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“Technology
advances mark the
way forward.”Dr. Dietmar Straub,
KraussMaffei CEO.
EDITORIAL
made by KraussMaffeiPublished by: KraussMaffei Technologies GmbH, Krauss-Maffei-Straße 2, 80997 Munich, Germany Phone + 49/89/88 99-0, Fax + 49/89/88 99-2206, www.kraussmaffei.com Responsible: Matthias Andreesen Viegas
PUBLICATION DATA
EDITORIAL | NEWS
Editorial office: mk publishing GmbH, Döllgaststraße 7–9, 86199 Augsburg, Phone +49/821/3 44 57 0, Fax +49/821/3 44 57 19, www.mkpublishing.de Photo credits: Becker Kunststofftechnik, Bikkoplast/Dopak, Evonik, Ford, Fotolia, Hans Arnold Kunst-stofftechnik, Intelligent Engineering, KraussMaffei, Kunststofftechnik Wiesmayer/Anton Mirwald, M B Fotodesign/Martin Banzhaf/Harald Mehnert, mk publishing/mk archive, VBM
02 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Dear Readers,
Forcing down costs, increasing efficiency and boosting productivity – these
are key concerns right now throughout the plastics industry. It takes new-
generation machines and systems to gain a key competitive edge; technology
advances mark the way forward.
This holds true for KraussMaffei as much as for the rest of our industry. It’s
why we’ve recently invested a substantial amount to boost quality and
productivity in our main production plant in Munich. Our new Surface
Treatment Center opened just a few days ago, replacing our previous paint
shop. All in all, the new facility cost around four million euros – you
couldn’t ask for a stronger sign of our conviction that the economy can and
will recover. Experts tell us that you’d have to look a long way to find the
equal of our new facility anywhere in the world. For example, we now
move parts and modules weighing up to 32 tonnes through the paint line on
an overhead track system synchronized with the rest of the assembly line.
When the system is operating at full capacity, it is handling the equivalent
of the take-off weight of an Airbus. As you see, we never let up in our
pursuit of quality and productivity for our machines and processes. But
your vote is the decisive one – as our customer you have the final say in
whether we’re offering you the right solution at the right time!
If you’re among the customers who currently have no plans for major
investments, we can nonetheless show you affordable options for increasing
the efficiency of your production. Our retrofit packages and upgrades can
significantly improve the productivity and energy efficiency of your installed
machines. You might opt for a higher level of automation with a robot from
our expanded portfolio, or for reduced energy consumption with one of our
efficiency packs. Especially in recent years, KraussMaffei has taken up the
theme of energy efficiency; today “BluePower” stands for the products and
upgrades we offer to help you reduce energy consumption. To add even
more momentum to this strategy, KraussMaffei has now launched the
BluePower Award, which will honour energy- and resource-efficient
production solutions. We’ll be announcing the winners during the world’s
biggest plastics show, the K2010, at the end of October. We’re looking
forward with great interest to your competition entries.
With best regards,
Dr. Dietmar Straub
BluePower is the
concept that bundles
our continuing
endeavours to
promote the
development
of energy- and
resource-efficient
production
solutions. As part
of this effort, KraussMaffei has now launched
the BluePower Award inviting entries from all
the innovative plastics processors among our
customers.
We’re looking for new developments that deliver
a significant increase in energy- and resource-
efficiency. They can be anything from individual
applications and processes to complete concepts
– and they can come from any area of the plastics
processing industry. We’re especially interested in
processes that make sustainable use of synergies
through intelligent combinations of different
technologies, such as injection moulding, reaction
moulding and extrusion. The entries will be
evaluated and the winner selected by an independent
jury panel made up of high-ranking representatives
from science and industry. KraussMaffei employees
will not be eligible to vote on this panel. The winner
of the BluePower Award 2010 will be announced on
October 28, during the world’s biggest plastics show,
the K2010 in Düsseldorf, Germany. Closing date for
entries, which must be in writing, is May 31, 2010.
More information and details of how to enter are
contained in a questionnaire that you can request by
email. p
KraussMaffei sets up a prize for efficiency!
BLUEPOWER AWARD 2010
CONTACT
Dr. Reinhard SchiffersPredevelopment/EnergyPhone +49/89/[email protected]
KraussMaffei Berstorff is now offering complete
systems for continuous production of PU-
insulated pipes. One, or two, plastic media pipes
is encapsulated in an insulating polyurethane
layer plus a protective polyethylene sheath.
The insulated pipes can transport either hot or
cold media. With this single-vendor production
solution, the company, a world leader in
plastics and rubber processing machinery,
once again demonstrates its multitechnology
competence – in this case in pipe extrusion and PU processing – built on
many decades of engineering excellence. This unique know-how enables
us to develop complete production solutions by skilfully integrating
modules from different technologies. p
NEWS
Events through to autumn 2010
TRADE SHOWS
19. – 22.04. Chinaplas Shanghai, China
19. – 23.04. Expoplast Algiers, Algeria
11. – 14.05. RusChem Moscow, Russia
11. – 15.05. Technics Belgrade, Serbia
13. – 16.05. Plastex Cairo, Egypt
25. – 28.05. Plastpol Kielce, Poland
26. – 28.05. PU China Shenzhen, China
14. – 16.09. Composites Essen, Europe Germany
27.10. – 03.11. K 2010 Düsseldorf, Germany
COVER
03
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Perfectly paired off:pipe plus insulation
Bavarian Economics Minister
Martin Zeil (right) and
Dr. Dietmar Straub,
KraussMaffei CEO, at the
opening of the new Surface
Treatment Center.
