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            injection-11


            injection 11
            June 2005
            News, Facts & more. Information for our customers.
            In this edition

            Engel’s global production principle

            Universal – and yet unique
            >> As a manufacturer of injection moulding machines, Engel already began to systematize its production concept according to the so-called platform and modular principle several years ago. The ENGEL VICTORY series, which was first introduced 2001 at “K” in Düsseldorf and today comprises tiebarless injection moulding machines with clamping forces ranging from 250 to 6,000 kN, reflects the consistency with which this concept has been realized. in terms of economic efficiency, is the entire corporate network on which the production concept is based. During the past several years, Engel has consistently standardized and interlinked both its organizational infrastructure and its design facilities and SAP systems, ensuring that all its manufacturing sites in Europe, North America and Korea operate with the same data. As this data pool is constantly augmented with data from all new projects, we are also familiar with market-specific differences in customer requirements between Europe, America and Asia. As a globally operating company, we manufacture our injection moulding machines at the site closest to the customer so as not to delay delivery unnecessarily through long transport distances and times. Not for nothing have we set up production facilities in North America and Korea in addition to our parent factory in Austria. So that we can process machine orders with the same efficiency at every production site, our investment in new machines is based on a consistent strategy of uniformity wherever possible. Moreover, the economic advantages gained through world-wide purchasing management can be passed on to our customers.

            The Engel network: systematic, comprehensive, global

            >> Page 2: ENGEL E-MOTION: economical not only as a highprecision and/or fast-cycling machine but also when used just as an “ordinary” standard injection moulding machine.

            The new platform-plus-module concept
            Meanwhile developed to absolute perfection, the new concept permits the manufacture of machines in exactly the same way in all of Engel’s factories world-wide – in the shortest possible production time and in accordance with the customer’s individual requirements, yet featuring the same quality and reliability as a time-tested standard machine. Today, every ENGEL VICTORY can be tailor-made from a platform adequately rated for the clamping force – the tiebarless machine frame including base frame and basic hydraulic system – and a modular system comprising around 350 prefabricated modules – and all at an economical cost-performance ratio.

            Austria

            >> Page 3: The new index plate drive from Engel: compact design, high positioning accuracy, high rotational speed, completely maintenance-free.

            Better cultural understanding for greater customer benefit
            Engel operates not only in different geographical locations of the world but also – by the same token – in different cultures. It is through our local production sites in particular that we have access to a great many different – often very different – cultures. Continual personal contact and the strategy of regular job rotation within Engel’s world-wide network help us to surmount any possible barriers which may stand in our way at the beginning. All these aspects find their way into our “modular production concept for the global injection moulding machine”, that is to say: >> Engel machines for the world market broadly and reliably based on state-of-the-art technology without forfeiting individuality. >> The machines are also quickly available, for we have been able to reduce our production times by half compared with around ten years ago. >> And our customers benefit not least from the enormously improved cost-performance ratio, for better performance increases their competitiveness. <<

            Are all Engel machines the same world-wide?
            Yes and no. All Engel machines feature the same technology and quality world-wide. The equipment, however, always varies from one machine to the next. Whether a machine is to have a wider than standard frame or larger than standard platens or a different than standard drive, to name just a few of the many possibilities, is a matter for the customer to decide. Any of our production facilities anywhere in the world can build a machine tailored exactly to the customer’s needs. That is why our modular system is so large and so comprehensive. Moreover, it is a system of “global modules”, having been developed by an international team under the overall responsibility of our central development department in Austria and based on hundreds of projects which we have realized for our customers all over the world in the past. However, there is more to Engel’s production strategy than just the basic principle of building individual machines from a modular system. That part of it is relatively easy. Much more complex, and also much more essential

            Canada

            >> Page 4: All-Plast, Fiskars and Manner: Guitars, scissors and castors – the specialities and branded products of three of Engel’s customers in the Land of the Thousand Lakes in the northernmost part of Europe.

            Korea

            An example of Engel’s global production principle: the assembly of three ENGEL VICTORY machines in our production facilities at Schwertberg/ Austria (top), Guelph/Canada (centre) and Pyoungtaek/Korea (bottom) – basically identical but individualized with modules for customer-specific applications.

            >> Page 7: ENGEL MiniCAM: a powerful software tool for minimizing set-up times on new projects, thus increasing the productivity of the injection moulding machine.

            Supplements
            >> injection Asia >> injection North America

            Page 2

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            Editorial Editorial

            June 2005

            Editorial

            Engel innavative Engel innovative Engel innovative Engel innovative Engel innovative Engel

            >> Global Partnership
            Dear Customers, Is the setting up of production sites overseas one of your concerns? If so, one of your main tasks will consist in deciding on the choice of machinery and equipment. As you will also be faced with other problems, such as market development, human resources, local conditions, to name only a few, you will certainly decide in favour of existing machines and equipment that have already proved themselves in service. But now you must ask yourselves whether your existing machine supplier can offer you the same service overseas as the one you have always received from him at your parent factory. Admittedly, all well-known injection moulding machine manufacturers have meanwhile built up service networks for their products, and in most cases worldwide. Engel, however, has gone a decisive step further in its endeavour to provide the right global solutions to its customer’s global problems. As we see it, an after sales service – which has always been one of Engel’s strong points – is not enough. That is why we have also set up production plants in all the relevant markets of the world. In North America, for example, we have been manufacturing our machines for many years on the same strategic principle as in Europe, with separate factories for small and medium-sized machines, large-capacity machines and automation systems. In Asia, we are currently developing our manufacturing infrastructure step by step. Now that our Korean factory for small and medium-sized machines in Pyoungtaek has been operating successfully since the autumn of 2001, we have just commenced the building of our new large-capacity machine factory in Shanghai (see report in the Asia Supplement). This on-the-spot presence enables us to develop the right answers to the demands of local markets: shorter delivery times and distances, machines that can be offered in local currency and also considerably more comprehensive support with a bigger work force than can be offered by a pure service organization. These answers also include customer training, a facility which is central to the services which Engel offers its customers in the Asian market, and, last but not least, the development and production concept of the “global Engel machine”, as explained in greater detail in the cover story of this issue of “injection”. It is with the sum of all measures that we at Engel meet the global requirements of our customers. We make it our responsibility to ensure that your own global production network operates smoothly and economically from the very beginning, and without any interface problems caused by incompatible systems. This does not mean that you must simply make do with an “offthe-peg standard”. The perfected and comprehensive modular system of the global Engel machine permits versatility and individuality of application. – And a “global partnership” with Engel is always a partnership based on local proximity. Yours sincerely, Peter Neumann
            Chairman of Engel Holding GmbH

            The ENGEL E-MOTION all-electric injection moulding machine offers the user advantages not only for special applications and/or for the production of ultra-high-precision parts. Thanks to its universal basic concept, this type of machine is suitable for a much wider range of posThe ENGEL E-MOTION 940/280 T, currently the largest all-electric Engel injection moulding machine with tiebar/toggle clamping unit, has a clamping force of 2,800 kN. An even larger machine – with a clamping force of 3,500 kN – is presently under development.

            sible applications than a fully hydraulic machine – and at a better cost-performance ratio as well. Thus, in terms of economy, the ENGEL E-MOTION is ideal both as a high-precision and/or fast-cycling machine and as an “ordinary” standard injection moulding machine.

            ENGEL E-MOTION

            Economical all round
            >> The advantages of an all-electric (servo electric) injection moulding machine are undisputable: >> greater precision and higher repeatability >> higher speeds (shorter cycle times), >> lower energy requirements – and >> it works entirely without hydraulic oil. All the same, it is the “high” price which – especially in Europe – is the reason why an allelectric machine has so far been used for specific purposes only – in most cases either for reasons of prestige or because a hydraulic drive cannot guarantee the required precision. Does this mean that an all-electric machine must be regarded rather as a “niche” machine than as a standard production machine? Engel holds the view that the choice of the very best in drive technology should not be purely a matter of philosophy, but that “plain facts” should be the decisive factors. The following brief overview of the currently available standard series of ENGEL E-MOTION machines reflects the status quo of all-electric injection moulding technology. machine concept was already introduced at K 2001 (we reported on this at the time). For the higher range of clamping forces (from 1,800 to 2,800 kN), a new machine concept featuring an innovative tiebar/toggle clamping unit has been developed. Although it is based on the traditional tiebar clamping unit, the system has been completely revised. The four tiebars serve merely to transmit the clamping force when the mould is closed, but not to guide the moving platen. This function is performed – as in the case of the tiebarless clamping unit – by low-friction precision linear bearings mounted on the machine frame, thus permitting the gentlest possible treatment of the mould irrespective of the weight of the moving mould half. The toggle geometry is rated for highly dynamic movements: the dry cycle time is only 1.6 seconds. High-resolution measuring systems (incremental measurement as on a machine tool) ensure highly constant movement within extremely narrow tolerance limits. Both clamp versions of the ENGEL EMOTION – the tiebarless vesion as well as the tiebar/toggle version – are equipped with identical injection units featuring Engel’s serviceproved compact design twin drives for the injection stroke. The individual structural units are mounted on carriage plates running on precision linear bearings. Screw rotation, forward movement of the nozzle and injection stroke are driven by separate servo motors. For the necessary axial movements, the rotational movement of the motors is transmitted instantaneously to the spindle drives via zero-backlash toothed belts.

