Multiplex Extruder

Tyre technology For effective production

Multiplex Extrusion Lines

IN PARTNERSHIP WITH INDUSTRY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Automotive

White goods

Construction

Medical / pharmaceutical

Whatever you aim to achieve in plastics or rubber

complete extrusion lines – is used in many

processing, KraussMaffei is your partner. We are

industries, including chemicals, pharmaceuticals,

the only company with intensive expertise across

automotive, construction, furniture and packaging.

the three main engineering fields. And we have a strong track record in integrating this expertise to

People for Plastics

develop new processes and systems.

We are the “people for plastics”. We are your partners from the first exploratory discussion,

Ready for any challenge

through development to commissioning, servicing

Our Injection Moulding Technology Division

and operating your system, and final disposal. At all

supplies machines and systems for standard and

times, you are assured of outstanding competence

special applications, very large machines and fully

in planning and engineering, as well as reliable and

automated solutions. Our main markets are in the

fast spare parts, service and support.

automotive, packaging, electrical, electronics, medical technology and consumer goods industries.

Adding value for customers

Our Reaction Process Machinery Division supplies

We put our expertise to work for your success.

machines and complete systems for processing

With machine ranges engineered for modularity,

polyurethanes and other reactive materials.

we can deliver application-specific solutions

Completing our product portfolio, Tooling

based on our wide range of standard modules and

Technologies supplies foam moulds, cutters and

specially engineered solutions. This strategy offers

routers. Our customer base is wide, with a focus

customers technical and cost advantages.

on the automotive, construction and white appliances industries.

Close to customers around the world

Our Extrusion Technology Division supplies

As an international company, KraussMaffei has a

machinery and systems for compounding, for pipe,

presence in all the major markets for the plastics

profile and sheet extrusion, physical foaming, and

and rubber processing industries and employs over

the production of technical rubbers and inter-

3,000 people worldwide. Our sales and service

mediates for tire production. Machinery from the

network keeps us close to all our customers around

company’s range – from single extruders to

the world.

Electrical / electronics

Combining excellent product quality with maximum production output – Multiplex extrusion lines

Packaging

As an expert partner for the tyre manufacturing industry; KraussMaffei Berstorff delivers complete leading-edge systems for the production of tyre components. Our goal is to offer the made-to-measure solutions you need to succeed in today’s fast moving competition. In our product portfolio you find Multiplex extrusion lines with the highest output-rates in the market. Proven engineering power, unrivalled technological expertise, numerous patented developments and active participation in the production processes of the tyre manufacturers testify to the innovative character of our machinery and made us what we are today: the world leader in this technology.

Multiplex Extrusion Lines

High technology, high quality, high output

The automotive vehicle tyre is a high-performance

The demands and expectations of our customers

precision unit. The requirements of safety, com-

are met with closely-targeted advice, highly-develo-

fort, economy and environmental compatibility

ped project management methods, computer-aided

demand a high level of quality in every single tyre

component design and state-of-the-art manufactu-

component.

ring and application-specific commissioning.

For the manufacturer, this means the application of

Our Technical Centres offer practical pre-contract

technologies, which combine excellent quality with

support with production-scale machinery and labo-

high output.

ratories with inspection and testing facilities. Trials are conducted under real conditions to secure the

KraussMaffei Berstorff’s response to this challenge

basis for each investment. The result is customer

is the delivery of complete high-tech extrusion lines

satisfaction right from the outset.

for the production of tyre components. High-tech extrusion lines with the highest output Our know-how matured over decades, our own

rates confirm our position as the world leader in

patented developments and our active participation

this technology as all the significant manufacturers

in the innovative processes of the tyre manufacturers

produce their tyres on KraussMaffei Berstorff

all go to make us an expert partner for the industry.

machinery. Tread

Tread compound

Capply Undertread

Belt layer 1

compound

Belt layer 2 Sidewall compound

Sidewall

Carcass Innerliner Apex Rim cushion

Seite 4

Bead wire

Multiplex Extrusion Lines

Bead

Multiplex Units for Pre-assembly

Pre-assembly: precision in detail

Pre-assembly defines the level of the production technology. This is because pre-assembly of passenger car and truck tyres utilises all the reserves of rationalisation, whilst simultaneously raisng the tyre component quality to a high level. KraussMaffei Berstorff machines are designed in concept to meet the special demands of the manu­ facture of semi-finished components. Duplex, Triplex and Quadroplex extrusion sets guarantee precise combination of the different components, totally free of air inclusions. The end result is always more than the sum of the individual parts – here is component technology in perfection, allowing significant rationalisation by reducing the number of working stages on the tyre building machines.