KraussMaffei has recently completed a future-oriented project in our main
production plant in Munich. Guest of honour at the opening of the new Surface
Treatment Center (STC), on March 5, 2010, was Bavarian Economics Minister
Martin Zeil. The new facility replaces our previous paint shop. In his address,
Martin Zeil commented, “The German plastics machinery sector has been
especially hard hit by the turbulence of the economic crisis. This is why I’m
absolutely delighted with every Bavarian company that has taken the crisis
as a spur to look ahead, modernize and invest. With its new and innovative
paint facility, KraussMaffei is among the leaders in this area too.” Despite the
economic crisis, KraussMaffei invested around four million euros in building and
equipping the STC. As Dr. Dietmar Straub, CEO of KraussMaffei AG, pointed
out, “With the new Surface Treatment Center we’re improving the transparency
of our entire assembly process; it will enable us to work more efficiently and
cut our turnaround times – our customers will benefit significantly.” The STC
was planned and built in a close collaboration between KraussMaffei and
Rippert Anlagentechnik GmbH & Co. KG, from Herzebrock-Clarholz/North
Rhine-Westphalia. Rippert, a systems engineering company with around 300
employees, has almost 40 years’ experience in planning and installing painting
and filtering systems and industrial ventilation units. Complex coating systems
are among its core competences. p
MULTI-MILLION INVESTMENT
New Surface Treatment Center opened
04 MADE BY KRAUSSMAFFEI 1 ¦ 2010
Cleanroom Competence Center in Rosenheim,
opened on January 29, 2010, provides an excellent
environment for researching this field,” emphasizes
Martin Würtele, Manager Predevelopment New
Technologies at KraussMaffei. Under the aegis of
Prof. Peter Karlinger, researchers in Rosenheim
are working on a complex production cell based
on a KraussMaffei all-electric EX 80/380. “Our
cooperation with the university in Rosenheim has
already generated a large number of successful
projects and graduate theses across all three key
technologies – injection moulding, extrusion and
reaction moulding,” says Martin Würtele. Much
of this research is aligned with KraussMaffei’s
“Technology to the Power of Three” strategy. With
the opening of the competence center, Rosenheim
University became part of the PRIMUS Network
for Innovation set up by KraussMaffei (responsible
for the focus area “Life Sciences”).
Focus on energy efficiency
The University of Duisburg-Essen (UDE) is
also a member of the PRIMUS Network. Since
January 15, 2010, there’s been a cooperation
agreement between the university’s Faculty of
KNOW-HOW SHARING DRIVES DEVELOPMENT
Development engineers in mechanical engineering companies are not the only people working on solutions to tough challenges in plastics processing – there’s a lot of academic research going on too. In Germany alone, KraussMaffei supports over 20 universities and other research institutions with machinery and know-how. Life sciences, lightweight structures and energy efficiency are among the key research topics.
One strong trend in
plastics research is
the increased focus on
the life sciences sector
– medical technology,
pharmaceuticals and
cosmetics. There’s
a long-standing
cooperation in
this area between
KraussMaffei and
Munich’s University
of Technology (TU), with ordinarius professor
for medical technology, Prof. Dr. Dr. Erich
Wintermantel. TU researchers and students have
two injection moulding machines, including an
EX 50/55, and a compounder at their disposal for
experiments.
Relatively new, by contrast, is the cooperation
agreement between KraussMaffei and Rosenheim
University of Applied Sciences. It’s also focused
on the life sciences field and especially on
cleanroom technology. “One of the main concerns
in this sector is to develop processes that make
post-mould sterilization unnecessary. The new
FOCUS
Industry and research hand-in-hand
Celebrating another
recent cooperation
agreement: Prof. Dr.
Dieter Schramm and
Prof. Dr. Johannes
Wortberg from the
University of Duisburg-
Essen with Dr. Karlheinz
Bourdon and Georg
Holzinger, from
KraussMaffei (l. to r.).
05
Engineering and KraussMaffei with the specific
goal of improving the energy efficiency of plastics
processing machinery. The strategic cooperation
partner on the university side is the chair of
Engineering and Plastics Machinery headed by
Prof. Dr.-Ing. Johannes Wortberg. The cooperation
partners have agreed on regular information
exchange and supporting engineering students and
researchers. One specific area of cooperation will
be developing and optimizing alternative drive
technologies for plastics processing machinery. The
remit for this project includes energy consumption,
energy recovery, precision and efficiency.
KraussMaffei is mainly concerned with developing
and optimizing components, in particular with the
practical implementation and with application-
related process engineering.
Combined process for function-integrated
lightweight systems
The cooperation between KraussMaffei and the
Institute for Lightweight Structures and Plastics
Technology at Dresden University of Technology,
headed by Prof. Dr. Werner Hufenbach, dates
back to 2008. One important area of research
here is fiber-composite lightweight elements and
the development of new resource-efficient process
chains for manufacturing them. The researchers
in Dresden have at their disposal an innovative
LFI (Long Fiber Injection) system, including a
shuttle mould carrier, supplied by KraussMaffei’s
Reaction Process Machinery division. The research
encompasses multitechnology and multiprocess
solutions.
The Center for Integrative Lightweight
Technologies (ZIL) at the Chemnitz University
of Technology is working in related fields. For
example on the development of a new combined
process for reinforcing plastics with long fiber
materials and fabric intermediates in injection
moulding. These types of lightweight composites
are used in making anything from aircraft to
rolling stock and road vehicles, because their
lighter weight reduces fuel consumption and
carbon dioxide emissions. The ZIL, headed
by Prof. Dr. Lothar Kroll, operates a total
of six KraussMaffei machines, including a
multicomponent spin-platen machine, a RIM
polyurethane system and an IMC injection
moulding compounder. A new addition to the
center’s machine park is a ZE 40 A x 50 D UTXi
twin-screw extruder from KraussMaffei Berstorff
engineered for high-performance compounding
tasks. “Basic research is very important for us
as a mechanical engineering company, because
it paves the way for adapting our extruders
to market requirements and to continuously
developing them,” points out Prof. Dr. Bernd
Poltersdorf, head of Foam, Film and Sheet
Extrusion at KraussMaffei Berstorff. p
FOCUS
CONTACT
Martin WürteleManager PredevelopmentNew Technologies/Process EngineeringPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Prof. Dr. Bernd PoltersdorfManager Foam, Film and Sheet ExtrusionPhone +49/511/[email protected]
Prof. Dr. Lothar Kroll,
Dr. Wolfgang Kempt and
Dr. Wolfgang Nendel
(from left) of the TU
Chemnitz with the ZE
40 A x 50 D UTXi twin-
screw extruder from
KraussMaffei Berstorff,
Hanover, which offers
new scope for research.