            1

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            Advanced technology for economic benefit
            The ENGEL E-MOTION series today covers the entire range of small to medium-sized machines with clamping forces from 550 to 2,800 kN. In the lower range of clamping forces up to 1,800 kN there are four sizes of machine with tiebarless clamping units offering ample, unrestricted space for even the most complex of robotic and automation peripherals. This

            As Engel’s design engineers attached particular importance to the optimum combination of high injection capacity and high injection pressure, every injection unit is available in two optional performance categories: “Standard” and “High”.

            Never compare apples with pears
            By further developing and improving its servo drive systems and standardizing its machine housing components (e.g. same design of

            1 2 View of the tiebar/toggle clamping unit of the new ENGEL E-MOTION: the five-point toggle with direct spindle drive on the crosshead ensures fast opening and closing of the mould (photo on left). The moving platen of box-type design runs on a double guideway on the machine frame (photo on right). The tiebars serve only as a means of transmitting the clamping force when the mould is closed.

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            Mould making news Mould making news Mould making news

            innovative Engel innovative Engel innovative Engel innovative

            3 Advantages of Engel injection units: the quick-action cylinder mounting system is a standard feature – all Engel cylinders and screws are fully compatible with all-electric injection units.

            tion software, we will be agreeably surprised to find that >> an ENGEL E-MOTION machine is not more than about 9 to max. 16 % more expensive than a comparable ENGEL VICTORY (in the clamping force range from 500 to 3,000 kN).

            Engel’s newly developed space-saving index plate drive operates with much greater precision and speed than a conventional rack-and-pinion drive. The chief components of this new index plate drive are a compact driving motor – either a hydraulic motor with a high-precision incremental angle encoder or, alternatively, an electrically driven servo motor – and a maintenancefree toothed belt.

            Engel’s new index plate drive

            Compact, fast, accurate
            The main benefits of Engel’s new index plate drive are: compact design, higher precision, higher rotational speed and complete freedom from maintenance and lubrication.
            >> Engel’s mould making division has developed a new drive system concept for the socalled index plates in multi-component injection moulds. The essential improvements compared with the standard rack-and-pinion system used hitherto are not only the considerably more compact design and hence considerably reduced space requirement for installation but also greater positioning accuracy, higher rotational speed and complete freedom from maintenance and lubrication. Drive may be effected by either a hydraulic motor with a high-precision analogue incremental angle encoder or an electric servo motor, which means that this new Engel drive concept is compatible with multicomponent injection moulds on both hydraulic and all-electric injection moulding machines. An index plate is required in cases where the second component material is to be moulded onto both sides of the preform in the second station. To this end, the index plate removes the preform from the first station and places it with absolute precision in the second station in readiness for the second injection operation. Specializing in the manufacture of injection moulds for multi-component and in-mould assembly applications, Engel’s mould making division meanwhile equips its index plate moulds exclusively with this new, compact drive system, which is configurable for every size of mould. When transferring the parts from one cavity to the other, index plates always perform two movements – an axial movement for removal from, and insertion into, the mould cavity, and a rotational movement for changing cavity positions. The axial movements are performed in conjunction with the ejector mechanism and are transmitted to the index plate via a central hollow shaft; the rotational movements are performed by the index plate drive which is an integral part of the mould. The rack-and-pinion drive used hitherto has now been replaced by a toothed belt drive. Unlike the rack-and-pinion drive, this toothed belt is maintenance-free, as it requires no lubrication, an advantage which definitely comes into its own in clean-room applications, for example. The rotational movement, too, is much faster: rotation through an angle of 180°, for example, takes only 0.6 seconds, approximately twice as fast as a conventional rack-and-pinion drive. Moreover, the analogue incremental angle encoder enables the hydraulic motor to work with extremely high positioning accuracy: its high resolution provides up to 4,000 absolute positions per 360 degrees. All movements of the index plate are monitored and feedback-controlled by the Engel machine control system,

            5

            Even competitive as a standard production machine
            If when making the comparison we also take into account the roughly 50 % lower energy consumption, the reduced cooling water requirement (cooling water is required only for cooling the mould) and the fact that there are no costs for the hydraulic oil and its disposal, the unit costs of parts moulded on an all-electric machine are altogether competitive with those of parts moulded on its hydraulic counterpart. Moreover, for a full and fair comparison it is necessary to make allowance for the fact that the cycle times of an all-electric machine are generally faster (higher output) and the process is more stable (less scrap). The reliability of the E-Motion machines is also extremely high. Shot weight fluctuations, for example, are only s = ± 0.01 % (s = standard deviation). Consequently, when planning to invest in an injection moulding machine for the mass production of moulded parts – whether for the automotive, medical equipment, electrical, electronics, telecommunications or even the packaging industry –, it is certainly worth including an ENGEL E-MOTION in your profitability calculation. After all, the “standard versatility” of an ENGEL E-MOTION machine cannot be matched by any hydraulic injection moulding machine today. <<

            4 For the axial movement of the injection unit,
            toothed belts transmit the high rotational speeds of the three-phase asynchronous motors to threaded spindles.

            4 3

            safety hoods for both all-electric and hydraulic machines), Engel has again been able to lower the prices of its all-electric machines. All the same, an all-electric injection moulding machine is still more expensive than a hydraulic machine with the same clamping force, not least on account of its basically more complex structural components. But what does such a “simple” comparison based just on price and clamping force actually tell us? Does it in fact enable us to compare the performance features of both systems properly? As everyone knows, there is little point in comparing apples with pears. An objective evaluation of both systems is possible only if the hydraulic machine is so equipped that it will work in just the same way as the all-electric machine. For example, an injection moulding machine equipped with a basic hydraulic system permitting only sequential machine movements is not a good basis for comparison, as the all-electric machine affords the user much more scope in this regard. The injection speeds should likewise be comparable. – Consequently, if we compare the ENGEL E-MOTION with a tiebarless ENGEL VICTORY equipped with an HV 5 hydraulic drive for parallel machine movements, a higher-quality bimetal melt cylinder, which is standard on the E-Motion machine, and Engel’s Autoprotect mould protec-

            D

            5 Innovative pressure measurement ensures the high precision of the injection unit: the pressure is measured directly behind the screw via an integrated pressure transducer (D) in the screw drive – hence unaffected by disturbing influences.

            which also has input provision for an acceleration and deceleration profile for the rotational movement of the index plate. This new Engel drive concept is also suitable, without any reservation, for multi-station index plates, i.e. not only for the most frequent two-station application (indexing in steps of 180°) but also for three stations (indexing in steps of 120°) or even four stations (indexing in steps of 90°). Besides featuring the above-mentioned technical improvements, Engel’s new, compact, maintenance-free index plate drive also affords the user an economic benefit. Built from standardized components, the drive costs approximately 10 to 15 % less than the rack-and-pinion drive fitted hitherto. <<

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            June 2005

            A visit to our customers All-Plast, Fiskars and Manner A visit to our customers A visit to our customers A visit to our customers

            Suomalaisia

            Creativity and the courage of their own convictions are what the firms have in common – from All-Plast to Perlos. One example is oped by Oy All-Plast AB featuring sound properties akin to those and managing firector) holds in his hands the result of four years’

            majority of successful Finnish a plastic electric guitar develof wood. Antti Vilenius (owner development work.

