2. Wittmann Group 2013-10
The WITTMANN Group
First supplier worldwide with a complete product portfolio for injection molding
application needs, consisting of:
Injection Molding machines
Robots and Automation systems
Temperature control units
Material handling systems and dryers
Dosing units
Granulators
Flow control units
Inmould Labeling equipment and Molds
3. Wittmann Group 2013-10
PRODUCTION
Vienna
(2)
Kottingbrunn Hungary France USA Canada China
WB WITTMANN GROUP
HOLDING GMBH
WITTMANN
Kunststoffgeräte GMBH
(Headquarters Vienna)
WITTMANN
BATTENFELD
(Headquarters
Kottingbrunn)
SUBSIDIARIES
Austria Germany Hungary Turkey France UK Benelux Italy Spain
Switzerland Russia Romania Bulgaria
Czech
Republic
USA Canada Mexico
Brazil China Taiwan Singapore Indonesia Malaysia Thailand India Australia
5. Wittmann Group 2013-10
WITTMANN BATTENFELD Injection Molding
WITTMANN BATTTENFELD develops, manufactures and supplies Injection Molding
machines, Automation solutions and robot systems for the production of plastics parts.
With a comprehensive, diversified range of machinery, including
all equipped with the latest technology – optimized for customer‘s needs in horizontal
or vertical design – WITTMANN BATTENFELD stands ready to meet any future
demands of the market. State-of-the-art process technology to solve a variety of tasks
are at the disposal of our customers.
Thanks to WITTMANN BATTENFELD‘s global presence, we are in a position to offer
our customers in a quick and competent way the necessary support and service
anywhere in the world.
modular Toggle machines
hydraulic machines
all – electric machines
6. Wittmann Group 2013-10
MISSION STATEMENT
We want to offer our customers an advantage when they work with us in
mastering their jobs.
HOW ?
With our products and technologies,
through innovation power, flexibility, reliability.
With our services,
fast, uncomplicated, globally close to customers.
With the sustainability and long-term commitment of
a family company with international business
orientation and quick decisions.
All from a single source:
from machines, robots, periphery, moulds,
up to complete plants.
7. Wittmann Group 2013-10
Milestones of the WITTMANN BATTENFELD History
Founded in 1876 by Ernst Battenfeld
First injection molding machine built in 1949; since then more than
80,000 IMMs built and delivered
BATTENFELD expands on a global scale in the 1960s
Acquisition by Schloemann Siemag AG (SMS) in 1977
Today worldwide more than 25,000 machines in operation
In 2005, the production is concentrated at the facility in
Kottingbrunn / Austria
In 2008, BATTENFELD is taken over by the WITTMANN Group.
2008-2012 development and market launch of the PowerSeries
2013 opening of the new assembly hall for the large machines
8. Wittmann Group 2013-10
The WITTMANN BATTENFELD Support Network
Worldwide activity
with 31
subsidiaries and
26 agencies
9. Wittmann Group 2013-10
Quality Products for the Plastics Processing Industry
WITTMANN is a Leading Supplier of Molding Machines & Peripheral Equipment:
Total Employees: 1750
2012 turn-over: € 275M / $360M
11. Wittmann Group 2013-10
Production of Injection Molding Machines
Production of precision parts such as plasticizing
units, tie bars, toggles, locking systems, flat jack
barrels
Gas nitrating equipment for screw barrels and
plunger units
Total Manufacturing Space of around 18,000 m²
DIN EN ISO 9001:2008 certified company
WITTMANN BATTENFELD – Production
Assembly at WITTMANN BATTENFELD
in Kottingbrunn
MacroPower locking
system
Screws Platen production
12. Wittmann Group 2013-10
New assembly hall for large machines
Opening April 2013
Assembly of machines of the MacroPower series
Increase of the existing production and stock
space of 15,000 m² to 18,000 m²
WITTMANN BATTENFELD – Production
13. Wittmann Group 2013-10
Machine Product Portfolio - Overview
Hydraulic models
35 - 300 t
Vertical models
40 – 270 t
t
Toggle line
180 – 500 t
EcoPower
55 – 300 t
Fast runner
160 – 450 t
MicroPower
5 – 15 t
MacroPower
400 –1.600 t
14. Wittmann Group 2013-10
MicroPower 5 t, 15 t
for the production of highly precise micro parts
designed for smallest part down to the single digit
milligram range
highly economical
two-step screw and plunger injection unit
extendable to complete production cell
specialized peripheral equipment and robots for
small and micro parts
Power Series
Machine Product Portfolio
15. Wittmann Group 2013-10
MicroPower 5 t, 15 t
Machine Product Portfolio
Design-Concept
without
rotary table
with
rotary table
Injection Process
2-step plunger injection
16. Wittmann Group 2013-10
MicroPower 5 t, 15 t
Machine Product Porfolio
basic version
tempering unit
material feeder
monitoring
camera
handling
device
rotary
plate
more modules to follow
material dryerclean
room
stacking
module
17. Wittmann Group 2013-10
EcoPower 55 – 300 t
all-electric machine
lowest energy consumption through use of
breaking energy within the machine
clean machine, suited for clean room
ultimate repeatability
low noise level
small footprint
open design
integration of peripheral equipment