06 MADE BY KRAUSSMAFFEI 1 ¦ 2010 FEATURE
– adding up to around 14 in total. “Thanks to our
joint project with Evonik, we can now offer our
customers a far more cost-effective process,” says
Dr. Karlheinz Bourdon, head of KraussMaffei’s
Injection Moulding Machinery division. And Josef
Renkl, R&D Manager for the company’s Reaction
Process Machinery division adds, “Thanks to our
multitechnology know-how – in this case injection
moulding and PU processing – we’ve been able to
develop the process to market readiness. It will
dramatically shorten the process chain. The new
CoverForm process has just four steps: incoming
check, injection moulding and coating in the same
mould, quality control, final assembly. All these
steps are performed in one and the same machine.
The process saves time, costs and production space.
In addition, the surfaces produced in this way are
often more scratch-resistant than those that are
COVERFORM PROCESS FROM KRAUSSMAFFEI AND EVONIK
Display panels in mobile phones, appliances,
consumer electronics and automotive instrument
panels are made of transparent polymers.
The displays must remain transparent despite
exposure to mechanical and chemical impact, for
example, through cleaning agents or handcreams,
otherwise they are not fit for purpose. The
material most used for these applications is
polymethyl methacrylate (PMMA) often known
by the tradename Plexiglass. The PMMA must
be specially coated to protect the surface from
scratches and chemical damage. In conventional
production, this coating is applied in a post-
mould paint process.
A far shorter process chain
A conventional process comprises multiple steps
including quality controls, storage and transport
Joint project in surface treatment technology
Dr. Karlheinz
Bourdon, member of
KraussMaffei’s Board of
Management (left) and
Gregor Hetzke, head of
Performance Polymers
at Evonik, at the opening
of the CoverForm
Competence Center.
The CoverForm process, developed by KraussMaffei, as machine supplier, and Evonik, as material supplier, substantially shortens the process chain for the production of transparent, scratch- and chemical-resistant parts. Processors save transport effort, time and production floor space – in the last analysis they save costs. The quality is often better than can be achieved in a conventional painting process.
COVERFORM PROCESS STEPS Inl ine scratch-resistant coating of PMMA
Inject PMMA
Compression/cooling
Open cavity & inject coating
Compression & heating 100%
Compression & cooling
Compression & start heating
FEATURE 07
conventionally painted. It couldn’t be simpler. This
is how CoverForm works – after injection of the
special PMMA, a mould stroke forms the surface
to be coated. The part cools in the mould. The
cavity is then enlarged slightly, creating a space for
the surface coating layer. This gap is flooded with
a liquid reactive system, ideally matched to the
PMMA material, and the mould closes in a second
compression stroke. The high-performance Dynamic
Temperature Control (DTC) ensures that the
temperature profile in the mould, required for the
different process stages, is exactly repeated in each
cycle. The only post-mould process is UV curing
which takes place immediately after demoulding.
The parts are then ready for assembly.
Competence center
for award-winning process
In November 2009, a CoverForm Competence
Center was opened at the Evonik plant in
Darmstadt – it’s the ideal
place to demonstrate
the new process. The
center was opened by
Gregor Hetzke, head of
Performance Polymers at
Evonik and Dr. Karlheinz
Bourdon. Evonik is using
the new center both for demonstrations and for
further development of reactive systems. Among
the possible candidates are new anti-reflective or
electrically conducting coatings. In addition, the
center is the ideal training environment for the
technicians in Evonik’s worldwide service teams.
despite its relatively short time on the market,
CoverForm has already won an award. At the
Materialica trade show, last autumn in Munich,
it won “Best of” award in the category Surface
and Technology. In its review, the jury noted
that CoverForm is a forward-looking,
market-ready process which is the
result of productive interaction between
materials, engineering expertise and design.
CoverForm is a system solution available
exclusively from the joint partners Evonik
and KraussMaffei. It’s yet another example
of the sustained increase in productivity
that can be achieved by joining up
processing technologies, as advocated by
KraussMaffei’s “Technology to the Power
of Three” strategy. p
KraussMaffei injection
moulding machines are
at the heart of CoverForm
production cells.
CONTACT
Marco GruberManager Application Engineering,Process Development IMMPhone +49/89/[email protected]
Josef RenklManager Research and Development RPMPhone +49/ 89/[email protected]
Sven Schröbel, Evonik
Industries, Martin
Eichlseder, KraussMaffei,
and Arne Schmidt, Evonik
Industries (from left),
showing off the “Best of”
award at the Materialica.
Demoulding Final curing (UV curing)
08 MADE BY KRAUSSMAFFEI 1 ¦ 2010FEATURE
LIFE CYCLE SERVICE
Technologies change over time. Part of KraussMaffei’s full-service offering is our commitment to maintaining and upgrading plastics processing machinery over the whole life cycle, so that it is always fit for purpose in fast-changing markets.
Multitechnology processes – such as CoverForm
(see page 6/7), nanoskin (see page 9) or inline
compounding – are an important way forward
for plastics processors. Production cells for these
processes are all based on a KraussMaffei injection
moulding machine. Our customers know they can
count on our many decades of experience with
injection moulding machines, which are one of
our core businesses. Our expertise goes beyond
developing and supplying highly productive ma-
chines; we also have the engineering skills to make
sure they stay that way over long service lives and
in the face of changing products and markets. “A
processor buying a machine today generally has
only the vaguest idea of what he’ll be producing in
five or ten years’ time. He would be well advised
to invest in KraussMaffei machinery, because we
can make sure that his production solution will
grow with his changing applications – even for
decades ahead,” says Josef Hammerschmid from
Service Marketing at KraussMaffei.
Retrofit, overhaul, move
A production cell may undergo many changes over
the years. The experts in our Service teams can
help our customers cope with them all. A pro-
cessor might come to us with a request to adapt
an existing machine for a new application, perhaps
with a MuCell package for physical foaming at low
unit cost. Or he might want to expand into multi-
component moulding. This upgrade can be achieved
relatively simply with a bolt-on unit. Hydraulic and
electric bolt-on units are completely self-sufficient,
so only minor changes, if any, need be made to the
machine.