Extrusion Head Product

Passenger car tyres

· · · · ··

Truck tyres

Duplex Duplex

Sidewall + rim strip





Cap + base



2-component apex

Triplex Triplex

Cap, base, wings



Cap, base, cushion



Black sidewall, rim strip,



shoulder pad

Quadroplex Quadroplex

Cap, base, wings,



cushion



2 x cap, base, wings



White sidewall, rim strip,



shoulder pad

Preline

·· · ·

Wings

Cap

Base

Cushion

Seite 5

Multiplex Lines

Pre-assembly of a Multiplex extrusion set

Quality and performance without compromise

All tyre makers are seeking ever-tighter manu­

material flow in the head. In addition, the compact

facturing tolerances, whilst throughput rates are

design makes for real space savings. A further

steadily rising.

feature to satisfy the quality requirements is the special design of the flow channels in the extrusion

KraussMaffei Berstorff extrusion lines are concei-

head. These ensure a very gentle, even material

ved for high product quality and maximum output

transfer from the round section at the extruder

and are equipped with extruders of different types

outlet to the rectangular flat form of the profile. In

(GE-SC or GE-KS) and sizes.

addition, the changes in direction of the material flow in the flow channel are kept to a minimum.

The modular design makes for rapid reconfiguration to suit the mode of operation – Mono, Duplex,

All stages of the process are controled by a monito-

Triplex or Quadroplex.

ring system, thus ensuring operational security.

KraussMaffei Berstorff Multiplex extrusion sets are

Throughput rates of up to 10,000 kg/h or about

designed in a piggy-back arrangement to achieve

30,000 passenger car treads per day are achieved

the highest product quality through symmetrical

with these modern extrusion lines.

Flow channels in the Multiplex extrusion head

Seite 6

Multiplex Lines

Preline

Seite 7

 M ultiplex extrusion heads and tools

 Versatile and efficient: systemised head operation

The range of different tyres dictates the require-

· Cassette changer unit on the operator side,

ments for changing the compound, dimensions

consisting of a housing and a vertical sliding unit

and programs run on any production line, whilst

on either cassette. One housing is in production,

the extrusion head determines the quality and efficiency of the tyre production.

whilst the other is in the preparation position. · Double wedge comb to shorten change of the

Multiplex extrusion heads from KraussMaffei

final die without changing the splice bar. While

Berstorff represent the state of the art with

the outer wedge comb is opened, the inner one

· working widths up to 850 mm for up to 2 treads

holds the housing and splice bar closed against

in one production pass

the head.

· locking forces up to 10,000 kN · connection of up to four extruders of different types and sizes

This minimises scrap and allows rapid restart of production.

To achieve rapid change times for different profile

The upper and lower parts of the head can be ope-

dimensions, KraussMaffei Berstorff have two

ned separately to facilitate cleaning when changing

solutions:

the compound and to accelerate the changeover.

Seite 8

Multiplex extrusion heads and tools

Easy to clean: extrusion head in opened position

Multiplex extrusion head with cassette changer unit

Accelerator roller train with blow-off jets

Width Continuous length

Profile scanner

Multiplex

Take-off roller train

weighing scale

extrusion set

with marking unit

and width scanner

 M ultiplex complete lines

System technology at a stroke The better the individual process stages fit together,

Each part mates with the next and every compo-

the more secure is the flow of the production.

nent of the line can be matched to the process-tech-

KraussMaffei Berstorff designs complete line con-

nical requirements of compound and dimensional

cepts to attain perfect interplay of all components

changes or changes from cut piece to wind-up

under changing parameters.

operation. The interface-free configuration of the machinery ensures constant product quality at

Based on our wide experience, we bring together

maximum capacity utilisation.

all elements of the production line into a systemised technological solution. From the feed units to the wind-ups – everything from one single source.

