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Innovative mixing

and metering machines


Outstanding product quality
in PU processing

Engineering Passion
2 Mixing and metering machines
Facts and figures

Facts and figures regarding KraussMaffei


metering machines

Application areas

Automotive Automotive Automotive Automotive

Automotive Utility vehicles Utility vehicles White goods


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Innovative mixing
and metering machines
Outstanding product quality
in PU processing
The extensive range of metering and mixing
machines from KraussMaffei is suitable for all
application areas in PU processing. The modular
design and flexible configuration of the machines
allows them to be optimally tailored to customer-­
specific requirements. This means KraussMaffei
offers the optimum solution for every production
requirement. This includes being easy to operate
and maintain.

Your advantages at a glance:


– High process reliability thanks to innovative
machine engineering
– Outstanding component quality thanks to precise
control engineering
– Excellent price-performance ratio
– Flexible machine configuration
– Easy to operate and maintain
Meet the machines:
Take a tour of the RimStar Series

Frequency converter for


metering pump drive

Proven tank design


with double-walled
agitator tanks

Automatic air dryer


Complete processing system
with heatless adsorption dryer,
pre- and after-filters and
condensate drain

Plate heat exchangers mounted


on machine frame
Covers all processing applications,
short pipelines, mounted compactly
on the base frame, higher compo-
nent quality and less scrap thanks
to improved temperature, pressure
and process control

Suction line with edge-type filter

Mixing head hydraulics


with feed pump, pressure accumulator,
high-pressure filter, return flow filter,
minimum fill-level sensor and oil cooler

(Image contains optional equipment)


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Easy-to-read displays
Easy to operate, service
and maintain

HMI interface

Switching cabinet with


Siemens control unit

KraussMaffei high-pressure
metering pump (axial piston
pump) with handwheel
adjustment
Pumps and motor with
magnetic coupling

Optional outrigger
Can be mounted on the machine base,
no additional costs thanks to external piping
6 Mixing and metering machines
Flexibility/flowchart

Enormous flexibility
Now and in the future
Our machine concepts offer Flexibility now: Proven tank design
you maximum flexibility so you – The modular design of our frames allows Double-walled agitator tanks with the
us to create flexible solutions to suit option to connect a nucleation unit, mounted
can respond to your industry's your space requirements compactly on the base frame (RimStar
latest demands at any time. – Switching cabinet can either be perma- Compact Series with max. 250 l tank),
This flexibility makes it possi- nently mounted on the frame or variably cartridge heaters for cost-effective com-
positioned ponent heating.
ble to build intelligent machine
components that can be easily Flexibility in the future: Central water supply
added to and combined. – Our machine concept offers you multi- Installed on-site to lower installation
ple options for adding to and upgrading costs.
machine components in response to
changes in production requirements

12-component metering machine with two pouring robots


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Technical equipment variations


in the RimStar Series
Pentamix

CO2 batch

POLY MAK Outrigger


4l
8l
4.5 bar 16 l
Robots
10 bar 29 l
TEMP
40 l
Standard agitator
80 l
Viscojet agitator Rotary table
155 l
Fill-level sensor T
P
Fill-level V T P Oval table
limit switch
Shut-down valve MAK
25 l FU
60 l Mold carriers
100 l
250 l Additional
500 l T
P color

Control system
COOL FA PUC
Profibus Robots
ISO P N2
T
4.5 bar
10 bar
Standard agitator 4l
MAK
Viscojet agitator 8l
16 l
Fill-level sensor Number of
29 l
Fill-level TEMP mixing heads
40 l
limit switch
80 l
25 l 155 l
60 l T
100 l P V T P USE
250 l
500 l Shut-down valve MAK
FU

P = Pressure measurement FU = Frequency converter MAK = Magnet coupling


V = Volume flow measurement FA = Non-KraussMaffei system USE = Switchover units
T = Temperature measurement
8 Mixing and metering machines
RimStar

RimStar Nano: For low output rates and minimum space requirements RimStar Compact: Space-saving thanks
to compact frame design

The RimStar Series at a glance –


RimStar Modular, Compact, Nano and Flex
KraussMaffei technologies were combined using "best prac- Outstanding component quality and
tice" processes when developing the new RimStar Series. minimal scrap
Short, rheologically optimized supply
The machines are so versatile that they can be used in any lines between the machine compo-
PU processing application. Their modular design allows them nents result in lower pressure losses,
to be flexibly configured and therefore tailored to customer-­ more precise temperature control and
optimized control engineering. This
specific requirements. increases process reliability and the
quality of your parts.