Combining an upgrade with a planned machine
move saves production time. “We’re professionals in
moving and transporting machines – we do it all the
time,” points out Josef Hammerschmid. “Our com-
mitment to our customers is to move any machine
any distance, on time and within budget. And to see
the job through from start to finish.” Occasionally,
the machines make a detour to the KraussMaffei
plant in Munich for a general overhaul. We also op-
erate a practical trade in used machines. In our skilled
hands machines get a new lease on life. p
CONTACT
Josef HammerschmidService SalesPhone +49/89/[email protected]
Always fit for purpose
KraussMaffei Service
professionals have
the expertise to make
a complete success of
any task, however big.
LIFE CYCLE
SERVICE FROM
KRAUSSMAFFEI
• Plasticizing units
• Refurbishing
• Functionality upgrades
Moving machinery •
Technology upgrades •
Consulting and advice •
Bolt-on units are a
fast, sure route into
multicomponent
moulding.
Teleservice •
• Robots, handling systems, automation
09FEATURE
NANOSKIN PROCESS
Integrated multitechnology processes are often the answer to the challenge of producing polymer parts with durable, functional surfaces at a competitive cost. The new CoverForm process (see page 6/7) is an example of this type of integrated process. Another new process – nanoskin – is approaching market readiness. Again teaming injection moulding with PU processing, the nanoskin process is being developed by KraussMaffei and a number of project partners.
Functionalizing materials by generating a finely
structured surface – a nanostructure – is among the
dominant trends in process engineering. There are
well-known examples of nanostructures with useful
properties in nature, like the self-cleaning leaves of
the lotus flower or the anti-reflective surface layer
of moths’ eyes. The quest is on to develop a process
for transferring the moth’s-eye effect to transparent
polymer parts so as to make them inherently anti-
reflective – in other words to eliminate the need
for a post-mould anti-reflective coating. The part
would also need to be resistant to mechanical and
chemical damage. Possible applications include
covers for dashboard instruments and displays.
The nanoskin process supplies the answer.
Injection moulding and RIM
The nanoskin project partners set themselves
the task of developing a cost-effective technical
solution for a one-step multicomponent moulding
process which would combine thermoplastic and
chemically crosslinking polymer materials. The
core of the part can be produced in a conventional
injection moulding process. Only the nanostruc-
ture surface is generated in a parallel RIM process,
using a chemically crosslinking polymer which also
guarantees the necessary mechanical and chemical
resistance. The nanoskin research and development
project received funding from the German Federal
Ministry of Economics
and Technology as part
of the government’s
InnoNet concept, which
aims to promote and
support networks for
innovation. It was carried
out with organizational
and technical support
from the project sponsor,
the VDI/VDE. “Now,
well ahead of the planned
project end in autumn
2010, we can already say
that KraussMaffei and
our partners are writing
the first chapter of a suc-
cess story. Together we
have taken the nanoskin
process to a point where we’ll be able to offer it to
our customers for concrete production applications,”
says Martin Eichlseder, who is leading KraussMaffei’s
contribution to the nanoskin project. p
CONTACT
Martin EichlsederProcess DevelopmentSystems & SolutionsPhone +49/89/[email protected]
Finely structured
The nanoskin process
generates transparent
parts with finely
structured surfaces.
NANOSKIN PARTNERS
• Plasmatreat GmbH and Fraunhofer IWM:
Regenerative hybrid layer systems and process-
integrated atmospheric plasma treatment
• Hochschule Heilbronn: Process integration
• Mast Kunststoffe GmbH & Co KG:
Durable, functional components, tested under
production conditions
• FHR Anlagenbau GmbH:
Mould coating and surface structuring
• Krallmann Holding & Verwaltungs GmbH:
Moulds with highest precision and rigidity
• RÜHL PUROMER GmbH and KraussMaffei:
Tough, transparent polyurethane systems
for surface functionalization and technology
development – flow moulding
MADE BY KRAUSSMAFFEI 1 ¦ 201010 KEYNOTE | NEWS REACTION
“Working
together to
add value!”Frank Peters,
General Manager,
Reaction Process Machinery.
KEYNOTE
Dear Readers,
Two important strategic responses to difficult economic times
are to optimize production processes and to open up new
business areas. KraussMaffei can support you here. As a
worldwide premium partner for the plastics and rubber
processing industries, we offer highly productive solutions that
deliver maximum efficiency and return on investment. Our
engineers deliver complete custom solutions by combining
modules from the wide KraussMaffei product portfolio and
pooling their special expertise in the different process
technologies and automation. Our solutions combine the
advantages of series production machines with the benefits of
application-specific technology. Typical examples are our
special machine for producing drug delivery systems, or our
mobile RimStar system for SPS sandwich plate systems. We
developed custom production solutions for both these
applications, supporting our customers’ drive to optimize their
production processes and reinforce their market success. As
with all our products and services, these customers can rely on
our competence as a system supplier capable of delivering the
quality and know-how they need.
We’ve also optimized our service and product portfolio, for
example, by adding to our WinCap series of mould carriers, by
improving our foam moulds, and with a revised price structure
for our EcoStar series. Together with our innovative engineering
and ultra-efficient production solutions, these improvements are
part of our drive to offer you real added value – the best basis
for our common success.
With best regards,
Frank Peters,
General Manager,
Reaction Process Machinery
Benefits for customers
MANUFACTURING METERING PUMPS IN-HOUSE
KraussMaffei’s Reaction Process Machinery division
has long pursued a policy of offering complete
production solutions as a single vendor. Key to
the success of this policy is our ability to apply
our experience and know-how to continuously
improve individual system components. Now we’ve
taken a further step in this direction by moving the
manufacture of metering pumps in-house. “This
change will give us the opportunity to align our
products even more closely with the needs of our
customers,” emphasizes Wolfgang Frehsdorf, Business
Area Manager in the Reaction Process Machinery
division. “In particular, we’ll be able to better adapt
our pumps to the specific processing requirements of
current and future plastic monomers.” In addition,
KraussMaffei made pumps will have longer service
lives – and deliver a better return on investment.
In future, the EcoStar, RimStar Compact, RimStar
Modular, MiniDos and our hybrid machines will all
be fitted with KraussMaffei metering pumps. From
April 2010, we’ll be producing pumps rated for
16 to 40 litres a minute. During the year, we plan to
add more pump sizes to our portfolio. p
CONTACT
Siegfried EidenmüllerManager Precision PartsAssembly and Service RPMPhone +49/89/[email protected]
KraussMaffei is now
manufacturing metering pumps in-house.