fast barrel and screw change
integrated servo-hydraulic for ejector,
core pull and nozzle
Power Series
Machine Product Portfolio
18. Wittmann Group 2013-10
EcoPower 55 – 300 t – servo-electric machines in 2 versions
Machine Product Portfolio
Injection unit
Standard:
servo-electric closing, injection and metering
integrated servo-hydraulics for ejector, nozzle movements and core pulls (optional)
All-electric:
servo-electric closing, injection and metering
servo-electric direct drive for ejector
servo-electric twin drive for nozzle movements
Clamping unit Injection unit
to 70 130 350 750 1330
55 ● ● ●
110 ● ● ●
180 ● ● ●
240 ● ●
300 ● ●
19. Wittmann Group 2013-10
Power Series
MacroPower 400 – 1,600 t
2-platen technology, small dimensions
highest precision
shortest locking build-up time through QUICKLOCK®
easy lateral mold insertion
modular design
energy saving servo drive technology (optional)
Machine Product Portfolio
20. Wittmann Group 2013-10
Machine Product Portfolio
Hydraulic machines (also in Multicomponent technology)
HM 35 – 300 t
central hydraulic clamping system up to 300 t
3-platen technology
highest precision
powerful injection unit
energy saving hydraulic system
HM ServoPower
low energy consumption and excellent ecologic
balance through servo drive technology
easy accessable open injection unit
compact, room-saving design
21. Wittmann Group 2013-10
Variety of configurations
Complete range of clamping force
from 35 – 1,600 t
For all multicomponent technologies
The BATTENFELD COMBIMOULD is
compact
flexible
multipurpose
Machine Product Portfolio
Multi-Component Machines
22. Wittmann Group 2013-10
Combimould Technology
Long-term experience
Various models in 2- and 3 color design
Rotary table with servo-electric drive for
quick and precise movements
Application technology consulting for the
selection of the best process
Integrated operation via highly efficient
UNILOG B6P control system
23. Wittmann Group 2013-10
Machine Product Portfolio
Toggle machines
TM 180 – 500 t
5-point toggle system
high precision
TM Xpress 160 – 450 t
highest performance fast runner
for high speed Inmould labeling
applications
for closures, boxes and thin wall
25. Wittmann Group 2013-10
VM R 40 – 270 t
VM 60 – 200 t
CM 40 t
open design for good access
hybrid version with servo injection unit and
servo rotary table
parallel function of ejector/core pull
modular concept machine for 2 and 3 c
modular concept peripheral equipment
Machine Product Portfolio
Vertical Series
3-colour
application
26. Wittmann Group 2013-10
B6P – One superior control for all machines
universal operating system Windows Embedded
high user comfort and functionality
easy connectivity to IT- and customer networks
BATTENFELD K4 process data capturing
WEB Service remote diagnosis, service and training
15“ Color-TFT-Touchscreen
freely configurable
comprehensive event protocols – quality recordings
online help system – online language switch over
access control via USB – online user manuals
hull curve monitoring – cycle time analysis – user page
functionality
29. Wittmann Group 2013-10
AIRMOULD®/AQUAMOULD®
High quality.
Avoidance of sink marks.
Reduction of frozen stresses.
Reduction/avoidance of warpage.
Reduction of required clamping force.
Reduction of cycle time.
Weight reduction.
Fluid injection process:
Gas or liquid is injected in a way
that cavities are formed in the
molded part.
30. Wittmann Group 2013-10
BFMOLD® – New Variotherm Process
Technology
perfect „High gloss parts“
reduction of sink marks
no weld lines
increase of product quality
reduction of cycle times
“BF” = Ball Filled
31. Wittmann Group 2013-10
BFMOLD® – New Variotherm Process
Technology
Function
BFMOLD® combines multi-functional
properties
ball filling takes over mechanical
support function
ball filling allows high flow rate of
temperature control medium
temperature control medium comes
very close to the surface
application for straight parts and
parts with contours
TEMPRO plus C 2/160 VARIO
32. Wittmann Group 2013-10
Physical blowing agent
Very fine cell structure
CELLMOULD®:
The new WITTMANN BATTENFELD direct gassing technology
33. Wittmann Group 2013-10
Advantages: Weight reduction 15 %; Cycle time reduction 18 %
Conventional injection moulding:
Sink marks opposite to ribs
CELLMOULD®:
No sink marks
Foam structure
CELLMOULD®:
The new WITTMANN BATTENFELD direct gassing technology
34. Wittmann Group 2013-10
Example: Support, PP TV 20
CELLMOULD®:
The new WITTMANN BATTENFELD direct gassing technology
Very fine cell structureCompact
Weight: 94,0 g
Cycle time: 36,0 s
CELLMOULD®
Weight: 88,9 g:
Cycle time: 30 s
35. Wittmann Group 2013-10
Machines of series TM, HM,
EcoPower and MacroPower
Chemical blowing agents:
needle type shut-off nozzle
special software
Physical blowing agents:
needle type shut-off nozzle
accumulator, quick injection
special screw and barrel
CELLMOULD® box
gas injector(s)
pressure generating unit
software
Equipment for CELLMOULD®
36. Wittmann Group 2013-10
Inline-Thermography
Permanently optimized cycle times by having a constant mold temperature control.