Minimal maintenance costs


The series is also extremely easy to oper-
ate and maintain, which helps to avoid
unnecessary downtimes.
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RimStar Flex: Especially for use in our T3 technologies ColorForm and SkinForm

RimStar Nano on one frame only and can be put into RimStar Flex
The RimStar Nano was specially devel- operation immediately thanks to the The RimStar Flex was specially developed
oped to handle low output rates and plug-and-play principle. for use with ColorForm and SkinForm
limited space requirements: This means technologies and is characterized by its
that the supply lines running between the RimStar Modular flexible system configuration and adjust-
tank and the high-pressure pump, and The RimStar Modular has a modular ment to individual requirements. Day
between the filter and the volume gage machine frame, which can be added to as tanks and metering pumps are installed
in the high-pressure zone, are kept as necessary to meet any current or future independently of each other on a supply
short as possible and that materials can requirements. The control cabinet can be module and a metering module. The
be changed quickly and easily. supplied as a standalone unit, if required. modules can thus be positioned individu-
ally and at different points on the injec-
RimStar Compact tion molding machines. In addition, it is
The RimStar Compact has a one-piece possible to combine two metering mod-
machine frame and a compact, space-­ ules with a supply module.
saving frame design: The machine is
installed together with the control cabinet
10 Mixing and metering machines
RimStar

Features of the RimStar Series


for perfect conditioning, metering and mixing
Machines in the RimStar Series Perfect conditioning heaters to complex systems with heat
can condition, meter and mix Heat exchangers, temperature control exchangers and heat-balancing sys-
and thorough mixing are required to tems. We also offer a large number of
PU materials to the highest keep the material in the day tank in per- design variations to bring you the best
standards. fect condition. KraussMaffei boasts an possible component heating and mate-
extensive range of different systems for rial homogenization. Agitation tanks in
optimal material conditioning – rang- different sizes for optimal distribution –
ing from proven double-walled agita- of filler materials, for example – are also
tion tanks and cost-effective cartridge available as an option.

Temperature-control system Perfect metering Perfect mixing


Heat exchangers can be installed in the High-pressure pumps, edge filters, high-­ Our range includes a large number of
return flow circuit, in the tank bypass pressure filters, magnetic couplings and mixing heads for outstanding processing
with a circulation pump, upstream of the volume- and mass-flow measurement in different PU systems.
pump on the suction side or upstream on ensure the material is metered precisely
the pressure side. and reliably.
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Pressure limiting valve,


HP line outlet

Outer rotor Pressure switch

Motor/drive unit Can

Metering pump

Inner rotor Suction line connection

Edge and high-pressure filters Measure, control, regulate Magnetic coupling


To ensure trouble-free processing of We offer manual and automated testing We also equip our machines with a mag-
different PU systems, we use one type of systems: We can integrate any available netic coupling if required. All the axial
filter for the suction (low-pressure) side sensor technology (including mass-flow piston pumps we use have been specially
and another type for the high-pressure side. measurement) to monitor the process engineered for processing polyurethane.
We also offer variants with switchover parameters – pressure, temperature and This way, you can benefit from machines
and motor-driven filter systems. throughput – in order to ensure machine that do not leak, are maintenance-free
processing stability. and have a long service life. Forced
rinsing also prevents materials from
overheating and becoming damaged.
Frequency-regulated drive units – the
basis of a closed-loop system – are also
available if required.
12 Mixing and metering machines
EcoStar

Premium quality
with low investment costs
The EcoStar Series
The EcoStar Series from KraussMaffei contains premium-quality
PU metering machines with low investment costs.