Frank Peters, member of
the board of management,
said the expansion
was indicative of two
of KraussMaffei’s great strengths, “On the one
hand, as a technology company with an in-house
mouldmaking operation, we’re big enough to serve
every market segment and specialized niches which
are still growing. And secondly, we are creating future
capacity ready for the time when the economy begins
a strong recovery, rather than the current hesitant
growth.” p
Frank Peters (center),
KraussMaffei RPM General
Manager, Heinz Lunte
(3rd from right), mayor of
Georgsmarienhütte, and
Plant Manager Rainer
Janotta (2nd from left) at the
groundbreaking ceremony.
EXPANDING THE SALES ORGANIZATION IN BENELUX AND AUSTRIA
KraussMaffei has expanded Reaction Process
Machinery activities in Belgium, the Netherlands,
Luxembourg and Austria. In these countries, the
company now offers not only injection moulding
machinery, but also our classic portfolio of Reaction
Machinery products – mixing heads, metering
machines, moulds
and tooling for
polyurethane
processing,
including cutting
and routing
technology. Sales
11 NEWS REACTION
Doubling production space
PRODUCTION PLANT IN GEORGSMARIENHÜTTE
Automotive Component Systems (ACS), a business
area of KraussMaffei, is expanding its production
plant in Harderberg-Georgsmarienhütte/Lower
Saxony from 1,350 to 2,700 square meters. A
symbolic groundbreaking ceremony took place
on February 4, 2010. Construction is due to be
completed by late summer 2010. ACS makes moulds
for polyurethane processing at its Harderberg plant.
Special order from the USA
OVAL CONVEYOR SYSTEM FOR ROYAL TECHNOLOGIES CORPORATION
Our US subsidiary, KraussMaffei Corporation,
recently booked a large order from Royal
Technologies Corporation. This company develops
and manufactures products mainly for the
automotive industry, but also for consumer goods
and office furniture. We supplied Royal Technologies
Corporation with a turnkey oval conveyor system,
with 26 stations and a four-component duplex mixing
head, to produce seat cushions from PU foam. The
conveyor system was modified to guarantee extremely fast mould
changing – a roller system that was integrated that allows just the
mould itself to be changed via a special screw mechanism. This
system ensures that mould changing
is extremely fast and completely
unproblematic; the customer is
spared the necessity of exchanging
the complete cassette with the mould
carrier as in a conventional system. p
CONTACT
Steffen BauerArea Sales ManagerPhone +49/89/[email protected]
More service, more performance
NEW ADDRESS
KraussMaffei BeneluxMinervum 7408NL- 4817 ZG BredaPhone +31/76 57 22 522Fax +31/76 58 75 686
Manager Johan Van Der Schueren
is now reponsible for RPM
customers in Belgium and
Luxembourg, while Mark
Verveer, Managing Director of the
KraussMaffei branch in Breda,
looks after customers in the
Netherlands. Austrian customers
can rely on Area Sales Manager
Wolfgang Rößler. By expanding
the Reaction Process Machinery division’s presence in these countries,
KraussMaffei has reinforced its status as system supplier – providing local
service and support, and complete system solutions. p
CONTACT
Mark VerveerManaging Director NetherlandsPhone +31/6 50 50 59 [email protected]
Johan Van Der SchuerenSales Manager Belgium & LuxembourgPhone +32/54 32 23 26johan.vanderschueren@ kraussmaffei.com
Wolfgang RößlerArea Sales ManagerPhone +49/89/[email protected]
12 MADE BY KRAUSSMAFFEI 1 ¦ 2010FOCUS REACTION
systems, individual foam moulds or extending and
upgrading existing lines,” explains Gianmario
Bossi, sales manager for white goods. “We can
supply customized concepts, for every manufacturer
and product specification – including high-end foam
moulds, optimally engineered for the manufacturing
process.” In addition to production systems for
white goods, the KraussMaffei Italiana product
portfolio also includes production systems for
panels and sandwich panels for the construction
industry. When we supply a system, our highest
priorities, from the planning phase onwards, are
efficient processes, a compact design and a very
high level of automation. Once the concept has
been accepted, we build, ship and commission the
system. Our comprehensive service and support is
available to our customers at every stage and our
after-sales service is unsurpassed.
RotoStar: designed for success
As a rule, KraussMaffei Italiana supplies the
dry side components of a system, with the other
components being engineered in Munich. One
example is the RotoStar drum unit for foam
filling and processing doors. This is a provenly
successful system, it consists of a base frame in
which the drum with the water-heated mould
carriers revolves. A hydraulic control system makes
it possible to adjust the acceleration and braking
phases and to ensure the drum revolves at
a uniform speed. “RotoStar systems can
be fitted with varying numbers of mould
carriers, depending on production
and process requirements,” explains
Andrew Garnett, Area Sales Manager at
KraussMaffei. “Short cycle times, highest
Within the worldwide KraussMaffei group,
KraussMaffei Italiana in Abbiategrasso is the
competence center for white goods and insulation
technology. The company’s core business is
production systems for foam filling refrigerator
doors and cabinets – for both household and
commercial refrigerators. Foam moulds and
thermoforming tools for these applications are
part of the product spectrum. The materials
used in all applications are heavy-duty PU rigid
foam systems capable of guaranteeing excellent
thermal insulation even in relatively thin layers.
“KraussMaffei combines the know-how and
the technology for high-performance
solutions for the white goods
sector – whether customers
want complete
refrigerator foaming
FOAM SYSTEMS FOR REFRIGERATORS AND INSULATION TECHNOLOGY
Competence in white goodsKraussMaffei Italiana is a competence center for PU systems for white goods and insulation technology. The innovative insulation solutions and high-performance systems for foam filling refrigerator doors and cabinets developed in our competence center in Abbiategrasso are already in operation around the world.
The RotoStar drum unit
is a reliable solution for
foam filling and finishing
doors.
13FOCUS REACTION
product quality and absolutely reliable control of
the process make the RotoStar the system most
frequently chosen worldwide for foam-filling
refrigerator doors.”
