KraussMaffei Presents Recyclate-based ‘Sandwich’ Molding at Fakuma

Lightweight, with a glossy surface and a sustainable message, describes the small blue turtle that will be produced on an all-electric PXZ 121-380-180 Multinject press using the sandwich process at the KraussMaffei stand at Fakuma. It has a black core made of mechanically recycled polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) and a high-quality outer layer made of chemically recycled ABS.

Numerous features of the PXZ 121 injection press — such as the new sandwich platen, near-contour mold temperature control from partner Contura MTC, and the APCplus machine function, which uses specific property values of different resin grades — make the multi-component process even more efficient and economical, according to KraussMaffei.

Sustainability reinvigorates sandwich structures

"The increased use of recyclates has brought sandwich technology back into focus in multi-component technology and offers great potential,” said Manuel von Varchmin, responsible for sales of injection molding technology and automation at KraussMaffei. “Thanks to its precision, efficiency, and flexibility, our all-electric PXZ Multinject version is ideally suited for this. We will be demonstrating this at Fakuma using the example of the Turtle project, which we have implemented with Contura MTC and other partners."

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The all-electric PXZ 121 Multinject demos a high-quality sandwich application with a high proportion of recycled material at Fakuma. Image courtesy of KraussMaffei.

The Turtle project combines a high-quality mold with a high-performance, all-electric injection molding machine from the PX series and the new LRXplus linear robot. This combination brings clear economic benefits with an early ROI, while at the same time using valuable resources responsibly.

The core material of the durable turtle at Fakuma consists of mechanically recycled PC/ABS E-Loop 5120MR from Elix Polymers. However, a foamed or reinforced core made from recycled material is also feasible and offers further potential for sustainable production. The visible, high-quality outer skin is made of chemically recycled and processed ABS E-Loop P2H-AT CR, which can be supplied in various colors.  

Another sustainable aspect is removal of the cold runner sprue, which is then shredded and fed directly back into the production process for the core material. This is accomplished with the new mini sprue mill from partner Getecha, which is being used for the first time. This also creates a closed material cycle.

Sandwich platen delivers production flexibility

The all-electric 1200-kN clamping force PXZ 121 Multinject features a compact, space-saving Z-position configuration for the electric injection units. In addition, the attached, removable sandwich platen offers a high degree of flexibility in production. This means that the PXZ 121 can be used as a single-component, two-component, or sandwich machine without any additional effort.

In terms of machine control, the simple switchover from skin to core melt flow ensures flexibility and quality at the same time. On the one hand, the skin material can be added to seal the sprue point. On the other hand, it is possible to switch between component A and B several times. This also allows marbling effects to be achieved for an individual design, for example.

Tooling and dynamic mold temperature control are supplied by partner Contura MTC. Near-contour temperature control optimizes the entire production process and is particularly important in order to achieve the required high-quality surface of the turtle at economical cycle times. 

Linear robot debuts at Fakuma

Part removal, separation from the sprue, separation into the grinder, and depositing on the belt are automated by the new LRXplus linear robot, which is premiering at Fakuma together with the MC7 control system. The LRXplus from KraussMaffei offers numerous new functions that make production even more flexible and economical. Thanks to its compatible interfaces, the LRXplus can be combined with almost any system, whether with KraussMaffei injection molding machines, injection molding machines from other manufacturers, or as a standalone solution for all other automation tasks.

Grade-specific process control

KraussMaffei claims that its Adaptive Process Control (APCplus) system is the only controller on the market that uses material-specific compression curves for process control. The APCplus database contains all common material types that can be selected by the converter for process control.

The patented APCplus machine function now incorporates individual grade-specific property data. Image courtesy of KraussMaffei.

KraussMaffei is going one step further at Fakuma. All materials for use on the PXZ 121 Multinject come from Elix Polymers, which, like KraussMaffei, is also a Sinochem Group company. With specific material parameters from Elix Polymers integrated into the APCplus database, the machine function is precisely adjusted to the material being processed, making the injection molding process even more precise and efficient overall.

KraussMaffei will exhibit at stand 7303 in hall A7 at Fakuma, the international plastics processing trade show in Friedrichshafen, Germany, on Oct. 15 to 19.