The EcoStar Series is equipped with pre- Optional additional equipment


mium-quality components to guarantee – Tank heating with heating cartridges
reliable process control and high compo- – Pump drive with frequency converter
nent quality. The very attractive price-­ (closed loop)
performance ratio of the series has been – Magnetic coupling on the metering
achieved through systematic standardiza- pumps
tion and a reduced number of variants. – Edge filter in the suction line
This also results in an attractive delivery – High-pressure filter
time. – Heat exchanger in return line
– Low-pressure bypass valve
Standard specification – Barrel pumps
– Double-walled feed hopper with – Mixing-head outrigger
agitators and fill-level monitoring (radius 2.2 m and 3 m)
– Suction line with screen pack filter – Compressor cooling unit
– High-pressure metering pumps
– Flow-rate monitoring
– E-control with S7-KTP400 Comfort Your advantages:
– Hydraulic unit for mixing-head control – Low investment costs
– Mixing head with hose pack – Attractive delivery times
– Machine base frame –Attractive price-performance ratio
– Reliable process control
– Premium-quality components
– High component quality
– Additional function packages are
also available if required
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The EcoStar Series is characterized by


an attractive price-performance ratio.
14 Mixing and metering machines
Comet

Comet metering machine with hydraulically driven pistons Precision with small quantities: Comet Nano

Metering machine for filled PU systems


The Comet and Hybrid Series
The Comet metering machine to meter PU components that are highly
Your advantages:
from KraussMaffei is ideally viscous or have a high gas content (up to
– Constant processing parameters
60 percent).
suited to processing PU formu- even in filled systems
– Highest production and process
lations containing filler. This Processing small quantities of material:
reliability
series also offers a solution Comet Nano
– Can be used with the most exact
The Comet Twin metering machine
for any requirement. enables precise processing of very small
output rates and shot weights
– Precision at high and low flow rates
quantities of material in PU high-pres- – Numerous items of additional equip-
For abrasive filler materials sure engineering. Each of the PU compo- ment to meet a wide variety of differ-
A hydraulically driven piston is used to nents is metered by a tandem piston unit. ent production requirements
meter polyols and isocyanates. The piston While one piston meters, the second pis-
speed is controlled servo-hydraulically. ton sucks the components – this allows
The Comet metering machines have flow rates to be continuous, for example
proven themselves in PU systems with for low output rates.
abrasive filler materials, such as barium
sulphate, calcium carbonate, glass fibers
or Wollastonite. They can also be used
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Combination of pump and electric piston metering of the Hybrid Series

Metering with pistons and pumps: Hybrid Your advantages:


The metering machine of the Hybrid – Flexible and cost-effective metering
Series is designed to process standard of abrasive PU components
isocyanates and polyols containing filler. – Technically and economically opti-
A frequency-controlled axial piston mized machine design
pump is used for isocyanates. Polyols
are metered using hydraulically driven
pistons. Two different models of hybrid
machine are available. Where a single
metering piston is used, the filled com-
ponent is fed discontinuously. A contin-
uous stream of the filled component can
be achieved with two electrically driven
metering pistons (Hybrid Tandem).
The tandem arrangement combines the
advantages of pump metering with those
of piston metering.
Comet Series metering
16 Mixing and metering machines
RimStar Thermo

Processing of systems in
higher temperature ranges
RimStar Compact -CCM, -RTM or -PA
Systems with demanding High-pressure engineering ensures that
Your advantages:
processing temperature the components are throughly mixed
– Can be used for different systems
in the mixing head. RimStar Compact
requirements can be metered -CCM, -RTM or PA metering machines
(epoxy, polyamide, polyurethane)
– High level of process reliability
to perfection with the RimStar are available with either pumps or pis-
thanks to constant machine moni­
Compact -CCM, -RTM or -PA. tons and can process two or more com-
toring and precise temperature
ponents. The machines are fitted with
control
special metering pumps that are also
– Clean, environmentally friendly and
suitable for corrosive materials, such as
efficient part production
hardeners for epoxy resins.
– High level of energy efficiency
thanks to the enclosure of high-
The temperatures between the tank temperature components
and mixing head are constantly mon-
itored. This allows stable and precise
temperature control with a constant
operating point. Direct heating of the
material-guiding machine components
increases energy efficiency. The tanks
can be evacuated.