RimStar: the perfect match
A polyurethane mixing and metering machine
from our RimStar range is the ideal match for
a RotoStar mould carrier system. The small
and compact RimStar machine can be flexibly
configured making it the optimal choice, for
example, for refrigerator production. Hallmarks of
the RimStar are minimal pressure losses, precision
temperature control and improved control systems
thanks to shorter, rheologically-optimized supply
lines between machine components. The machines
are easy to operate and maintain and engineered
for easy access. Add-ons for the RimStar system
– from tanks with integrated agitators to complex
configurations with heat exchangers and circulation
pumps – help to ensure that the PU components are
perfectly conditioned, mixed and metered. This is
important for white goods production as well as in
other sectors.
Worldwide success
Today, KraussMaffei production solutions for
white goods and insulation technology are in
operation around the world. In a joint project,
KraussMaffei Munich, KraussMaffei Italiana and
KraussMaffei Machinery in Shanghai recently
supplied a complete multicomponent system
with 20 stations to manufacture refrigerators in
China. Qingdao Haier Refrigerator China, the
biggest white goods manufacturer in China, is
using the system to produce refrigerators for the
Sanyo Electric, Japan.
Production uses the
Side-by-Side system,
where two mixing heads
foam-fill the refrigerator
elements simultaneously.
“Engineering and
building this system
was a real first for
KraussMaffei, it was the
result of outstanding
teamwork involving
KraussMaffei people in Germany, Italy and China,”
says Gianmario Bossi. “Innovative process know-
how and our grasp of the complex technology
enabled us to supply a complete, highly-customized
solution – and the customer naturally profits from
our comprehensive, local service offering”. We also
shipped systems for white goods and insulation
technology to China and Brazil. Six RimStar
systems with six Pentamix units and 20 mixing
heads went to Maersk Container Industry Qingdao
China. In Brazil, Electrolux do Brasil is operating
two RimStar machines and three RotoStar systems
in the production of refrigerator cabinets while two
more RotoStar systems are foam filling refrigerator
doors. p
RimStar mixing and
metering machines
(below) are ideal for
applications in the white
goods and insulation
sector (left).
CONTACT
Gianmario BossiSales Manager KMIPhone +39/02/[email protected]
Gianmario Bossi,
Sales Manager
for white goods
at KraussMaffei
Italiana.
MADE BY KRAUSSMAFFEI 1 ¦ 201014 APPLICATION
CONTACTSteffen BauerArea Sales ManagerPhone +49/89/[email protected]
RIMSTAR SYSTEMS AT ELELE, BURSA, TURKEY
KraussMaffei’s RimStar range of polyurethane mixing and metering machines includes models capable of meeting every production requirement. Elele, a KraussMaffei customer in Turkey, has recently taken delivery of its third RimStar system. Its delivery marked a special milestone for KraussMaffei, because it brought to 100 the number of mixing and metering machines the company has supplied to processors in Turkey.
Market leader in reaction process
machinery
The machine was shipped directly from
KraussMaffei’s Munich plant to Bursa. The sale was
processed by Alp Chemicals, KraussMaffei’s sales
partner in Turkey, headquartered in Istanbul. Taner
Erbil, responsible for sales at Alp Chemicals, says,
“This machine was the third RimStar to go into
operation at Elele, as part of a capacity expansion.
Elele’s decision to invest in this new machine not
only shows the company’s satisfaction with
KraussMaffei’s machinery and customer care, it is
also a sign that the market for plastics processing
machinery in Turkey is picking up again.” With its
three technology divisions, Injection Moulding
Machinery, Extrusion Technology and Reaction
Process Machinery, KraussMaffei supplies not only
the Turkish automotive industry, but also other
industries, such as construction, home appliances,
medical technology and packaging. By shipping the
100th mixing and metering machine to Turkey,
Reaction Process Machinery has underscored its
claim to be market leader in the region. p
Milestone machine with proportional technology
Emre Yilmaz,
Commercial Manager
at Elele (right) and
Steffen Bauer, Area
Sales Manager at
KraussMaffei.
KraussMaffei’s RimStar machines are engineered as
modular systems. This means they can be flexibly
configured to match application specifications and
customer requirements. One of the customers who
welcomes this approach and who has installed a
total of three RimStar machines is Elele Döseme
Sanayi ve Ticaret, in Turkey. The machine supplied
to Elele at the end of 2009 was a RimStar Compact
40/16. Together with the machine, Elele also
installed a foam robot and an MK 12/18 ULP-2KVV-
G mixing head with proportional technology. As
Steffen Bauer, KraussMaffei Area Sales Manager,
points out, “It’s only our proportional technology
that allows the very fast shot cycles that are essential
if users plan to manufacture different products on
one and the same production system.” Elele is using
this RimStar machine to produce seat squabs for
automotive seating in its production plant in Bursa.
One of Turkey’s major
cities, Bursa is a center
of the country’s
automotive industry
where carmakers and
international
components suppliers
operate production
plants.
APPLICATION 15
PRODUCTION SOLUTION FOR DRUG DELIVERY SYSTEM
KraussMaffei recently developed a production solution for a drug delivery system. The solution consists of a mixing and metering machine together with a sheet mould and a punch with tooling. The innovative, application-specific, integrated solution was developed as a joint project by teams from the KraussMaffei plants in Munich and Viersen, in Germany.
Efficient teamwork on an innovative project
The mixing and
metering machine
is at the heart of the
three-part production
solution.
To develop a highly automated process for the
production of drug delivery systems was exactly
the right challenge for KraussMaffei development
and application engineers. They planned a three-
part production system, consisting of a mixing
and metering machine, a sheet mould and punch
tooling. The mixing and metering machine was built
in Munich, the other two elements were supplied
by Tooling Technologies, KraussMaffei’s subsidiary
in Viersen. Every part of the machinery in contact
with the end product at any stage of the production
process had to be manufactured from a stainless
steel grade approved by the US Food and Drug
Administration (FDA). The hydraulic oil used in the
system had to be certified for conformity with FDA
specifications.
Precision drug delivery
In the mixing and metering machine, the raw
material is melted and dehydrated under vacuum
conditions. It is then mixed with the isocyanate
and a catalyst in the mixing head. “The focus was
on high-precision metering”, explains Andrew
Garnett, Area Sales Manager at KraussMaffei.
“The mixing ratio for the components – which are
both processed at approximately 70 °C – must be
precisely adhered to.”
