prod
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solde
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mac
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Prod
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par
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mac
hines
Take
-ove
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inium
foun
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Prod
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foun
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mac
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s
Foun
datio
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Kur
Tz N
orth
Am
erica
New
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Foun
datio
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ar E
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Hon
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Take
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Alta
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Foun
datio
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urTz
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Kur
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Take
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solde
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tech
nolog
y
Foun
datio
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MBW
shee
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logy
Foun
datio
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Kur
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Foun
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st in
Mos
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HIP
Ham
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Inno
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Prod
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Prod
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ProduKT -Thema
SeiTe
TECHNOLOGIES & SERVICES FOR METALS • ELECTRONICS • PLASTICS
Kurtz Holding GmbH & Co.Beteiligungs KGKreuzwertheim, [email protected]
MBW Metallbearbeitung Wertheim GmbHWertheim, [email protected]
ERSA GmbHWertheim, [email protected]
KURTZ North America Inc.Plymouth, [email protected]
KURTZ Far East ltd. / ERSA Asia Pacific Hong [email protected]
KURTZ Shanghai ltd. / ERSA ShanghaiShanghai, [email protected]
Kurtz Zhuhai Manufacturing ltd Zhuhai, china
KURTZ France S.A.R.l.Talant, [email protected]
KURTZ Italia S.R.l.Travedona Monate, [email protected]
KURTZ Systems Africa (Pty) ltd.KwaZulu-Natal, South [email protected]
OOO KURTZ OstMoscow Region, [email protected]
KURTZ GmbHWerk WiebelbachFrankenstraße 2D-97892 KreuzwertheimTel. +49 (0) 93 42 807-0Fax +49 (0) 93 42 [email protected]
The World is Kurtz Present in 135 countries
www.kurtz.info www.kurtz.dewww.kurtz.ru
KURTZ Particle Foam Machines
KURTZ GmbH, KreuzwertheimPhone: +49 (0) 93 42 / 807-0
KURTZ North America inc.Phone: +1 920 893 1779
KURTZ Far east Ltd.Phone: +852 2331 2232
KURTZ Shanghai Ltd.Phone: +86 21 3126 0818
KURTZ Zhuhai Manufacturing Ltd.Phone: +86 756 399 7888
KURTZ France s.a.r.l.Phone: +33 (0) 3 80 56 66 10
KURTZ italia s.r.l.Phone: +39 03 32 97 80 35
KURTZ Systems Africa (Pty) Ltd.Phone: +27 (0) 32 538 1200
OOO KURTZ OstPhone: +7 91091 68534
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