            *) Finnish specialities

            1

            Oy All-Plast AB

            Cool products from the Land of the Thousand Lakes
            >> After a freezing night (minus 20 °C), it is still cold, very cold on this March morning as our taxi leaves the centre of Joensuu, the capital of North Karelia, and drives us through what seem to be endless forests. After about half an hour, we reach the small township of Hein?vaara. Our destination is an industrial estate on the access road, where two very innovative companies are based – the wellknown ski pole manufacturer Exel Oyj (www.exel.net) and Oy All-Plast AB (www.allplast.fi), the company we have come to visit. But why, you might ask, have we travelled all this way from Austria to one of the northernmost countries of Europe? – Because we wanted to learn more about the manufacture of guitars and snowshoes, it’s as simple as that. Finland and snowshoes, you will now say, go together like mustard and hotdogs, but Finland and guitars? Antti Vilenius, the founder and managing director of All-Plast, enlightens us with a brief historical background. Vilenius first established the company in Helsinki as a custom injection moulding facility and ran it there for a good 22 years. When the Finnish government set up a plastics cluster in 1990 in Hein?vaara in collaboration with the University of Joensuu as part of a regional development project, AllPlast relocated to Karelia. The attraction was the available labour force in this region and also the prospect of involvement in development projects. Of the six firms originally taking part in the project at that time only two

            have survived – namely Exel and, yes, you’ve guessed it, All-Plast. The question as to how a company can possibly survive in such difficult terrain on the fringe of Europe automatically brings us back to the reason for our visit: guitars, snowshoes and special porthole systems in plastic – but it is an innovative plastic, namely polypropylene or polystyrene with a high content of natural fibres such as wood and/or flax. All-Plast currently has 19 injection moulding machines in operation. Industrial parts account for 80 percent of production, for the company has always remained faithful to its original concept as a custom injection moulding facility. The remaining 20% constitute the innovative part of the company, and it is this part which is to expand in future. So let us begin with the guitar or, to be more precise, with the electric guitar. Anyone who thinks that an electric guitar, unlike an acoustic guitar, does not need a sound box is quite mistaken. Research has clearly shown that the choice of material for the body and the neck does indeed influence the quality of the sound. As many as 18 firms – operating under the auspices of Joensuu Science Park Ltd. – were involved to various extents in the four-year research project. The end result was a PS injection moulding compound containing 50% wood and flax fibres. It required no upstream processing and could be injection moulded with a shrinkage of only 0.1 %. The resultant moulded parts have properties largely akin to wood, but without being prone to moisture, woodworm and fracture. The machine used is a large tiebarless Engel machine (6000 kN). The parts are

            not only injection moulded on All-Plast’s premises but also assembled into complete instruments there by All-Plast’s tenant and customer, the guitar manufacturer “Flaxwood” (www.flaxwood.com). It is not without some pride that the Flaxwood people tell us that “Slow Hand” Eric Clapton was quite impressed by the soft sound of the “Flaxwood” when trying one out. What better testimonial to quality could one ask for? A further application for PP-based natural fibre compounds is the “porthole-design” window system developed by All-Plast for sauna cabins and similar special-purpose applications. These window systems are marketed under the brand name “FENRON”. Completely different, but just as innovative, is All-Plast’s range of snowshoes in modified PP (sports version) or PA 12 (military version). Originally developed for military personnel, forestry workers and electrical fitters, these “utility articles” have meanwhile been developed by All-Plast into modern, colourful, fashionably styled items of sports equipment. Programmed interval injection moulding on an Engel 4550H/1050W/600 HL-2F makes this possible. All-Plast puts its trust in Austrian injection moulding technology not least because collaboration at the development stage worked very well – and also because one of Engel Finland’s service engineers is available in nearby Joensuu. And that is very reassuring – especially in Hein?vaara, so far away from all the main centres of industry. As you can see, there is no end of “cool” products in this very cool region of northern Europe! <<

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            Fiskars Brands Finland Oy Ab

            The story of the orange-handled scissors
            >> ”Fiskars gave the Orange to the scissors.” – Who could possibly be puzzled by this advertising slogan today? Since Fiskars (www.fiskars.com) first introduced them in 1967, no fewer than 300 million pairs of their “classic” scissors have been sold worldwide. By the way: the colour orange has been a registered trade mark in Finland since 2003. Fiskars does not manufacture just scissors but also their bigger, stronger and more innovative brothers: pruners, loppers, hedge shears and grass shears plus a large assortment of garden tools ranging from rakes, spades and saws to axes and snow shovels. And all of them feature not only the typical orange handles but also Fiskars’ typically innovative and ergonomic designs. All of these products come from a “centuries old” manufacturing firm named after the

            Photo left: Parts injection moulded from a special wood fibre and plastic compound are painstakingly assembled by hand into high-quality musical instruments. The instrument makers at “Flaxwood” – All-Plast’s tenant and customer – meet every individual wish as regards surface finish and equipment. Photo right: All-Plast has developed the traditional Lapland snowshoe into a modern, fashionable item of sports equipment and a useful aid for outdoor workers during the winter months.

            A very typical example of the production process at Fiskars is the combination of a metal blade with a two-component injection moulded handle.

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            Finland in facts and figures
            >> Area: 338,000 km?, of which: 10 % is covered by water(188,000 lakes), 68 % is covered by forest land, 6 % is covered by agricultural land >> Population: 5.2 million, 79 % of the population live in urban conurbations – with 1 million living in Helsinki/Espoo and Vantaa 1

            A visit to our customers A visit to our customers A visit to our customers A visit to our customers A visit to our customers

            Erikoisuuksia* )
            place where it was founded 356 years ago. Fiskars is a small village in the valley of the River Fiskars. It was there that a Dutch merchant obtained a licence for the processing of Swedish iron ore. At that time, the ore was shipped in boats across the sea from Sweden for smelting in Finland. As the smelting furnaces were fired with charcoal, the surrounding forests were valuable sources of energy, as was the waterpower from the river for driving the hammer forge. The production of iron and the manufacture of various iron products continued under changing ownership until around 1822, when the chemist Johan Jacob Julin took over the firm and developed it from a raw material producer into a processing and manufacturing firm. It was under his management that the firm’s first precision forging plant was built and also, in 1837, Finland’s first machine workshop. In 1838, Fiskars manufactured the steam engine for Finland’s first steamship. It was around that time, too, that a precision casting plant for household goods went into operation; Fiskars has been manufacturing cutlery and scissors ever since then. Agricultural machinery was added to the range of products in 1850 and remained an important branch of production until well after 1900. By 1895, Fiskars was already employing 1,000 people. Thanks to brisk export business with Russia, the processing of iron and steel continued to be profitable right up until the First World War. After the war, the production facilities were modernized and quality improved. A rolling mill and a spring factory were built. The Second World War was an enormous setback, and Finland recovered from it only very slowly. Although reparation deliveries to the Soviet Union also meant more business for the iron and steel industry, the prevailing conditions in industry worsened considerably. Takeovers of a number of inefficient firms caused additional problems for Fiskars, necessitating a complete restructuring of the company. The steel plant was sold in 1970. From then on, Fiskars concentrated on its core business – the manufacture of scissors and related products. In 1977, Fiskars established its own scissors factory in the USA, and companies operating in the power electronics field (Televa, Finland, and Deltec, USA) were also acquired. Innovative utility goods constitute Fiskars’ core business today. Besides garden tools, Fiskars’ range of products includes knives and cutlery sets, pottery, garden furniture, as well as electronic equipment and even motor boats. The manufacturing side of the business is complemented by real estate management, the operation of two restaurants and participation in industrial enterprises. Today Fiskars is a joint stock company with around 3,900 employees. Collaboration with Engel goes back as far as 1981, when the first vertical machine with a sliding table for scissors production was purchased. As many as 26 Engel machines are now in service at Fiskars: 21 conventional and 5 vertical injection moulding machines. Fiskars is the largest PA consumer in Scandinavia, processing more than 1000 tonnes of glass fibre reinforced PA every year. The use of wear-resistant marathon screws has significantly increased the service life of the plasticizing units. Who would have thought 350 years ago that orange plastic and not grey steel would eventually be communicating Fiskars’ corporate identity – and that “green machines” would be making a decisive contribution to its success? <<

            >> Languages: 92 % Finnish, 6 % Swedish, 2 % others >> Education: 73 % of the population between 25 and 54 have a certificate of secondary education, 33 % have a university degree (highest percentage in the EU) >> Growth: 2 %, inflation rate per year (Dec. 2004): 0.4%, >> Per capita income: Men: 2,660 EUR/month, Women: 2,140 EUR/month, Unemployment (OECD Standard): 8.7 % >> History: > until 1809 under Swedish rule, > 1809 - 1917 autonomous Grand Duchy of the Russian Czar, > since 1917 parliamentary democracy, > since January 1995 member of the European Union 2 3

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            Oy Mannerin Konepaja Ab