Feed units with

Gauging instruments

· metal detectors

· continuous weight per meter and weight per piece for

· automatic setting of the feed rate · simple service and maintenance

precise weight measurement · width measurement before and after the cooling unit · profile scanning for continuous monitoring of the geometry · length measuring units for monitoring the cut profile lengths

measurement Cutting machine skiver

Reject roller train

Cross-cutting unit

Manual pick-off roller train –

Spray cooling

Wind-up stations

cut-piece operation

Marking units for

Cooling systems

Cementing station

· printing of coloured stripes

· units for spray or immersion cooling

· to increase adhesion of the

· printing of identification codes

splice surfaces

· imprints of numbers and letters

Cutting units (Skiver)

Wind-up operation

Cut-piece operation

· flying cut or start/stop cut for cut-piece

· cassette winders

· manual pick-up roller train

· spool winders

· automatic booking system

operation with the highest cut quality, length precision and maximum cut rates per minute, rotary cutting for wind-up operation

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Control and automation

Multiplex Extrusion Lines

Planning and construction of the electro-techni-

each extruder. If the actual process values deviate

cal equipment for the extrusion lines are carried

from the set points, the process parameters are

out in modular form to the latest standards.

corrected individually or, depending on their

Customised configurations can be quickly created

proportion of influence on the profile components,

without problems.

of all extruders. Auxiliary drives are equipped with low-maintenance three-phase standard motors

The extruder motors are equipped with micropro-

and vector-controlled frequency converters. Non-

cessor drives, digital actual value access and bus

contact sensing systems such as CCD cameras and

connector set point provision. This technology

ultra sonic sensors and special digital dancer-type

ensures a high degree of repeatability, exact regu-

regulators provide tension-free material transport.

lation and dynamic screw speed control. All this

Each system is provided with a digital software con-

has a direct influence on the quality of the extruded

trol, which guarantees optimal speed matching with

profile. KraussMaffei Berstorff developed control

its adjacent downstream drive. The PLC automation

software mimimises start-up scrap and keeps the

units of the individual machines are networked via

extruded profile within the prescribed dimensi-

TCP/IP with each other and with the visual display.

onal and weight tolerances during production.

Operator-friendly visualisation and easy-to-use

The system continuously reads the weight and

recipe management facilitate flexible production

the dimensions of the profile as well as the screw

planning, high product quality, minimal start-up

speed and the stock pressure and temperature in

scrap and rapid changeovers.

Seite 12

Control and automation

WIN CC (Win NT)

1 Service

16 PLC customer

2 Host

communication

3 Modem

17 Profibus DB

4 Switch

18 AC Drive with

5 OPC server

pulse generator

6 Main operator panel

Extruder 1 –  4

7 Operator box head

19 AC drive with

8 Ethernet TCP/IP

pulse generator

9 Profibus DB

Mini Rollerhead

10 Extruder control

20 Heating controller

11 Terminal- and

21 Camera

operator-boxes

22 Scale

12 Feeding for

23 AC Vectordrive

extruder 1 –  4

with pulse generator

13 Feeding for Mini RH

Downstream 1...n

14 Head 15 Terminal- and operator-boxes

Roller-Head lines

Tandem operation for maximum precision Roller-Head technology from KraussMaffei Berstorff combines precision and economy into one: close-tolerance work for the production of innerliners and filler strips. The rubber compound is plastified in the extruder and fed directly to the roll gap of the two-roll calender via a wide-slot extrusion die. The calender calibrates the web exactly to the preset final thickness. This process avoids the formation of a rolling ball in the calender and thus the risk of air inclusions. The narrowest of tolerances over the entire web width and optimal homogeneity of the compound ensure the perfect tyre innerliner and filler strip. Both profiles are doubled with the highest centricity and absolutely blister-free.

Roller-Head lines

Seite 13

SERVICE WORLDWIDE

Service, support and spare parts – when you need them, where you need them Rely on us for a fast and competent response to

Customer trials and prototyping in our test lab

all your service needs anywhere in the world.