RimStar RTM metering machine with heat-balancing cabin Roof module made from carbon fibers with
(machine with extensive customer-specific equipment) epoxide matrix, made in HP-RTM process
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Powerful in continuous production


Metering machines for double-belt systems
Large-format sandwich ele- KraussMaffei metering machines for heads, one is always on standby. A static
ments with fixed or flexible double-belt systems can process all mixer is used for additives in high-pres-
common PU and PIR systems and their sure systems, whereas a dynamic pre-
top layers are made on con- additives, depending on the specifica- mixing station is used in low-pressure
tinuously running double-belt tion. The modular design of the meter- systems.
systems. ing machines increases the flexibility of
your production: In addition to the basic
components polyol and isocynate, they
can also be expanded to process many
other additives as required.
Your advantages:
– High-performance metering
The metering machines are equipped
machines for continuous processing
with high-performance, high-pressure
– A bility to process all common
axial piston pumps for metering the main
PU and PIR systems
components. Additives are metered using
– Outstanding product quality
high- and/or medium-pressure piston
– Modular machine design that can
or gear pumps. Mixing heads are sup-
be expanded at any time
plied for use in simple portals, i.e. with
– Specifically tailored to customer
one mixing head, and in portals with two
requirements
mixing heads. When there are two mixing

Metering machine for a double-belt system Sandwich panels have outstanding thermal
with six components insulation properties
18 Mixing and metering machines
Low-pressure metering machine

Metering under low pressure


F Series low-pressure metering machines
The F Series from KraussMaffei In the low-pressure process, the reac- systems to be changed quickly. Storing
tive PU mixture is mixed using dynamic colored polyols is not necessary when
has a wide range of applications
agitators and poured into the mold using paints. The low-pressure machines
with use of medium- and low-­ under next to no pressure, usually while can also be used in the upper discharge
pressure procedures. the mold is open. The low pressure zone (up to 7000 g/s), such as in discon-
results in splash-free laminar pouring tinuous block foaming applications.
of the mixture into the mold. F Series
machines are also suitable for mixing
even very small pour rates of less than
2 g/s. This allows them to make parts
with a low shot weight. The series can
Your advantages:
even process high-viscosity components
– Great flexibility
and systems that do not mix well. Meter-
– High efficiency
ing of up to seven individual components
– Low loss of material
(polyol, isocyanate, paints, catalysts,
– Optimal mixing quality in different
etc.) directly into the mixing chamber of
PU systems and discharge zones
the 7K mixing head allows colors and

F Series for reaction-casting under low pressure (lower output rates)


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F Series for reaction-casting under


low pressure (lower output rates)
20 Mixing and metering machines
Gas nucleation

Low-weight molded parts


thanks to nucleation with air or CO2
and the component. The nucleation unit
Nucleation using air or gas is installed in the day-tank bypass circuit
lowers the mold part weight and has its own controller.
and reduces material costs.
CO2 nucleation
Gas nucleation is carried out either KraussMaffei offers two different processes
directly in the day tank of the metering for CO2 nucleation: CO2 nucleation in the
machine or in a separate tank connected buffer tank (batch) or directly in the day
upstream of the day tank. Precision tank. CO2 concentrations can be varied
metering, high throughput and quick from shot to shot.
post-nucleation ensure an optimum pro-
duction process.

Your advantages:
Air nucleation
– Lower-weight molded parts
The air is metered in the machine's day
– Lower materials costs
tank. This ensures a uniform gas charge
– Better flow properties in the mold
from shot to shot and from the beginning
GBE-CO ² batch nucleation unit and improved mold filling
of a shot to the end. A dynamic mixer
– Higher process reliability
ensures perfect homogenization of the gas

CO2 nucleation in day tank CO2 nucleation in buffer tank

6
CO ²

7
2
2
3

3
1

4
5 4

5
6

1 Mixing head 4 Metering pump 1 Mixing tank 5 Axial piston pump


2 Day tank component 5 Recirculation pump 2 Screw pump 6 Mixing head
3 Static mixer 6 CO ² mass-flow controller 3 Static mixer 7 CO ² mass-flow controller
4D ay tank/buffer tank
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Precise, reliable, user-friendly


and economical in operation
Intelligent color-metering systems
tems offer you the most innovative solu-
The innovative systems from Faster color changes
tions from both worlds with their closed-
KraussMaffei guarantee pre- Certain applications require using sev-
loop control system and double-walled
eral colors that are to be changed fre-
cise metering, and thus excel- quently. The MicroDos color metering
agitator tanks for constant color compo-
nent temperature. In addition, a central
lent component quality, even system allows for fast and cost-effective
supply for several mixing and metering
for the smallest flow rates. color management without needing to
machines is possible (multi-point meter-
be cleaned. All elements in contact with
With the compact frame con- the color are integrated in a module that
ing), with a large selection of multi-color
mixing heads.
cept, tailored solutions can be is completely replaced within minutes
provided. when the color is changed.