            Manner wheels and castors – a household name for over 50 years
            >> On our way to Hanko, a small port on the southernmost tip of Finland, we are amazed at the many car transporters bearing Russian and Baltic licence plates. Whole shiploads of cars “rolling eastwards”. Rolling – on wheels or castors – will also be our theme for the next few hours. Our journey ends near the docks in a large factory yard with three brick buildings. We are visiting the firm of “Oy Mannerin Konepaja Ab” (www.manner.fi). Even our short walk through the modern injection moulding shop with its ten machines – nine of them from Engel – tells us that everything re-

            ally does revolve around wheels and castors at Manner – and has been doing so for the past 75 years, and around plastic versions since 1958. And yet it all began very differently – back in 1890, when Finland was still under Russian influence. Together with his brother Kaarlo, Juho Manner set up a small forging shop in Hanko, mainly for sheet metal products, such as kitchenware, metal roofing or tin boxes for the famous “Hanko Biscuits”. The repair and hiring out of bicycles, involvement in the building of Finland’s first waterworks, the manufacture of sports equipment and repair work on ships were the next stages of this firm’s early development. By 1928 Manner was operating its own foundry and, thanks to the increased flexibility which this afforded, grew into a medium-sized company by 1939. During the war years, however, production was confined to coast artillery shells and components for sea mines. Then, after the Second World War, the company embarked upon the production of steel structures for radio transmitters and also machines and workshop equipment. By 1955, when Aarne Manner took over the helm, the company was already in its third generation. It was Aarne Manner who initiated a shift of corporate strategy from custom production to specializing in the manufacture of products under its own name. Water tanks and boilers were the first products. On the strength of past experience in the production of wheels for rail vehicles, the company then

            concentrated its activities largely on the manufacture of castors and wheels. During the fifty years that have passed since then, Manner has developed a wide range of standard-type castors and wheels in diameters from 30 to 250 mm (special wheels up to 465 mm) and with load-bearing capacities from 20 kg to 2 tonnes (special wheels up to 10 tonnes). Altogether there are as many as 2,500 product items. With an annual production of 3.5 million castors or wheels, Manner is the No.1 supplier in Scandinavia and is up among the market leaders in Europe, exporting its products to more than 20 countries. Its main customers are manufacturers of warehouse trolleys for logistics activities in supermarkets, dairies and large-scale bakeries. Manner’s wide range also covers niche markets and special applications, e.g. castors with hubs and centres in electrically conductive polypropylene or twin-wheel castors with offset axles which reduce rolling noise on tiled floors by 90%. Production manager Stefan Gr?nroos sees Engel machines as an important success factor: “As we mainly process polyamides, quality of melt and exact temperature control are really important. And another advantage which cannot be underestimated is the fast and competent on-the-spot service we always get from Engel.” Let us hope that Manner wheels and castors will continue to be a “rolling success” for years to come! <<

            Production of hedge shears at Fiskars: Metal inserts are encapsulated with handles in polyamide and then fitted with the typically orange grips.

            Manner: 2,500 product items demand high flexibility from the injection moulding machines. Photo left: Wheel hubs of 60 mm diameter are the basis for many applications and are therefore manufactured in large quantities. In this particular case, the assembly of the wheel bearing is integrated in the injection moulding process (insertion and encapsulation). Tiebarless machines offer optimum ease of access for changeover operations and absolute freedom of movement for the robots. Photo right shows a production cell for the mounting of prefabricated PU wheel tyres on the hubs.

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            True to its name, Schneegans Silicon GmbH has to this day remained an important elastomer processor. In 2004 alone, it processed more than 400 tonnes of elastomer, a good 350 tonnes of which consisted of solid silicone. Indeed, Schneegans can justifiably claim to be Austria’s largest solid silicone processor. Elastomer parts account for around 26 % of the company’s sales. With a total of 28 injection moulding machines ranging from 250 to 4,000 kN and a work force of 85 employees, the company produces a diversity of car components, such as stabilizer bearings, vibration control and damping elements and, above all, spark plug caps. All told, the company operates 15 horizontal tiebarless Engel Elast injection moulding machines, most of them equipped with solid silicone stuffing units. Many of these parts are “long runners”, i.e. parts produced in large quantities over long periods of time. Consequently, the time-saving advantage of the tiebarless clamping units for mould changing operations is not one of Schneegans’s priorities. Nevertheless, their excellent accessibility is certainly very welcome, not least when it comes to mould maintenance – and also for automatic demoulding.

            June 2005

            Engel flexible Engel flexible Engel flexible Engel flexible Engel flexible Engel flexible Engel flexible Engel flexible Engel flexible

            Schneegans Silicone GmbH, Losenstein/Austria, manufactures innovative elastomer parts (rubber and silicone), rigid/ flexible and metal/elastomer composites, chiefly for the automotive industry, using the most modern injection moulding machines and equipment.

            Schneegans Silicon – Austria’s largest processor of solid silicone

            Even when ear muffs are used, the noise level in the silicone parts production department is quite unbearable on account of the highpitched whistling and hissing of the compressed air used for demoulding. Thus, wherever possible, Schneegans equips its machines for automatic demoulding, sprueless production and unattended operation, less as an efficiency measure than as a means of making working conditions more comfortable. Comprehensive material know-how was one of the decisive factors to this end.

            Automotive parts – flexible, innovative and economical
            In the last issue of “injection” we reported on Starlim//Sterner, leading moulder “Silicone LSR in Europe’s injection Austria’s This
            >>Schneegans Silicion GmbH, a subsidiary of the North German firm of Schneegans GmbH, Emmerich, is located in a part of Austria where one would normally spend one’s holidays – in the Alpine foothills to the south of Steyr. But our reason for today’s visit is purely a “high tech” one. Resulting from the take-over of a ski and sports products manufacturing company in 1989, the Austrian Schneegans subsidiary began as a contract injection moulder of rubber parts. The proprietors – the brothers Dieter and Jürgen Schneegans – have meanwhile developed the company into a system supplier to the automotive industry. often moulded in glass fibre reinforced polyamides or POM, and flexible seals in rubber or TPE enjoy application in a wide diversity of component parts and assemblies, especially in the automotive industry. Typical examples are door lock housings and ventilation and air intake system components. A particular highlight are heat-resistant components mounted either directly on the engine or in its close proximity, such as oil dipsticks and dipstick tubes in a variety of innovative designs.

            Close partnership
            For years now, Schneegans and its German parent company have together been evolving structures and systems for the fast and flexible realization of development projects. The aim is always to achieve a considerable reduction in development times for new vehicles and to create the correct production environment for the supply of component parts. To this end – and Schneegans is convinced of this – it is not least the close partnership with Engel that has contributed decisively to the success of numerous projects in the face of the keenest competition from lowwage countries. <<

            Valley”.

            series of reports now continues with a visit to Schneegans Silicon GmbH, the specialist in the injection moulding of solid silicone rubber in Losenstein, Upper Austria. The fully automated mass production of spark plug caps is this firm’s speciality.

            Innovative applications for elastomers
            Based on the vast know-how acquired by the German parent company in its own compounding facility, the innovative use of elastomers – both rubber and TPE – has always played an important part at Schneegans Silicon GmbH, especially when it comes to combining materials for greater ease and efficiency of assembly. Composite parts consisting of rigid structural bodies,

            Like these angled spark plug caps in the above photo, most Schneegans products (a small selection is shown on the right) are demoulded fully automatically.

            injection
            Publisher
            ENGEL AUSTRIA GmbH, Ludwig-Engel-Stra?e 1, A-4311 Schwertberg www.engel.info

            News in brief News in brief News in brief News in brief News in brief News in brief News in brief News

            And the lucky winner is ...
            It goes without saying that there was also something to be won on Engel’s stand at “K” last October: what the contestants had to do in order to have a chance of winning was simply write the answers to three qustions on a postcard together with their address and pop it into a box on the reception desk. The main prize was the six months’ free-of-charge trial of an allelectric ENGEL E-MOTION in the contestant’s own production facility. Several hundred visitors tried their luck and then when the fair was over an Engel “lucky fairy” drew the following winner: >> The Czech firm of TWIST spol. s r.o. in Strá?ná, in the district of Pardubice (near the Moravian border). TWIST was established in March 1994 by the two business partners Josef Zwesper and Jan Kylar. Currently equipped with 35 injection moulding machines (including 15 Engel machines) ranging from 250 to 9,000 kN, TWIST mainly produces precision parts for the automotive, electrical and light engineering industries. Some of the parts are also assembled into complete components or units. TWIST plans to use the “prize machine” – an ENGEL EMOTION 200/55 – for exploring new business potential for high-precision parts. <<

            Editors
            D. I. Reinhard Bauer (responsible), E-Mail: reinhard.bauer@engel.at, Tel.: +43 (0)50 6 20 30 60, Dr. Georg Krassowski (Konsens)

            Layout
            Konsens Public Relations GmbH & Co. KG, D-64823 Gro?-Umstadt www.konsens-pr.de

            Printed by
            KB-Offset GmbH & Co. KG, A-4844 Regau injection is the customer newspaper from ENGEL. Reprinting of articles after agreement with the editors and with indication of source permitted.
            Printed on paper produced using environmentally safe process.