The KraussMaffei MK 5/8 CCM tandem piston
mixing head is ideal for this task, the catalyst is
added using a micro-volume metering piston. The
polymer sheet – 0.8 to 1.0 millimeters thick – is
then formed in the sheet mould and a punch tool
stamps out the shape of the pessary, the drug
delivery system.
Complete application-specific solution
The three system elements are being integrated
into the final system at the KraussMaffei plant in
Munich. „The ultimate challenge in this project
was to select the correct components and materials
to ensure full compliance with the standards,“
says Andrew Garnett. “The project shows that
KraussMaffei experts from our different locations
and specializations are more than capable
of teaming up efficiently to produce highly
customized, integrated solutions for totally new
application areas.” p
CONTACTAndrew GarnettArea Sales ManagerPhone +49/89/[email protected]
A punch stamps out
the final drug delivery
system.
The polymer sheet –
0.8 to 1.0 millimeter
thick – is formed in the
sheet mould.
MADE BY KRAUSSMAFFEI 1 ¦ 2010
CONTACT
Andrew GarnettArea Sales ManagertPhone +49/89/[email protected]
16 APPLICATION
PU METERING FOR SANDWICH PLATE SYSTEMS (SPS)
The RimStar system that
KraussMaffei recently supplied
to Intelligent Engineering Ltd.
was an unusual one. Intelligent
Engineering specializes in
making and installing sandwich
plate systems (SPS) made of two
metal sheets with a PU core. SPS has
several advantages compared with steel alone
or concrete. These include high stiffness combined
with light weight, soundproofing and vibration
damping properties, and the fact that the plates
can be installed quickly and easily. SPS elements
are used in new construction, but also in repairs,
of ships, oil platforms, conveyor systems, bridges,
stadiums and high-rise buildings. The sandwich
elements are generally fabricated at the site where
they are to be installed.
Demanding product specifications
The RimStar system will be used to mix and
meter polyurethane in various grades to form the
plate cores. Fitted with two 80-litre pumps, it
stands for extremely reliable and stable processes
and premium product quality. Hallmarks of the
RimStar are minimal pressure losses, precision
temperature control and improved control
technology thanks to short rheologically-optimized
supply lines between machine components. The
RimStar’s modular engineering makes for flexible
configuration of customer- and application-specific
machines. Intelligent Engineering specified a number
of unusual features. “The whole system had to fit
into a 20-foot container, have its own drive system
and be fitted with a universal power connection so
as to be able to operate anywhere in the world”,
explained Andrew Garnett, Area Sales Manager
at KraussMaffei. “This RimStar machine was
engineered as an autonomous system, capable of
being simply plugged in to the local power supply
and starting production immediately.” The machine
was mounted on a tracked vehicle sourced from
an Italian manufacturer. It can move under its own
power to wherever the sandwich panels are required,
for example, in a dry dock, or on a bridge.
Strong market potential
This latest RimStar system is the fourth that
KraussMaffei has supplied to Intelligent Engineering;
each machine is engineered and modified to match
specific customer needs. “The outcome is always a
highly effective production solution that is absolutely
right for the job,” sums up Andrew Garnett. “As
a preferred partner of Intelligent Engineering, we
look forward to continuing cooperation and to more
projects in this interesting market.” p
One of the many
applications for sand-
wich plate systems
(SPS) is repairing and
strengthening ships.
KraussMaffei recently shipped a RimStar system installed on a tracked vehicle to Intelligent Engineering Ltd.. The PU mixing and metering machine will be used in the production of the company’s sandwich plate systems (SPS) made of sheet steel with a PU core. The mobile RimStar system fits into a shipping container and has a universal power connection – at the touch of a button, it’s ready to operate anywhere in the world.
Mobile RimStar is ready for action worldwide
Compared with steel
and reinforced con-
crete, the sandwich
plate system (SPS)
delivers notable
engineering and cost
advantages.
The mobile RimStar
machine can be
connected up and
operated anywhere in
the world.
17FEATURE
THE WINCAP ELECTRIC MOULD CARRIER SERIES
Success story with a future
CONTACTErich FriesArea Sales ManagerPhone +49/89/[email protected]
KraussMaffei developed the first electric mould
carriers for automotive applications around
three years ago. Now there are many of them
in operation with customers around the world.
They’re used in encapsulation of car windows
and glass roofs and for backfoaming interior
trim elements and other automotive components.
Our policy of continuous optimization applies
especially to our best-selling models. “The know-
how and experience of our whole division flows
into the ongoing development of our electric
mould carriers,” says Erich Fries, Area Sales
Manager at KraussMaffei. “Then add our strength
in innovative engineering and the outcome is
application-specific mould carrier solutions which
will drive our future success in this area.”
Application-specific performance profile
The standardized, modular engineering of
our WinCap range cuts the time required for
assembly and commissioning. Very easy operation
and excellent ergonomics were high on the
list of development priorities. For example,
programming mould functions in situ using the
OP177B touch panel is a simple task. All mould
carrier movements and mould functions are freely
programmable at the operator console; this adds a
high degree of flexibility to production processes.
High-speed and parallel mould carrier movements
yield shorter cycle times and higher productivity
in almost any application. Even heavy moulds are
moved fast and reliably, thanks to the use of poly-
V-belt with transfer rolls for the lift function.
Customized flexibility
Low maintenance effort is another important
plus-point of the WinCap series – together with the
quieter operation and lower power consumption
associated with electric motors. There is a wide
choice of practical options, including additional
mould functions, extra safety features and a
customer-specific mould-fixing system. Moreover,
WinCap mould carriers can be flexibly adapted to
many different types of plant.
The acid test
The ability of
KraussMaffei’s electric
mould carriers to deliver
the performance required
in the challenging
automotive environment
is underlined by recent
orders from international
automotive components
suppliers. They include
10 mould carriers
shipped to ArvinMeritor
in Slovakia and Germany
and 3 systems for
Webasto in Korea. p
Productivity that’s hard to beat, outstanding ergonomics and practical options – all these have made our WinCap mould carrier series a real success story. At the same time, KraussMaffei is committed to continuous further development of all our mould carriers.
Glass roof for an Audi
A5 , foam encapsulated
on a WinCap mould
carrier in a mould
made by KraussMaffei.
