FABRIK 2018

• 1st place GREEN FACTORY Austria 2018
• 2nd place for the best production in Austria in 2018

MAPLAN won the “Green Factory 2018” category and second place at the factory price

Our commitment to saving energy was key to MAPLAN being awarded the “Green Factory 2018” company competition in November 2018 in the company competition “Factory – The Best Production in Austria”. Once a year, the Fraunhofer Austria Research GmbH, an independent foreign subsidiary of the largest organization for applied research in Europe, organizes this competition together with the Austrian trade magazine “Industriemagazin”. A team of experts from Fraunhofer Austria conducted an evaluation at our headquarters in Kottingbrunn, Lower Austria.

The results of this evaluation not only led to the distinction of being a “green factory” – they also confirmed to us that we are on the right track. However, it is also an important part of our corporate responsibility that the more than 200 MAPLAN employees feel at home in their workplace – and this can be wonderfully combined with ecological measures.

Lower Austrian flagship company in terms of energy efficiency & mobility

MAPLAN was honored at an event under the motto “Erfolgs.Faktor.Realisierte.Energieprojekte” by state councilor Petra Bohuslav and Lower Austrian Chamber of Commerce President Sonja Zwazl. A total of 42 Lower Austrian companies participated in the competition.

The way to energy efficiency

With the MAP.EnergyWatcher resource hoggers can be identified in your production chain, thus saving valuable resources. In many production plants inefficient setups go unnoticed for a long time and keep using energy uneconomically. The knowledge of the energy flows and the visualization of the exact consumption serve as the basis for setting appropriate measures and reducing the costs.

MAPLAN’s MAP.EnergyWatcher program permanently records the consumption of an injection molding machine. Consumption is recorded in detail and can thus be precisely calculated and constantly optimized. Ideally, this leads to a significant cost savings.

Any changes in the production process, such as temperature and speed variations, affect the energy consumption and result in an adjustment of the energy and trend display within the machine control generation 6 (C600.web, C6000.web & X6.web). The data allow immediate conclusions as to whether the adjustments have led to an improvement or reduction in the use of energy.

Exact calculation based on real data

Experienced process engineers can use the MAP.EnergyWatcher to calculate the energy input per machine part. This is a huge advantage in the calculation of new and related parts, as these calculations are based on real data.

Three different variants are available:

• a medium for water measurement: WaterWatcher
• a medium for compressed air measurement: AirWatcher
• a medium for current measurement: PowerWatcher

Each variant is delivered in a package with appropriate hardware and software. Sensors (included) collect the necessary data for monitoring. The data is forwarded to the control software and allows extensive analysis options, such as:

• Energy / layer
• Energy / day
• Energy / selectable period (comparable to trip odometer)
• Energy consumption for the product just produced

All calculated data can also be transferred to higher-level systems using the standard export function of the C6.x controller.
The MAP.EnergyWatcher package is now available from MAPLAN, your customer advisor is looking forward to your inquiry!

MAPLAN at the K 2019

With “Injection Intelligence” for efficiency gains

The focus of the exhibition presentation of the Austrian rubber injection molding machine manufacturer MAPLAN in Hall 16 on Stand D 40 will be the upgrading of existing plants in addition to the restructured new machine program. Both focal points are designed to give users economically interesting options for increasing their competitiveness in times of uncertain economic prospects. This includes the cost-effective replacement of the machine control as well as the retrofitting of automation equipment and energy consumption displays. Representing the new machine series, a horizontal RAPID + 700 Dual / 300 and a vertical ERGO + 6000/400 including extensive automation modules will be presented, thus presenting the new MAPLAN options as a provider of 360 ° complete solutions.

With this year’s K trade fair presentation, MAPLAN makes strong reference to the current uncertainties in the further development of the economy and thus in important customer sectors for elastomer molded articles, for example the automotive industry. In order to provide the companies concerned with opportunities to reduce production costs and increase competitiveness, MAPLAN presents a whole bundle of measures and equipment for upgrading existing plants, which can be used to extend their useful life with economically interesting investments or their production efficiency can be increased. This area will be dedicated to the central area of ​​the enlarged exhibition stand.

There, a wide range of control and monitoring devices will be presented and demonstrated, such as the retrofit version of the current MAP.commander C6 control with the type designation X6, and those on MAPLAN machines of the control generation 4 (= from year 1995) in just three working days can be retrofitted and makes it web-connectable, or allows the connection to a corporate network. Or the retrofitting of utility meters for electricity, air and water as a basis for decision-making for saving measures.