            Formal handing-over of the ENGEL E-MOTION 200/55 (including X-Melt) to the winner of the “E-Motion Prize”, the firm of TWIST spol. s r.o. (left to right): Jan Kohoutek, regional representative of Engel in the Czech Republic, Viktor Starman, general manager of TWIST, Christian Pum, sales and marketing director of Engel Austria GmbH, and Josef Zwesper, managing partner and director of TWIST, and his wife Iwana.

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            Know-how for injection moulders Know-how for injection moulders Know-how
            Car interior application: heater control panel IMD with co-extruded film IMD & thin-section parts

            What does it mean ... What does it mean ... What

            ... ?MiniCAM“?
            “Minicam” is a powerful software tool offered by Engel for minimizing set-up times on new projects, thus increasing the productivity of the injection moulding machine.
            >> The work of setting-up and resetting an injection moulding machine always “costs” a lot of time – and, by the same token, reduces the machine’s productivity. In order to keep setting-up times as short as possible, Engel has developed “MiniCAM”, a software tool which is integrated into the control system of the injection moulding machine. This software guides the user quickly and systematically towards the correct initial settings when installing a new mould. feeding of the mould during initial set-up, MiniCAM calculates the shot weight with a safety factor, ensuring that the amount of material in the mould does not exceed 80 % at the change-over point.

            Two-sided IMD of flat film with PUR

            Car exterior application: radiator grille

            In-line thermoforming and trimming

            Systematic set-up procedure
            MiniCAM is divided into four sections: The section “Open/Close” is for setting the clamping unit parameters. The selectable velocity profiles “fast”, “medium” and “slow” also take into account the rate of deceleration at the end of the movement. For this set-up operation the user may key in any additional parameters which cannot be computed, such as ejector movement, opening stroke of the mould etc. For the section “Material”, the database offers a choice of 36 different types of polymer. On the

            Stored expertise for practical machine set-up
            The nucleus of MiniCAM is a database in which all the necessary expertise for machine set-up is stored. The entire set-up is configured by the software and then imported into the machine control system and clearly displayed on one single

            MiniCAM: Stored expertise and a material database permit machine setters easy, fast and safe computation of basic machine settings when installing new moulds.

            >> In-mould decoration (IMD) today represents a neat and economical means of combining visual appeal with practical function in a multitude of applications. Using suitably formulated and converted films, the plastics processor can produce parts capable of meeting many different demands, e.g. abrasion resistance, high colour intensity and diversity, symbols, pictograms, day/night designs, to name just a few. The IMD process takes several different forms: >> The decorative film is first placed uncut into the mould. The melt is then injected into the mould. The edges of the moulded part must then be trimmed and finished. >> The film serves merely as a transfer backing for the decoration. The decoration fuses with the melt during injection. When the part is demoulded, the backing film (PET) is removed, leaving the decoration on the moulded part. >> A preshaped film, cut exactly to size, is placed in the mould and then the melt is injected. This process can be used for parts of complex, three-dimensional shape (3D-IMD). Engel has gained many years’ experience with every known IMD process (see examples illustrated above) and now offers fully automated, turnkey systems for specific applications. Just two examples:

            Engel Foilmelt

            Appeal + Function ...
            ... in one single operation: in-mould decorated parts produced fully automatically using perfected Engel technology.
            Foilmelt process stages

            with parts of a thickness of at least 1.8 mm. In-mould decoration of thinner parts was not possible because the injected melt tended to wash away the decorative film as it entered the cavity. The decorated top part of this handset, on the other hand, has a thickness of only 1.2 mm (including 0.3 mm film gauge) and is injection moulded together with the undecorated bottom part in a 1+1-cavity hot runner mould in a cycle time of 9 seconds. The economic efficiency of this injection moulding process is ascribable not least to the speed and accuracy of the automation process (exact positioning of the insert in the cavity coupled with high insert-placing and partsremoval speed).

            Flexible changes in design
            1 Thermoforming (or vacuum forming, highpressure cold forming) 2 Trimming (e.g. punching, milling, ultrasonic cutting)

            3 Insertion in mould

            4 Injection

            5 Decorated part

            Thin-section IMD
            screen page. MiniCAM is a valuable asset both to the beginner and to the experienced user. Using its entire repertoire of stored expertise, this innovative software automatically calculates – from just a few material and part parameters – the relevant settings for the entire metering, injection and holding pressure phases. >> The experienced machine setter may of course use the MinCAM selectively, availing himself of the help of this “competent assistant” only where it is actually needed – perhaps for a recommended temperature or a calculation of the cooling time or metering stroke, for example. The settings displayed on a screen page may – if specifically desired – be changed individually prior to being imported into the machine control system. In order to avoid overbasis of stored data, the software suggests suitable parameters – mould and cylinder temperature profiles, screw speed, back pressure – for the gentlest possible treatment of the melt. The different methods of operation necessitated by the use of a barrier screw or a three-section screw are likewise taken into account. The section “Moulded part” calculates the required metering stroke from the shot weight or volume. The recommended decompression for the optimum closing action of the non-return valve is likewise computed at this stage. The fourth section gives information on “Representative wall thicknesses” for the selected material, permitting computation of the cooling time, the holding pressure, the holding pressure time and the rate of injection. << The cordless telephone handset (see adjacent illustration) is an example of what can be achieved today using IMD. The partners involved in this development project (the manufacturer, the decorative film supplier, the material supplier and Engel) have redefined the limits of what is technically possible. Hitherto, IMD was possible only

            For the manufacture of this in-mould decorated handset, the 1+1-cavity hot runner mould was thermally and rheologically rated in such a way that direct gating without vestige was possible. Special knowhow was required for the design of the thinsection top and bottom parts of the casing. In order to meet quality requirements, it was necessary both to optimize the preshaped multi-ply decorative film and to develop a special ABS/PC blend.

            The casings of the external car mirrors “painted” in their car colours (see illustration below) are in-mould decorated parts using unshaped, pigmented flat fim. The thermoforming process prior to in-mould decoration and the subsequent trimming operation are performed in-line in the fully automated production cell, which is equipped with a vertical tiebarless Engel machine with integrated rotary table. Change of colour is easy – all one has to do is use a differently coloured film. Thus even the smallest of colour batches can be processed with the same economic efficiency as a mass production run. These examples are just two of the many possible applications of IMD. And what about its future? Well, there will certainly be many more product properties and functions that can be realized with IMD, such as scratch resistance in conjunction with the glazing technique, or the integration of transponders for non-contact product coding. The list is endless…. <<
            In-mould decorated mirror casing: the preheated film in station 2 is prestretched in station 3 – its final contours are obtained through injection of the melt in station 4. The mould is an injection-compression mould which simultaneously trims the film when performing the compression stroke. No subsequent finishing is required after the parts leave the production cell.

            3 Prestretching

            4 Injection/ trimming

            2 Preheating 1 Placing/removal

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            Engel invests in replacement parts logistics
            delivery in the event of a requirement. Each individual one of these replacement parts can be of decisive importance for the customer. – Our aim is to ensure that 85 % of all orders for replacement parts are ready for dispatch within 24 hours.

            June 2005

            Names and News Names and News Names and News Names and News Names and News Names and News Names and News

            What is the benefit to the customer?
            >> Higher availability of replacement parts and faster response times (85% of all orders ready for dispatch within 24 hours). >> Getting replacement parts to the customer faster, more cheaply and more easily – this declared aim became a reality on 1st April 2005, when the new European logistics centre of the Engel Customer Service Division (CSD) began operations. The basis of the new logistics concept is the virtual integration of all warehousing sites into a centrally managed system, beginning for the time being with the three main warehouses of the Austrian production facilities. The warehouses of Engel’s European branches will then be integrated in the course of the year. The task of the logistics centre is to manage over 36,000 active replacement parts – many of them being special parts for special-purpose and custom-built machines – and to ensure their fastest possible >> The cost benefits made possible by the new integrated logistics concept will be passed on to the customer in the form of price reductions. >> Same prices for all countries within the EU (the ultimate aim is a “global pricelist for replacement parts”). <<

            www.engel-automationtools.com
            >> Since last October, Engel has been operating a new customer service for its product category “Automation Technology”: an on-line shop offering a wide range of automation components and units for injection moulding machines. >> Engel’s website “www.engelautomationtools.com” now affords users in all parts of the world on-line access to the complete Engel catalogue of automation tools (German or English), enabling them to fill their shopping trolleys comfortably and quickly at the click of a mouse. The products fall into four main groups: Grip Tools (a wide range of accessories for the D.I.Y. construction of robot grippers) – Conveying Systems – Safety Components (for automation systems) – Grip Tool Kits (gripper construction kits for standard applications). Bargain hunters also get their money’s worth: “Special offers” are a regular and perma-