Best sellers with
multiple benefits:
our WinCap series
of electric mould
carriers.
MADE BY KRAUSSMAFFEI 1 ¦ 201018 FEATURE
CONTACTRainer JanottaPlant Manager, Automotive Component Systems, GeorgsmarienhüttePhone +49/5401/[email protected]
MORE EFFICIENT, LESS WASTE
KraussMaffei has optimized the foam moulds it supplies for automotive instrument panels. New seal technology now minimizes material consumption and almost completely eliminates trimming and waste. This saves time and money, resulting in more efficient processes and lower manufacturing costs. Instrument panels for the new Peugeot 3008 and 5008 are being made using these innovative moulds.
a joint development by KraussMaffei and
Visteon Systémes Intérieurs, one of the leading
international automotive components suppliers.
One development priority was lower material
consumption. “The new foam moulds with their
innovative seal technology minimize material
consumption. At the same time, the process
becomes more efficient because trimming and
waste are practically eliminated,” explains Rainer
Janotta. “This brings substantial savings in
material costs and in processing time.”
One of the detail changes is in the windscreen
area where the décor film is inserted into the
reinforcing section directly in the mould. Around
the tachometer, the center console and the air
vents, tear-off edges in the décor film eliminate
trimming and disposal of the PUR foam and
reinforcing material. 48 of these optimized foam
moulds are already in operation, 23 more are
currently under construction. Apart from the new
Peugeot models, they’re being used to produce
components for carmakers like BMW, Citroen,
Ford, Renault, Volvo and VW, where they ensure
highest precision and quality, plus lower material
consumption and unit manufacturing costs. p
Automotive Component
Systems (ACS) in
Georgsmarienhütte,
Germany, a
KraussMaffei
subsidiary since 2005,
specializes in tooling
technology, mainly
for the automotive
industry. Of more
than 500 foam moulds
sold to date, over 100
of them have been
for instrument panel
production. Each KraussMaffei production system
is engineered as an exact match for customer
requirements. Customers profit from application-
specific solutions supplied by a single expert
vendor. “Our foam moulds deliver what customers
want,” says Rainer Janotta, plant manager at
Automotive Component Systems, “That’s premium
product quality and vanishingly low reject rates.
But we never stand still – our engineers work
continuously to make foam processes, and the
whole process of making a component, more
efficient and economical.”
Less trimming, shorter cycle times
Currently, one of the best examples of this
continuous-improvement approach are the new
foam moulds for the instrument panels for the
new Peugeot 3008 and 5008. The moulds were
Optimized foam moulds
The instrument
panels of the new
Peugeot 3008
and 5008 models
are made using
KraussMaffei foam
moulds.
The newest foam
moulds practically
eliminate trimming
and waste.
19FEATURE
PREMIUM QUALITY, WIDELY AFFORDABLE
Our EcoStar series of mixing and metering machines has a sure-fire formula for success – modularity, reliability and ease of operation. Following a systematic improvement programme, KraussMaffei has revised the pricing structure for EcoStar machines and is offering them at budget prices. This will attract especially small and medium-sized PU processors in many parts of the world, who are already using EcoStar machines in a wide range of manufacturing processes.
New pricing structure for the EcoStar series
KraussMaffei’s EcoStar mixing and metering
machines meet the highest standards in
polyurethane processing. These are small, high-
performance systems, based on high-quality
components, for high-pressure processing with
transfer and linear mixing heads. A very compact
configuration keeps the supply lines between the
separate machine components very short.
This, in turn, enables temperatures to be precisely
controlled, minimizes pressure losses and makes for
optimal process control. In this way, KraussMaffei
customers can count on a stable process and highest
product quality. The machines are easy to operate
and maintain and they’re specifically engineered for
easy access.
Improved price/performance ratio
Through systematic standardization and reducing
the number of variants, KraussMaffei has been
able to improve the price structure for the series, so
that customers can now benefit from an improved
price/performance ratio for the EcoStar. This makes
powerful, premium-quality PU metering machines
available at budget prices, which should appeal
especially to small and medium-sized PU processors.
The basic EcoStar version includes volume flow
meters, double-walled component tanks, MKE3B
mixing heads, axial piston pumps and the Siemens
control system. This basic version can be upgraded
with function packs to suit product specifications
and production requirements, for example, closed-
loop control, transfer mixing heads, plate heat
exchangers and different-sized outriggers.
Worldwide sales success
Customers around the world have been buying
EcoStar systems. Typical are some of the latest
orders, mainly from small and medium-sized
enterprises, which are using the KraussMaffei
machines to produce a huge range of projects. Three
EcoStar systems recently shipped to processors
in Brazil: two to Piatex Indústrie e Comércio
de Fiberlass Ltda. and one to Frisokar
Equipamentos Plásticos Ltda.. Both
companies are using them to produce
components from flexible, semi-
rigid and integral foam that are
widely used in the automotive
sector. The latest system supplied
to India went to Supreme Treves
PVT. Ltd., which will be using
the EcoStar for backfoaming
carpets. In Iran, by contrast,
the Pishgam company is
using an EcoStar to make seat
squabs for office chairs. p
CONTACTKlaus BangeSales Manager Reaction Process MachineryPhone +49/89/[email protected]
Small, compact and
a power pack: the
EcoStar series is ideal
for small and medium-
sized PU processors.
High-performance PU
mixing and metering:
our EcoStar series
delivers premium
quality at budget
prices.
KraussMaffei Technologies GmbH ··· Phone +49 89 [email protected] ··· www.kraussmaffei.com
What’s your choice for ultralight components that are also ultrastrong? Fibre composites are the answer. Today’s production technology delivers cost-competitive, fi bre-composite products with outstanding mechanical properties and paintable surfaces. To source this technology you need to look no further than KraussMaffei. We offer far more than high-performance production systems. We partner with you all the way to drive the success of your production project. However specialized your product and however demanding the specifi cations, we’ll supply the process for the job – LFI, FCS, RRIM, SRIM, SCS or RTM.
In-depth information and contact details are at www.kraussmaffei.com.
Ultimate performance with machines from KraussMaffei.
› INJECTION TECHNOLOGY› REACTION PROCESS MACHINERY› EXTRUSION TECHNOLOGY
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