Efficient through automation: “RAPID +” – horizontal machine for high-volume production

One of the two machine exhibits is representative of the newly revised horizontal machine series, which will be available at the K-fair under the model name “RAPID +” in a clamping force range from 2000 to 4000 kN. It is the RAPID + 700 Dual / 300 (3000 kN clamping force) with the energy-saving “MAP.cooldrive” servo drive for the hydraulic system. On the injection side, the machine has a 725 cm³ MAP.fifo plasticizing unit with an injection pressure of up to 2,300 bar. “50 Shore A HTV silicone” is used for the stuffing device with hydraulic locking. Elastic “crown cork” bottle caps are produced with a 16 cavity cold runner tool from OR.P. STAMPI s.r.l.. The 16 cold runner nozzles are hydraulically controllable and can therefore be adjusted individually or in clusters as required in their filling behavior. In the concrete case, the demolding function in the tool assumes a stripper plate. To demonstrate alternative Entformungsmethoden located on the machine and a servo-electrically driven double brush device.

Ergonomic and productive: Fully automated production cell based on an “ERGO +” vertical machine

The second machine exhibit is a hydraulic, bottom-closing vertical machine from the new “ERGO +” series, which is available in four clamping force levels up to 4000 kN. This is followed by the “ERGOMAX +” series in three sizes up to a clamping force of 9000 kN. The common feature of all ERGO + machines is the design of the clamping unit, which is optimized to a minimum operating height, which usually eliminates the need to add walk-in platforms or install the machines in foundation pits.

Specifically, an ERGO + 6000/400 with a clamping force of 4600 kN will be available at the stand. It is equipped with a 6000 cm³ MAP.fifo plasticizing unit with 2000 bar injection pressure. In combination with an ABB industrial robot, which handles the cavity plate manipulation between the machine and a demoulding and reworking station, the machine becomes an automated production cell. The smartphone multi-function holders made of 75 Shore A EPDM manufactured by AS-Zerspanungstechnik GmbH in conjunction with a needle valve cold runner by PETA Formenbau GmbH are labeled with a laser by Bluhm Systeme GmbH after demoulding in a rework station of WEASystec GmbH. decorated.

System networking and status transparency through Industry 4.0 – capabilities

With regard to Industry 4.0, the application examples show what is currently possible in the machine environment. The basis for this is the machine control MAP.commander C6000, whose processing speed has been significantly increased. It communicates with robots and peripherals via the industry-standard OPC / UA interface and connects to MES systems for data exchange within corporate networks.

MAPLAN at the K-2019: Hall 16 – Stand D 40

Abbildungen:

E-cars are demanding new solutions, in rubber processing as well. The new MAPLAN SPECIAL+ QUATTRO- RAM 700-700/850 injection moulding machine was specially designed for the production of battery seals in the electric car industry. It is the largest machine to have left the MAPLAN production hall in Austria to date.
With a unit weight of approximately 100 tonnes and dimensions of around 8 x 9 x 6 m, this injection moulding monster broke all of MAPLAN’s previous records and demanded maximum performance from both the MAPLAN construction team and the transporters.

BIG & FAST:
CLOSING UNIT AND HEATING PLATES
IN IMPRESSIVE DIMENSIONS

Eight tie bars each with a diameter of 170mm ensure the mechanical stability of the locking unit. The four impressive main locking cylinders guarantee perfect locking force distribution across the 1500 x 2500mm size of the heating plates. Just two 50 kW pumps with a hydraulic pressure of 260 bar are required to ensure that movements are fast and smooth despite its size and enormous weight.
The servo-electrically driven MAPLAN Fast Double Shuttle moves two alternating centre plates and guarantees that continuous unloading or loading is pos-sible during the heating time. The travel speed in this process is a remarkable 600mm per second. The long travel distance of 3200mm is covered in just seven seconds.
The generously dimensioned and movable heating plates use automatic contacting for the heating cur-rent in the particular end position of the shuttle and in the machine. This keeps the temperature of the al-most permanently heated lower part of the mould stable. The software-controlled, hydraulic auto-levelling system for the ejectors compensates for the dynamic load during shuttle movement.

2K: WITH RUBBER & SILICONE

The injection system with two 700 ccm MAP.fifo injection units and independent hydraulics also had to be adapted to the new size. Special injection chambers designed for the powerful injection plates of the 850-tonne machine are used. Both rubber and silicone (multi-compound) can be processed with the two injection units (multi-component).