            ?E-Motion Days“ went down very well
            >> “Engel E-Motion, the four-in-one standard machine” – this was the motto under which Engel announced its “E-MOTION DAYS 2005”, a practice-oriented symposium taking place in Schwertberg on 27th and 28th April 2005. As many as 100 visitors from 11 European countries attended the symposium on each of its two days. True to its motto, the event focused on the versatility of Engel’s all-electric injection moulding machines, drawing particular attention to the fact that even the standard version of the machine is suitable not only for standard injection moulding applications but also for precision injection moulding, fast cycling injection moulding and micro injection moulding. Technical lectures and user reports were the starting point for concrete case studies. The four machines and applications demonstrated at the symposium were as follows: >> ENGEL E-MOTION 200/55 as a micro injection moulding machine This smallest machine of the E-Motion series (550 kN clamping force), equipped with a standard injection unit and a 25 mm diameter plasticizing screw, demonstrated the production of “lens holders” in LCP for the laser units of DVD players. The process used for this application – the parts weigh only 0.14 g – was ENGEL X-MELT, the so-called expansion injection moulding process involving high compression of the melt in the space in front of the screw and injection of the compressed melt into the mould without any forward movement of the screw. The parts were moulded in a four-cavity mould, removed by an ERC 33/1FH robot and inspected for 100 % quality by a vision system which also records the inspection data. >> ENGEL E-MOTION 310/100 as a precision injection moulding machine This tiebarless 1,000 kN machine demonstrated the production of a battery housing in PA in a six-cavity mould. The very close tolerances of the moulded parts were no problem thanks to the high repeatability possible with the electric screw drive. >> ENGEL E-MOTION 940/225 T as a standard machine Equipped with the new design of tiebar/toggle clamping unit (2,250 kN), this machine demonstrated, as a standard application, the production of PP pipe fittings (120 mm diameter) in a two-cavity mould. The core pullers were actuated mechanically. >> ENGEL E-MOTION 940/280 T as a fast cycling machine The use of the E-Motion as a fast cycling machine (high precision in conjunction with extremely short cycle times) was demonstrated on the currently largest machine (2,800 kN) equipped with a 48-cavity mould for PE-HD softdrink bottle caps and rated for a cycle time of 5.5 seconds. The electric drive concept is particularly suitable for fast cycling applications, as its basic principle permits parallel operation of the injection and clamping units as standard. Rounding off the presentation was a “hybrid” machine – an ENGEL VICTORY 310/110 electric (clamping force 1,100 kN). This machine combines the hydraulically operated tiebarless clamping unit with an all-electric E-Motion injection unit. The machine at the symposium worked in conjunction with a LIM unit for the processing of liquid silicone rubber and demonstrated the production of flexible seals for cable bushings. <<

            www.engel-automationtools.com: Detailed information on each individual part can immediately be called up on the screen.

            nent fixture of Engel’s new on-line shop. Given the same priority as urgent replacement parts, customers’ orders for components and spare parts for their automation systems are expedited in the shortest possible time. Using the new on-line shop is as easy as you could possibly imagine. Once the customer has registered as a “New Customer”, all he has to do the next time he logs into the website is to key in his e-mail address and password. Like the user’s guide in Engel’s Automation Tools cata-

            logue, this “virtual departmental store” has a clearly arranged menu which will help the on-line user to find his way to the right “product shelf” and “compartment” as quickly as possible. An integrated search function also helps the customer to obtain a complete overview of a certain product group. By keying in “bellows suction cups”, for example, he will obtain details of all of the 74 bellows suction cups currently available in the “Grip Tools” section, which so far comprises a good 1,000 parts. <<

            The

            1000th DUO
            DUO – which is already Seeber’s 51st ENGEL DUO – will be installed at the Seeber site in Duncan, South Carolina/USA. With a total of 3,300 employees working at 10 production sites worldwide, Seeber counts among the leading manufacturers of systems and components made of polymer materials for the automotive industry.<<

            >>Still being assembled at our St. Valentin factory as this issue of “injection” went to print, this ENGEL DUO 5550H/1050W/800 Combi is the 1000th DUO with the space-saving two-platen clamping system. It has been built for our long-standing customer Seeber – R?chling Automotive, a company of the R?chling Group based in Mannheim. This

            North America Supplement

            injection
            N e w s , F a c t s a n d m o re . I n f o r m a t i o n f o r o u r c u s t o m e r s .
            Engel Canada has begun production of the new Insert machine line for the global market.

            June

            2005

            11

            Engel Canada has begun implementation of the “competence center” production concept with the new Global Insert machine design.
            >> To begin with, Engel Canada will produce the Insert machine line in two formats: a core machine for the global market, and complete machine for the North American market. The core machine consists of machine base, clamp frame, platens and rotary table. This core machine is supplied to the other Engel manufacturing facilities for addition of the hydraulic system, and electrics to meet local requirements. The first 100 US ton (90 metric) core machines were shipped to Engel Austria in February 2005, and another 20 machines are currently on order. The first complete series of production machines will be available for the North American market in the summer of 2005. Additional

            Competence Center Canada

            Update

            sizes are scheduled, with the 265 US ton (240 metric) machine prototype for August 2005 and 155 US ton (140 metric) prototype to be completed by the end of 2005, with full production for both models to start soon after. The implementation of this new machine design provides a global unification of both machine design and options, providing customers with consistency in their equipment, no matter the location of purchase. One new feature that is standard on the new horizontal clamp Insert machines is the no-lift table. This new table design provides a cycle time reduction of 0.5 - 1.0 seconds, dependent on machine configuration. In parallel will be production of the EMOTION T-series (toggle) all-electric machines. The first prototype in this new machine series is scheduled to be complete in the summer of 2005, with the first 200 US ton production machines being available in October 2005. >> Engel’s new global manufacturing strategy is only one of the ways that we prove our dedication to providing for the worldwide needs of our customers. <<

            Freudenberg-NOK

            Leading in Sealing Systems and Vibration Control Technology
            >> From its beginning as a German tannery in 1849, the Freudenberg Group has grown to a truly global company, employing some 30,000 people in 54 countries worldwide, with specialization in seals and vibration control technology, nonwovens, household products and more. The division of Freudenberg into separate business groups enables the company to act and re-act better to the individual markets served. Freudenberg-NOK is a North American leader in automotive sealing and noise, vibration and harshness products, supplying to most automakers producing in North America, as well as most major tier one chassis and drivetrain suppliers. The company also offers an extensive portfolio of special precision seals for a multitude of markets including aerospace, appliance, business machine, fluid power, marine and medical. Freudenberg-NOK purchased their first Engel rubber injection molding machine in 1993 and have since been a steady customer, relying on Engel’s technology and machine control to produce high quality components for their customers. With the need to maintain a competitive edge always prevalent at Freudenberg-NOK, the next obvious step was fully integrated automation systems to help re-

            A company rooted in the innovation of its parent, Freudenberg-NOK General Partnership was founded in 1989 as a joint venture between Freudenberg & Co. of Germany and NOK Corp. of Japan.
            duce labor and gain production efficiencies. Engel was an obvious partner due to our extensive automation background and existing strong working relationship with FreudenbergNOK. Freudenberg-NOK had an OEM application – to produce a fully rubber covered steel insert. The decision was made to purchase the Engel 150 ton horizontal tiebarless Elast machines and ERC 54/0 E-series side entry robots, creating fully integrated machine cells to handle the process from insertion of the steel inserts to packaging the finished parts. The integration of these manufacturing cells is extensive, and Engel’s CC100 machine controller provides a common control panel for machine, robot, automation and peripheral equipment (in this case, three external temperature control units). Each press is equipped with an ERC 54/0 E-series, 4 axis, servo driven side entry robot. The robots are supplied with a uniquely designed end of arm tool, allowing a single robot to place the metal insert, remove the molded part, deposit the molded parts into a queue for automated camera inspection, retrieve the inspected parts and place them into packing trays which are utilized by the OEM customer’s automation. All that is required of the operator is to supply raw materials in bulk and to remove the trays of finished goods at certain intervals. >> A full cycle, from raw material to inspected and packed parts, takes less than three minutes per cycle. The development of these manufacturing cells has provided a multitude of savings to Freudenberg-NOK: >> the increased platen size of the tiebarless press allowed for the purchase of a smaller tonnage machine than would have be possible with a tiebar design, >> the ability to purchase smaller tonnage machines that provided a 15% smaller foot-

            print, saving costly space on the plant floor, >> the use of the side entry robot eliminated costly work that would have been required to the facility’s ceiling, to accommodate the robot travel, if using a standard robot, >> use of robot lowered manpower requirements; as an operator was no longer required for each machine, and >> automation provided stability to the process, helping guarantee part repeatability. As many companies are just beginning the process to become more efficient and eliminate waste, Freudenberg-NOK is a company that has already embraced this philosophy, and develops every product and process with these factors in mind. Engel’s ability to supply a unique machine technology for many different materials has also proven to be invaluable to Freudenberg-NOK. They have been able to use Engel machines in not only organic rubber applications but also solid silicone, liquid silicone (LSR) and thermoplastics with great success. Forward thinking in mold design coupled with highly repeatable and capable injection molding machines has allowed FreudenbergNOK to become a North American leader in drivetrain sealing systems and vibration control technology. <<

            Fully integrated machine cells consisting of Engel 150 ton horizontal tiebarless Elast machines and ERC 54/0 E-series side entry robots, handle the process from insertion of the steel inserts to packaging the finished parts. Photo right: Automation provides stability to the process, helping guarantee part repeatability.

