SPECIALIST rubber machine maker Maplan highlighted the MTF750/160 editionS with Cure² process optimisation, in a collaboration with PETA Mould Construction from Germany for the fully automated production of Frisbee discs or membranes. The mould possesses two cavities of different sizes. Direct injection into the cavities is performed through a dual nozzle cold runner using hydraulically actuated shutoff nozzles. In order to achieve an optimal degree of filling, the shut-off nozzles on the machine’s control system are adjusted separately. The demoulding employs a middle plate sliding system used in conjunction with a push-out device. The 160-tonne machine has a standard energy-saving, servo-electric CoolDrive II drive concept, allowing for 50% energy savings. The Cure² process optimisation system monitors all relevant production parameters in real time and calculates the optimal heating time for the moulded parts using current data, allowing for a 40% increase of productivity, says the Austrian firm.- Meanwhile, Maplan’s MTF3500/580 machine is the result of a cooperation based on a year-long partnership with Vorwerk Autotec. It combines different sliding systems that can also handle heavy tools of several thousand kilogrammes. For quicker feeding of inlay parts, it can be coupled with a Liftmaster. Consequently, a semi-automated production process for the manufacturing of metal-composite parts in the automotive industry is realised. The “ergonomic” clamping unit, with low operating height provides optimal conditions. The exhibit shown was also equipped with a servo-electric drive and tempering device. Additional drive aggregates and software package provide an optimal overall system. The firm also premiered its new C6000 web controller, equipped with a 21” full HD panel with multi-touch. It offers the ability of utilising different cross-platform terminals for visualisation and relies on the latest Intel processor technology. Other characteristics of the hardware are fast industrial memory technology based on semiconductors, Powerlink system bus for connection of control components and the use of RFID technology for different tasks.
Size reduction equipment supplier Pallmann launched a new grinding system for vulcanised rubber waste to be turned into fine powder for direct reuse in rubber processing. A key feature of Karakal is its ability to devulcanise technical parts and retreaded tyre waste as well as 4 mm-sized material, fed continuously by a series of screws positioned along the gap between the rollers. The firm says that though a large amount of rubber waste from old tyres is already re-used, mostly as low-grade filler in building and construction, some is also pyrolysed into carbon black, oils, fuel gas, and other residues. In the past, cryogenics have been used for producing powder from rubber waste, but this creates particles with cubic geometries. More recently, conventional roller mills have been used, but these create particles of around 800-1,000 microns, which is too big for reprocessing operations, and the process is also energy-intensive. Karakal relies on friction and has two main rollers with a diameter of 400 mm and a length of 1,000 mm, each covered with micro-serrations. Roller speed and direction of rotation are controlled via variable frequency drives. The distance between the rollers can be adjusted to an accuracy of 0.1 mm. The rollers are pre-tensioned by an assembly of springs and a hydraulic cylinder. Pallmann has applied for several patents on technology incorporated in the equipment.- Germany-based KraussMaffei Berstorff introduced the EcoLine for the production of rubber profiles. According to the company, the microwave channel of the new EcoLine reduces energy costs and environmental impact. The firm says, “Three essential OEE (Overall Equipment Efficiency) targets o f maximum machine availability, high output rates and unparallelled final product quality have played a vital role in the development of the new system.” Each of the three microwave channel modules is equipped with a generator designed to supply 6 kW power. A circulator integrated into the energy supply transfers the energy not absorbed to the connected water load, thus improving the magnetron service life. The microwave generators are arranged above and below the conveyor belt, allowing for a homogeneous field distribution. Both the microwave power and the conveyor belt speed can be continuously adjusted. The microwave channel has an effective cross-section of 130 mm width and 60 mm height. KraussMaffei Berstorff claims to be the only manufacturer worldwide that has managed to reduce the opening and closing times of microwave and hot air treatment channel doors to a few seconds. Where frequent material changes are necessary, the pneumatic doors reduce set-up and cleaning times substantially, says the firm. When the treatment channel is opened, the hot internal panel of the doors automatically moves downward towards the frame, giving operators easy access to the profiles and enhancing operator safety. The energy savings achieved with the EcoLine system are the result of reduced waste gas loss and the use of energy optimised switched-mode power supplies in the
microwave channel. Closed circulation of the process air provides maximum cost savings because the air is heated centrally and 90% of the energy-intensive hot air remains in the system. Another new feature is the improved thermal insulation of the process chambers. - Austria-based Elmet debuted its new production approach for the processing of liquid silicone rubber (LSR), which cures under UV-light from a LED source. According to Elmet, this method eliminates the high curing temperatures required for conventional heat-curing LSR grades. Thermoplastics with a low melting points, including PP, PE or PMMA, are suitable for two-component injection moulding with LSR as the soft component, otherwise materials providing higher temperature resistance that are more costly are required, such as PA or PBT. Thus, a broad diversity of new applications is opened up in the production of hard/soft composites using LSR as the soft component. An application example is a soap dish made of translucent PP that has a directly moulded-on silicone support base. For making this item, Elmet had developed a complete turnkey production system in cooperation with Austrian machine manufacturer Engel and raw materials supplier Momentive Performance Materials. One key element of the system is the mould operating in a standard injection moulding machine, such as Engel’s e-mac 170/50. In this mould, which has steel sealing surfaces on both mould halves, the moulding is initially produced from UV-transparent PP. After demoulding and relocating this PP part to a higher mould region, the LSR base is then moulded onto it. Afterwards, the silicone component is exposed to UV light through the PP article for curing. The light sources used in this application are rugged LED lamps, which are noted for their long service life. Moreover, the activation point and duration of these LEDs can be accurately matched to the curing reaction so as to minimise energy input and cycle time. The system is equipped with the new air-powered injection unit for the LSR component. Integrated into the machine control system, it
provides a repeatable injection pressure and velocity for process stability. The space-saving TOP 1000 Mini metering system is another novelty; it reportedly delivers an accurately metered amount of LSR into the injection unit. The cross-linking agent and dye are introduced using a standard additives line. - conventional heat-curing LSR grades. Thermoplastics with a low melting points, including PP, PE or PMMA, are suitable for two-component injection moulding with LSR as the soft component, otherwise materials providing higher temperature resistance that are more costly are required, such as PA or PBT. Thus, a broad diversity of new applications is opened up in the production of hard/soft composites using LSR as the soft component. An application example is a soap dish made of translucent PP that has a directly moulded-on silicone support base. For making this item, Elmet had developed a complete turnkey production system in cooperation with Austrian machine manufacturer Engel and raw materials supplier Momentive Performance Materials. One key element of the system is the mould operating in a standard injection moulding machine, such as Engel’s e-mac 170/50. In this mould, which has steel sealing surfaces on both mould halves, the moulding is initially produced from UV-transparent PP. After demoulding and relocating this PP part to a higher mould region, the LSR base is then moulded onto it. Afterwards, the silicone component is exposed to UV light through the PP article for curing. The light sources used in this application are rugged LED lamps, which are noted for their long service life. Moreover, the activation point and duration of these LEDs can be accurately matched to the curing reaction so as to minimise energy input and cycle time. The system is equipped with the new air-powered injection unit for the LSR component. Integrated into the machine control system, it provides a repeatable injection pressure and velocity for process stability. The space-saving TOP 1000 Mini metering system is another novelty; it reportedly delivers an accurately metered amount of LSR into the injection unit. The cross-linking agent and dye are introduced using a standard additives line.
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