The Extrusion Division operates a test lab in Ger-

Whatever you need – from troubleshooting or

many and USA fitted with the latest machinery and

training to spares or repairs – we’re on the job.

equipment. We can run trials and fine-tune processes on your behalf. We can work with you to test

We’re dedicated to supplying service quality on a

and evaluate processes, machines and equipment in

par with the outstanding quality of our machines

order to identify the best approach for a particular

and systems. We offer far more than spare parts

project. Our highly-qualified application engineers

and hotlines. We’ll work with you to choose the

are there to help you.

best and most cost-effective solution for your production. We’ll help you test new applications

Training with high hands-on content

and we’ll plan customized service packages.

Courses are held in our lab and training centre, or, optionally, on your premises. We offer

All-round service

clearly-structured basic and advanced training in

Our service offering is broad. We’ll configure your

operation, process control and maintenance for

system, install and commission it, train your staff,

KraussMaffei extrusion systems. On request, we’ll

plan measures to minimize your downtime risk and

plan and hold special courses on topics of your

maximize productivity, and carry out maintenance,

choice. All participants spend a high proportion

repairs and upgrades. You’ll find us fast, reliable

of their training working hands-on with original

and competent. Our hotline is manned by highly-

KraussMaffei Berstorff machines. A well-structured

trained and experienced service technicians.

training program produces skilled operators and

If necessary, we’ll get a technician to you quickly.

technicians, which will positively impact your up-

Remote diagnosis, interfacing directly with your

time and productivity.

machine’s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We’re continuously expanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business.

Worldwide hotline numbers

KraussMaffei

Phone rubber

Berstorff GmbH

technology: +49 172

Hannover, Germany

511 9620

Customer Service  Phone: +49 511 5702-533 Email: service-ext. ha@kraussmaffei. com

Phone plastics technology: +49 172 511 9621 Phone service hotline: +49 172 511 9623

Krauss Maffei Italiana S.r.l. Rezzato, Italy Phone: +39 030 2590707 Fax: +39 030 2592369 Email: [email protected] BKM Servicegesellschaft OOO KraussMaffei Berstorff Moscow, Russia

Krauss Maffei Corporation

Phone: +7 495 9377554

Florence, USA

Fax: +7 495 6265745

Phone: +1 859 2834376

Email: [email protected]

Fax: +1 859 2830290 Email: [email protected] Krauss Maffei Mexico Mexico City, Mexico Phone: +52 81 15211604 Fax: +52 55 53081727 Email: ser [email protected]

KraussMaffei Co., Ltd. Shanghai, China

Krauss Maffei do Brasil Ltda

Phone: +86 21 58682662

São Paulo, Brazil

Fax: +86 21 58681173

Phone: +55 11 56412273

Email: [email protected]

Fax: +55 11 56419337 Email: [email protected]

Krauss Maffei Asia Pacific Pte. Ltd. Singapore Phone: +65 65 535828 Fax: +65 64 550419 Email: [email protected]

Contacting us by post If you need to contact any of our

Customer Service

international service or spare parts teams

KraussMaffei Berstorff GmbH

by post, use this address:

An der Breiten Wiese 3-5 30625 Hannover Germany

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of experience and a strong

As an expert partner for the tyre manufacturing industry; KraussMaffei Berstorff delivers complete leading-edge systems for the production of tyre components. Our goal is to offer the made-tomeasure solutions you need to succeed in today’s fast moving competition. In our product portfolio you find Multiplex extrusion lines with the highest output-rates in the market. Proven engineering power, numerous patented developments and active participation in the innovative processes of the tyre manufacturers testify to the innovative character of our machinery and made us what we are today: the world leader in this technology.

KraussMaffei Berstorff GmbH

An der Breiten Wiese 3-5 ··· 30625 Hannover Phone +49 511 5702-0 ··· Fax +49 511 5619-16 www.kraussmaffei.com 

1.0 WE . 1st edition 06/07. EXTH XXX A PRO 06/2007 GB ··· KraussMaffei reserves the right to make technical changes.

commitment to research and development.