            North America Supplement
            Page 2

            injection

            Engel machines in operation Engel machines in operation Engel machines in operation Engel machines in operation Engel machines

            The large platen area on Engel’s high precision 200 ton tiebarless press enables GW Plastics to utilize a smaller tonnage machine than the comparable competitor machine. Photo left: Founded in 1955, GW Plastics has grown to one of the largest custom molders in the United States.

            GW Plastics, Inc., headquartered in Bethel, Vermont (USA) does not just deliver products to their customers, they deliver

            Quality Technical Solutions
            >> Founded in 1955, GW Plastics has grown impressively from a four molding machine operation located in rural Vermont to one of the largest custom molders in the US, with over a hundred and thirty injection machines in four facilities. Under its present management, the financially strong, closely held organization has more than doubled in size since 1983. The GW customer base is divided equally between automotive and medical markets. The automotive market concentrates on high volume complex components that include under the hood electrical connectors, seat position sensors, fuel handling and safety restraint systems. Electromechanical switches for windows and door locks, turn signals and HVAC controls are also produced, as well as high precision gears. With multiple cleanrooms for manufacturing and assembly, the medical side of GW produces products that are used in cardiopulmonary bypass surgery, in-vitro diagnostics disposables, blood diagnostics, filtration and endoscopic surgery. The automotive and medical markets both require highest demands in regards to quality standards. GW currently services a portfolio of Fortune 1000 customers in the Automotive and Healthcare industries nationwide. To what does GW Plastics contribute their success? By adopting the most advanced molding technologies available, they are now able to delivery high precision turnkey solutions. Embracing this philosophy has allowed GW Plastics to separate themselves from the traditional custom molder philosophy of “shoot and ship”. With the change in company philosophy, Engel proved to be a perfect compliment. One of the first challenges GW and Engel shared was designing a manufacturing cell for

            a component of a complex 6 cylinder engine ignition module. The customer solution included high precision 200 ton tiebarless molding machines equipped with Engel designed automation and robotics. Engel was the chosen supplier for several reasons: 1. The large available platen on Engel’s tiebarless presses allowed utilization of a 200 ton Engel press in comparison to a competitor’s 300 ton tiebar model. 2. Superior shot to shot consistency from the CC100 controls and smart pump hydraulics. 3. Turnkey solution from one source. 4. Service and support commitment starting from the manufacturing locations, continuing with spare part centers, and local field service and sales support. This project was not only challenging technically, but time challenging as well. The technical challenge of the system included loading 3 different inserts into each cavity of a 4 cavity mold (total of 12 inserts per cycle) with insert present confirmation, and removal of the finished assembly to an in-line conveyor for additional post-molding operations. The existing tooling, which had been

            designed for vertical clamp machines, required modification to run in a horizontal press. The change to a horizontal press, and addition of automation, allowed for a more consistent cycle and provided improved part quality. >> All of this to be accomplished and shipping product in 20 weeks! With Engel and GW working side by side, the new system was running successfully and delivering over 12,500 parts per day with greater quality and efficiency than the customer had seen with previous molders. – This is but one example of GW Plastics’ commitment to advanced methods of plastics processing. GW Plastics continues to grow and succeed as other molders in North America lose business to overseas competition. Engel has been an instrumental part of this growth, supplying numerous machines from 40 to 500 tons, in both tiebarless and toggle clamp configuration. In addition, all Engel machines at GW Plastics, over 200 tons, are equipped with Engel servo robots. GW Plastics remains convinced that smart investments in technology are the key to customer satisfaction and long term survival in North America. <<

            >> In the fast paced and highly competitive world of automotive plastics, US Farathane is a perfect example of how to not just survive, but to thrive. US Farathane is a privately held company with four molding facilities located in the state of Michigan, housing a total of 85 injection molding machines. The machines range in size from 75 to 720 tons clamping force. Having been a leading supplier to the Automotive Industry for nearly three decades, US Farathane has tripled in size over the past five years, and currently employs 510 people, with annual sales in excess of 75 million US dollars. Their mission statement: “To lead the Automotive Market in the development and

            US Farathane

            Innovation by Design
            US Farathane and Engel share a common goal: to be a full-service provider of value-added design and the highest quality solutions.
            US Farathane Corporation’s facility in Sterling Heights, Michigan is home to both a 68,000 square foot manufacturing plant and a 15,000 square foot Technology Center.

            US Farathane is an industry leader in automotive application two component molding, using technology to set themselves apart from their competition.

            manufacture of highly engineered plastic products and materials, adding value to each product solution offered”, is a true representation of how they conduct day to day business. The true indicator of a company’s success is measured by the statements made by their customers: >> Ford Motor Company says US Farathane has made a significant contribution to Ford’s cost saving efforts. >> General Motors depends on US Farathane to consistently supply innovative designs and solutions. >> Daimler Chrysler states that “US Farathane components have played a key role in the significant improvement of our door systems.” In addition, Daimler/Chrysler recognized the company with Gold Award honors for outstanding achievements. These are truly impressive statements from the largest automotive companies in the world. One of the largest technology sectors to which US Farathane owes its current success is multi-component molding. The company purchased its first Engel 200 ton two-component molding machine in 1993, and has since purchased an additional 27 Engel multi-component machines ranging from 200 to 500 tons for their facilities in Sterling Heights and Utica, and are now recognized as the industry leader in automotive application two component

            molding. The application solutions that the company has developed are impressive. Peter Pouget, General Manager, says the technology has set USF apart from their competition – allowing them to produce parts more efficiently and cost competitively. “More and more is being expected of suppliers, and we are a full-service supplier”, says Andrew Greenlee, company president and CEO. “We don’t want to be just another injection molder.” One example of a multi-component solution developed by USF is its innovative HVAC seal design. The conventional design involved open cell foam that produced an odor when the car’s air conditioning was activated. USF replaced the foam with a multi-component sealing part that did not retain moisture, and therefore greatly reduced the bacterial buildup that was present in the original open cell foam part. The new design is also more forgiving and accounts for build variation in the HVAC housings and cores. “Our ability to innovate and then pair that innovation with solid value has made us a leading supplier to the automotive industry”, Greenlee says. “We reached this point by being customer-focused and solution-oriented.” US Farathane – another North American success story of survival (success) through technology. <<

            Asia Supplement

            injection
            N e w s , F a c t s a n d m o re . I n f o r m a t i o n f o r o u r c u s t o m e r s .

            June

            2005

            11

            In recognition of the growing demand on high level, large scaled injection molding machines in Asia, the resent signing of the land contract in Shanghai Xinzhuang Industry Park was the first cornerstone in the project of setting up a factory in China for the production of large injection molding machines.
            >> It is a big step for Engel and firm commitment to the ever-growing importance of the Chinese injection molding machine market. Engel Machinery (Shanghai) Co., Ltd. is to be a wholly Engel owned enterprise and together with Engel Machinery Korea Co., Ltd. Engel now will have production capacity in Asia to cover the full range in clamping force of the Engel scope of products from 25 tons to 55,000 tons. The location was selected after investigating various options. Considering the location of our current customers in the Yangtze delta area and other factors such as infrastructure and accessibility, the location in Xinzhuang Industry Park in Minhang District on the outskirts of Shanghai City was found most suitable. With 12 km to Hongqiao International Airport, 35 km to Pudong International Airport, only 15 minute drive to Shanghai-Ningbo and Shanghai-Nanjing Expressways and public transportation connection via light railway and subway to the 18 km distant city center the site location offers convenient transportation connections to national and international destinations. With an investment volume of 30 Mio. USD the plant capacity is designed for the production of large injection moulding machines with clamping forces ranging from 5,000 kN to
            While Engel is currently engaged in the legal steps and procedures to register and establish Engel Machinery (Shanghai) Co., Ltd. infrastructure preparations on the site are already ongoing.