Easy start-up, reduction of start-up scrap.
Quality improvement through constant temperature distribution.
Improvement in quality by having a constant temperature distribution.
Immediate detection of scrap.
Statistic process control inform in time about necessary maintenance of the cooling
channels.
Traceable „finger print“ of relevant process parameters.
Advantages
37. Wittmann Group 2013-10
SKZ-Software for Inline - Thermography
Reference
picture done
during
approval run
Actual
picture
shows the
current
temperature
distribution in
the mold
Online visualization of the difference Input
parameter for control of the TCU
38. Wittmann Group 2013-10
Up to 6 views are shown in each
injection molding cycle In each view, the temperature
deviations are assigned to the
temperature control circuits.
The software generates the variables
for the control of the magnet valves.
WFC systems which are directly
attached to the tool reduce the effort
for adjustment.
Control active
39. Wittmann Group 2013-10
Integrated Molding Work Cells –
Production Monitoring
Kistler CoMo Injection – visualization by UNILOG B6P
System with
Kistler Monitor
CoMo Injection System to Switchover,
process monitoring and scrap separation
with B6P control, no
external Monitor needed
40. Wittmann Group 2013-10
Integrated Molding Work Cells –
Production Monitoring
Detection of surface failures by integrated vision system
sink marks
weld lines
good part
bad part
41. Wittmann Group 2013-10
Energy consumption in plastics processing
Machine concepts (2) – electric machines
recovered energy 400 W
production hours 6000 Std.
price / kWh 0,13 EUR
savings / machine 312,00 EUR
recovery of braking energy
hydraulic vs. electric driven machine
connector 4-cav., shot weight 27,48g, cycle time 13,2s.
2,237
4,032
0,000
0,500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
HM 65 Eco Power 55
energyconsumption[kWh]
cycle time 30,09 s
shot weight 109 g
active power 3,684 kW
material throughp 13,04 kg/h
energy / kg 0,282 kW/kg
energy / kg > 0,85 kW/kg
Eco Power 110
hydraulic machine
42. Wittmann Group 2013-10
Drive systems of the benchmark machines
Hydraulic machine HM 240 DFEE:
Standard hydraulic
drive system with energy saving Hydraulic –
electronical adjustable pump
Hydraulic machine HM 240 ServoPower:
Servo electric driven drive with constant pump
Servo electrical machine EcoPower 240:
Servo drive for all movements
Machine benchmark – clamping force 240 t
43. Wittmann Group 2013-10
Specific Energy consumption, power, cos phy
0,65
0,44
0,27
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
[kWh/kg]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
specific energy consumption
12,30
8,31
5,267
0,00
2,00
4,00
6,00
8,00
10,00
12,00
14,00
[kW]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
power consumption
0,49
0,80
0,766
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
cosphy
mould VTA 208
shot weight 106g
cycle time 20sec.
Machine benchmark – clamping force 240 t
44. Wittmann Group 2013-10
0,65
0,44
0,27
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
[kWh/kg]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
specific energy consumption
Cycle time 20sec., shot weight 106g
HM 240
DFEE
HM 240
ServoPower
EcoPower
240
100,00% -32,44% -57,19%
- 2,94 Jahre 2,31 Jahre
- 7,06 Jahre 7,69 Jahre
- 23.720 € 45.600 €amount of coverage with lower energy costs (10 years)
remaining live time after ROI (basis 10 years)
ROI (higher investment costs)
effective energy costs - difference
Specific energy consumption – economic comparison
Machine benchmark – clamping force 240 t
45. Wittmann Group 2013-10
Servo Robots – Customized solutions
W 823 D
for stack molds up to 2* 10kg of
payload
W 828
for long kick reach and easy
mounting of sub-arms
Clean Room Kit
Special execution for lowest particle
emission and easiest cleaning
W 821-831
Universal servo robot for a great
variety of applications
W 837
Side entry robot for shortest
overall cycle times
Insider
Highly compact solution, free
access to the mold
46. Wittmann Group 2013-10
IML – In-Mold Labeling Systems
Top entry robots
for flexible solutions
W827 F/W
side-entry system for up
to 300t machines
W837 F/W
side-entry system for up
to 800t machines
W837 FLEX
Dual production for flat
and wrap-around labels
on unique frame
47. Wittmann Group 2013-10
Service Portfolio
Battenfeld offers its customers a comprehensive, highly efficient service portfolio
WEB SERVICES: leading in online service on internet basis
Inspection & maintenance packages:
- Preventive service
- Calibration service
- Full service
Service Help Desk: available from
7:00 am to 10:00 pm, 7 d/week
Processing Technology counseling to optimize processes
Wide range of (individual) training seminars
Web-Service 24/7 – around the clock and worldwide
50. Wittmann Group 2013-10
With almost 60 years
experience in building injection
molding machinery, we offer
efficient, innovative solutions for
all applications.