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Engineering Passion
2 Mixing and metering machines
Facts and figures
Application areas
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.
Easy-to-read displays
Easy to operate, service
and maintain
HMI interface
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
CO2 batch
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
RimStar Nano: For low output rates and minimum space requirements RimStar Compact: Space-saving thanks
to compact frame design
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
Metering pump
Premium quality
with low investment costs
The EcoStar Series
The EcoStar Series from KraussMaffei contains premium-quality
PU metering machines with low investment costs.
Comet metering machine with hydraulically driven pistons Precision with small quantities: Comet Nano
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
17
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
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
6
CO ²
7
2
2
3
3
1
4
5 4
5
6
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
22 Mixing and metering machines
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
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
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.
25
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
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.
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