            Engel Machinery Shanghai

            New Engel plant will meet the growing demand
            55,000 kN. As a major portion of the total investment is going into manufacturing equipment, we are determined to machine major mechanical components in house in order to secure the “Engel-like” high standard in quality and accuracy. A state of the art European made travelling column horizontal machining center with a table load of 60 tons will enable us to machine even the largest platens and base-frames of the ENGEL DUO series. The first investment phase will provide sufficient space for an annual capacity of up to 100 machines. With a total land size of 35,000 m?, the location provides enough space for expansion phases to meet the growing demand on large injection molding machines in China even in the long term. >> Current layout planning consist of the manufacturing and assembly area and a technical center and show room where we will be able to run customer requested mold tests and trial runs. >> With a ware house serving not only as a buffer for the production but also as storage for spare parts the material and component stock enables us to ensure shortest possible delivery time of spare parts throughout China. >> The building will also house the service department including a training room equipped with a training machine. >> Office space for a D&E department, the factory management, and the general management as well as the sales department for mainland China are also integrated into the building. Finalization of the detailed design planning is expected to be finished in August this year and construction is to start within late summer this year. The new Engel Shanghai factory is planned to be ready for production start in spring 2006 and will produce 30 DUO injection molding machines within the first year of operation. <<

            Meiling Plastic

            Top with machine and process technology from Engel

            >> Shanghai Pudong Meiling Plastic Plant was established in 1982 with a factory building area of 23,500 m? and a total capital of RMB 100 million Yuan (about 12 million USD). Since 1998, they have started to order Engel machines with tonnage ranging from 110 to 1,500 tons. Now, 16 sets of Engel machines are run-

            At the beginning of 2005, Meiling ordered an Engel 2,300 ton machine with ERC robot (ENGEL DUO 23050/2300 + ERC114-E) for their new project with Sony. Richard Ho (photo on right) from Engel Shanghai is pleased that the production is running accurate from the very beginning.

            ning in their plant. There are tiebarless, toggle and DUO machines. Some of them are equipped with ENGEL ERC robots. Special applications such as Gasmelt Systems and In-Mold-Decoration (IMD) have been applied on some Engel machines. In the coating workshop, there are double-pass spray chambers with automatic electrostatic precipitation for 43-inch TV set housing and third-grade purification wind, computer controlled automatic drying system coating lines and equipment for ultrasonic welding, transfer printing and silk-screening. With more than 20 years of experiences and disciplined management, the plant has passed ISO 9001:2000 international quality management system authentication, UL authentication and is operating with ISO/TS 16949 system, so as to secure the quality of products, to meet the requirements of injection molding items and to keep a close pace with the development of global technology. Their products are extensively used in products of famous companies such as Shanghai Sony, Panasonic, Mitsubishi Electric, Hitachi, Fujitsu, Dakin, Sharp, Whirpool, Fedders, etc. and are sold abroad to US, Europe, Japan, etc. In addition, the plant extends its business to the injection molding area of inner decorations and light of cars, with an annual sales amount of more than RMB 200 million Yuan, and plays a leading role in the industry. <<

            Asia Supplement
            Page 2

            injection

            Engel machines in operation Engel machines in operation Engel machines in operation Engel machines in operation Engel machines

            With their new ENGEL DUO machines (1,300 ton and 1,100 ton) with ERC Robots equipped with Tecomelt technology and MuCell technology Yanfeng Visteon is producing interior door panel assemblies and door pillars.

            Yanfeng Visteon

            “To be the best automotive components supplier”

            >> Yanfeng Visteon Automotive Trim Systems Co., Ltd., previously, Shanghai Yanfeng Automotive Trim Co., Ltd., is a 50/50 joint venture company invested by Shanghai Automotive Industry Corporation (Group) and Visteon International Holdings Corporation. The Company was established in 1994 with a total investment of USD 223 million and is headquartered in Shanghai’s Caohejing Development Zone. Yanfeng Visteon has a strong manufacturing presence in Shanghai’s Anting area. The primary products of the Company are cockpit systems (incl. instrument panel assembly), interior systems (incl. door panel assembly and door pillar), exterior systems (incl. painted bumper and trims), seating systems, safety systems, and electronics systems. Key customers of Yanfeng Visteon are Shanghai VW, Shanghai GM, FAW-VW,

            Dongfeng Citroen, Chang An Ford, Beijing Hyundai, Beijing Jeep, Chery and BAIC Foton. The company’s export reached USD 168 million in 2004. Additionally, Yanfeng’s technical center and tooling center is capable of completed product design and development for automotive interior and exterior systems and has an in-house national level laboratory for interior and exterior product testing. Since 1997, the company has attained numerous quality certifications – ISO14001, OHSAS 18001, QS-9000, VDA 6.1 as well as TUV ISO/TS16949:2002 and ISO 9001:2000. In 2002, Yanfeng Visteon achieved the Golden Quality Award of Shanghai City. Furthermore, the company received recognition by the Shanghai Municipal Government as a Shanghai Civilization Unit. – The vision of the company is:

            >>“To be the best automotive components supplier in the world – in terms of quality, cost, timing and function.” To support this vision, Yanfeng Visteon has set up strategies such as “Lead in Customer Satisfaction” and “Achieve Worldwide Product Excellence.” Between 2003-2004, the company ranked 238th among the top 500 foreign invested enterprises in China (in term of sales). Since 2002, Yanfeng Visteon Automotive Trim Systems Co., Ltd. have bought several sets of ENGEL DUO Machines with ERC Robots and Quick Mould Change Tables (1,300 ton and 1,100 ton) equipped with “Tecomelt“ technology and “MuCell” technology for production of interior door panel assemblies and door pillars. They consider Engel as one of their most important long term partners for technology development. <<

            Samjin LND

            Leading in the mechatronics business with global competitiveness
            >> Sam-Jin LND was established in 1987. Since 2000, they have started to order Engel machines with tonnage ranging from 45 to 600 tons. Now, 69 sets of Engel tiebarless machines are running in their plant. Some of them are equipped with ENGEL ERC robots. Based on Samjin’s in-house Mold technology, since 1999 they have implemented the Total Production System which produces the Mold Frame (M/F), an essential part for the TFT-LCD Monitor, and allows for the production of parts in-house. In particular, the Total Production System enables the design, mold creation and the use of other technology needed to produce the Mold frame within the company. They have the largest facilities and production capability of Mold Frames in Korea, attaining cost reduction by adapting the Hot Runner systems, thereby ensuring their competitiveness in the overseas market. At the same time, their environmentally friendly cleaning method and innovative development of a cleaner and automated production line have contributed to the consistent creation of high-quality products and high productivity. Samjin is producing a . 14.1 inch and 15.1 inch M/F for Notebook PCs; and a 15 inch and 19 inch for Monitor, Car Navigation and Cellular phones. In addition, Samjin is developing a 22 inch and 26 inch M/F for TVs. And they have produced LGP (Light Guide Panel), the most important part among the 20 parts of the LCD Back Light Unit (BLU). As the BLU uses a 1st dimension light source (dotted line like LED, CCFL), it requires the LGP to deliver light to the front side of the BLU. Since 2001, Samjin LND has produced LGP using No-printing Stamper Technology and Samjin’s own patter design technology, developing a Prism-less type LGP that makes it possible to achieve high-level technology and productivity so that they may supply BLU to leading companies in the TFT-LCD market. Samjin is producing 20 models of LGP for cellular phones, Car Navigation, TFT-LCD monitors and Notebook PCs and last they have produced battery parts. Li-ion battery include the Gasket, PP Case, Insulator, CapAss’ym, and Samjin is now producing a Gasket the Company developed for the 32-cavity mold. Recently, Samjin has succeeded in the unique development of the Inner Pack Thin Film Case (0.25mm thickness) using by ENGEL VICTORY 200/120 high speed machines for Cellular Phone use and is now supplying these to their customers. With almost 20 years of experience and disciplined management, Samjin has attained quality certifications (ISO 9002, ISO 14001). With its products – extensively used in products of famous companies such as LG Electronics, Sanyo, Samsung, Becker, Bosch, etc. – Samjin achieved in 2004 a turnover of more than RMB 1.1 billion Yuan (130 million USD), and plays a leading role in the mechatronics. Samjin consider Engel as one of the most important partners. <<

            Within Samjin’s five production sites (three in Korea and two in China) meanwhile 69 tiebarless Engel machines are running in the plants. One of the production lines is the injection molding of components and assembling of CD and DVD Decks (photo right).

            At the headquarters in Hwasung-city, Kyunggido/Korea Samjin is producing the LCD Back Light Units by cleanroom conditions.


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