Innovative color-metering systems


Your advantages:
With the hydraulic or servo-electric piston
– High process reliability
metering, highly viscous and abrasive col-
– Outstanding component quality
ors can be processed. For the processing
– Maximum reliability and availability
of non-abrasive colors, the color-meter-
– Easy to operate and maintain
ing system with a frequency-controlled
– Space-saving
metering pump is appropriate. Both sys-

MicroDos: Cost- and time-saving color manage- Color-metering system: Hydraulic or servo-­ Color-metering system:
ment with exchangeable color module electric piston metering Frequency-controlled metering pump
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Premixing stations

Optimal preconditioning:
Premixing stations, drum stations
and container stations
Manufacturers of raw materi- Premixing stations operate fully auto- Container stations are used when PU
als supply PU components matically to process PU components with components are supplied in IBC contain-
filler materials, such as glass fibers, ers. Very simple stations or highly com-
either in drums, in IBC con- barytes, melamine and blowing agents plex stations – such as piggyback systems
tainers or pumped from a (e.g. pentane). The filler materials are fed with an additional buffer container, special
tanker. Premixing, drum and in the desired concentration from con- agitators, intermittent operation for the
tainers, such as BigBags, into the pre- recirculation pump and agitator, etc. – can
container stations from mixing tank, where they are mixed with be used depending on requirements.
KraussMaffei precondition PU the PU components. Then the metering
components in the optimum machine's day tank is automatically sup-
plied with the filled PU components.
way for processing. Your advantages:
Drum stations are cost-effective systems – Day tanks are filled automatically
that can be used to automatically fill day – Consistently high component quality
tanks. They are used to hold the compo- thanks to optimal preconditioning of PU
nent drums as an alternative to simple components
barrel pumps. – Cost-effective, tailored solutions thanks
to the modular design

Container station for preconditioning Pentamix premixing station for pentane


PU components
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Robots and mixing-head manipulators


ensure exact, reproducible PU pouring
patterns

Reproducible material pouring:


Robots and mixing head manipulators

When pouring PU into open Manipulators or robots are used to han- assigned pour-pattern program, which
molds, the mixing head must dle mixing heads. The movement of the has been taught in advance, by reading
mixing head can be freely programmed codes on the foaming station or mold.
usually move in pouring patterns to pour the PU mixture even into nar- The start of the shot is enabled via an
to distribute the material. Manip- row sections, for example. Challenging interface to the metering machine, and
ulators or robots from Krauss- product specifications are met by con- the pour pattern is executed.
tinuously operating systems, in which
Maffei can be used to execute the pour pattern in the mold must be
exact, reproducible foam pour additionally overlaid with the movement
patterns across the mold. of the mold on a conveyor system. To do
this, KraussMaffei has developed special
software that can control the foam pour
Your advantages:
rate on the conveyor, section by section.
– High product quality thanks to repro­
ducible pouring patterns
The mixing head is attached to the
– Cost reduction thanks to automated
flange of the manipulator or robot and
production
connected to the metering machine via
– Greater freedom in PU pouring
pipes or hoses. The robot identifies the
24 Mixing and metering machines
TP1200

Clear and reliable


Touch Panel TP1200 Comfort

Touch Panel TP1200 Comfort

The Touch Panel TP1200 The TP1200 can be programmed using Your advantages:
Comfort is a user-friendly WinCC in the TIA Portal and Visual Basic – Can support up to six component pumps
Script. It is connected to the control – Can connect up to sixteen mixing heads
and reliable visualization system via Profibus or ProfiNet. The with shot-time correction
system for PU processing. Touch Panel is available in two designs, – Graphic display of the machine with all
either as an integrated control panel production parameters
in the switching cabinet or as a mobile – Tolerance monitoring of all process data
control panel. The mobile control panel – Flexible shift data allocation
can be used at a maximum distance of – Password protected
20 meters away from the Touch Panel. – Large-screen view of throughput or
Up to 99 programs, each for eight partial pressure
shots, can be stored – of which nine – External application via Ethernet inter-
programs, each for eight partial shots, face optional for remote service con-
can be variably allocated to each mixing nection or transferring shift protocols
head via foam program management.
The machine continues production, even
if the TP1200 Comfort breaks down.
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Intuitive to use and highly reliable


PUC08 process data acquisition

Process data capture with the PUC08

The PUC08 from KraussMaffei The clear and intuitive-to-understand Your advantages:
allows process data for poly- user interface reduces training time and – Touchscreen with intuitive user interface
costs while ensuring quick analysis of – Flexible system visualization
urethane processing to be errors and faults. Wetside and dryside – Alarm, stoppage and shot records, plus
acquired in a clear and user- components are visualized. The PUC08 all other process-relevant data, are
friendly way. gives users a complete overview of the logged and stored in an SQL database
system's current status and is not only – Production is extremely reliable as all
comfortable to use but also extremely production parameters are saved in the
reliable. The robust computer has been PLC
designed without any moving parts – that – System runs even when the computer
means no fans and flash memory instead breaks down
of a hard drive. The PUC08 communi- – Robust industry computer without
cates with the PLC via Ethernet. moving parts
– Easy to expand thanks to modular
design
26 Mixing and metering machines
Further information

Further information
which might also interest you
Ask us for information about the following,
for example:
– High-pressure mixing heads for PO pro-
cessing
– Foam molds and mold carriers
– Milling and punching machines for trim-
ming PU parts
– Special techniques in PU processing,
such as spraying, SkinForm or Clear Coat
Molding

You can find our brochures and flyers online


at: www.kraussmaffei.com. On request, we
would also be happy to send you information
and technical data for our products free of
charge.
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KraussMaffei
A strong brand in a unique global group
Cross-technology system and There for you around the world Individualized service
process solutions With our worldwide sales and service Our employees from customer service,
Whether in Injection Molding, Reaction network, we offer our international application technology and service help
Process Machinery or Automation – the customers an excellent basis for a you with your questions and needs on
KraussMaffei brand stands for pioneer- successful business relationship. Due every topic dealing with machines, sys-
ing and cross-technology system and to the close proximity to our customers, tems and processes – around the globe,
process solutions in plastics processing we are able to answer your individual quickly and with a high level of expertise.
worldwide. For decades, our expertise, inquiries very quickly. We work out the We have developed an extensive custom-
innovative ability and passionate commit- best possible technical and economical ized service spectrum with our lifecycle
ment to plastics engineering have been solution for your product and production design, which accompanies you through-
your competitive edge. As a cross-indus- requirements together with you. Test our out the entire lifecycle of your machines
try system provider, we offer you modular machine technology for your applications and systems. Take advantage of the per-
and standardized systems as well as and let our experts put together an indi- sonal interaction and flexibility we offer
solutions customized to your needs. vidualized service package for you. in our practically oriented seminars.
We carry out customer-specific trainings
either at your location or at our sales and
service locations.

KraussMaffei Group
You can find additional information about
KraussMaffei at: www.kraussmaffei.com

Comprehensive expertise
Unique selling proposition Technology3
The KraussMaffei Group is the only pro-
vider in the world to possess the essen-
tial machine technologies for plastics and
rubber processing with its KraussMaffei,
KraussMaffei Berstorff and Netstal
brands: Injection Molding Machinery,
Automation, Reaction Process Machinery
and Extrusion Technology.

The group is represented internationally


with more than 30 subsidiaries and over
ten production plants as well as about
570 commercial and service partners.
This is what makes us your highly skilled
and integrated partner. Use our com-
prehensive and unique expertise in the
industry.
The KraussMaffei Group has a global presence.
Countries ­with subsidiaries are marked in dark blue.
You can find additional information at: In the white-colored regions, the Group is represented
­www.kraussmaffeigroup.com by over 570 sales and service partners.
Innovative mixing
and metering machines
Outstanding product quality
in PU processing
The extensive range of mixing and metering machines
from KraussMaffei is suitable for all application areas
in PU processing. The modular design and flexible
configuration of the machines allows them to be
optimally tailored to customer-specific requirements.
This means KraussMaffei offers the optimum solution

1.0 WE . 2nd edition 08/16. RPM 492 BR 09/2013 EN ··· Subject to technical changes ··· Printed in the Federal Republic of Germany.
for every production requirement. This includes being
easy to operate and maintain.

www.kraussmaffei.com

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