During silicone processing, the material is fed into each injection unit via a vertically arranged 15 litre stuffing unit. For rubber processing, all that needs to be remo-ved is a sealing plug on the injection units. Despite the exceptional machine height, it is kept ergonomic by way of integrated climbing aids for the operator.

QUATTRO-RAM 560 with 4 clamping cylinders and two 700 ccm MAP.fifo injection units injected from the top.

KEY FACT:
20 TONNES
ONLY BASE PLATE WEIGHS

ONE component of the SPECIAL+ QUATTRO-RAM 700-700/850 is heavier than the total weight of most other injection moulding machines. Its surface area is about three times larger than the single largest machine built by MAPLAN to date. The mould weight is about four times heavier than a standard mould on a 460-tonne machine. In the picture below, you can see the machine’s moving plate.

To sum up in other words:
The SPECIAL+ QUATTRO-RAM is a machine of superlatives!

Societal and industrial change, new customer requests and new technology: everything is interconnected. No one can get past the need for digitalisation any longer. The world is becoming digital, but is also supposed to become more sustainable at the same time. This would appear to be paradoxical and no easy task. However, Industry 4.0 represents both a challenge and an opportunity for companies. This is because digitalisation also facilitates innovation for economic activity that is ecological and social if the considerable potential here is made use of.

How are we facing this challenge here at MAPLAN? Our answer reads: MAPLAN INJECTION INTELLIGENCE. This holistic message takes into account MAPLAN’s new philosophy. Innovative, smart and energy-efficient technology which is easy to use, promises sustainable production of the highest quality. And the individualised customer experience is the key to success. For us, sustainability is an all-encompassing issue since it cannot simply be reduced to individual aspects. For this reason, we at MAPLAN take economic, ecological and social factors into account when creating the conditions for effective cooperation. Sustainability also has the added benefit of increasing efficiency. At MAPLAN, our entire process chain is continually enhanced for optimum efficiency – from the supplier through production to the customer. Using resources efficiently and sustainably is part of our corporate culture. For us, this is not just an empty promise, but a corporate responsibility which we live and breathe to the benefit of all. And this ideology is reflected in our technology in turn.

OUR TECHNOLOGY IS LONG LASTING

MAPLAN can offer the right type of machine for every application or bespoke system solutions. In this way, we ensure that the size of the machine is correct in relation to the quantities that should be produced, that predefined budgets are held to and that as few resources as possible are used in production. MAPLAN machines consist of durable, high-quality components and are equipped with every option available today for the optimisation of energy efficiency.

„INJECTION INTELLIGENCE constitutes innovative, smart and energy efficient product and service solutions which are simple for users and which facilitate sustainable production of the highest quality.”

Wolfgang Meyer, CEO

OUR TECHNOLOGY IS UNDERSTANDABLE

MAPLAN offers machinery that captivates through the simplicity of its operation and the straightforward construction of its components. This has been clearly evident on the original MAP.fifo injection unit for many years. Consisting of few individual components, optimal basic construction and simple operation options, this concept continues to offer unparalleled performance. Very low pressure-losses owing to the short nozzle, hardly any waste when changing materials and a high level of precision make for perfect article quality with the highest possible conservation of resources. All MAPLAN systems use the MAP.commander C6 as a central control unit. This technological heart of INJECTION INTELLIGENCE distinguishes itself through exceptionally high user friendliness, simple logic and comprehensive assistance systems which make the user’s life simpler. The control unit warns employees the moment processes get out of tolerance and not only later on when products of inferior quality are being manufactured.

OUR TECHNOLOGY IS FORWARD LOOKING

MAPLAN guarantees efficient processes because we know that time is money. We believe that innovation in injection moulding technology means pursuing all possible avenues in order to optimise production processes that are in line with the latest technological standards. For this reason, the MAP.commander C6 serves as a basis for the networking of machinery in the sense of Industry 4.0. Real-time data, monitoring and remote access to machines offer completely new opportunities. Good examples of this include remote maintenance or diagnosis from distance by way of online camera support and energy monitoring.

INDIVIDUAL CARE AS ADDED VALUE

In an era of unending digitalisation, we value personal relationships and empathy. We look to foster long-term partnerships with our customers and suppliers: we know how you operate, the specific problems you face and how to solve them.

Our employees play a crucial role in the holistic message of INJECTION INTELLIGENCE. Long-standing and competent specialists who maintain a close dialogue with the customer and who contribute to MAPLAN technologies guaranteeing our customers’ success are a good of which we are very proud.

New developments with respect to INJECTION INTELLIGENCE are focused on innovations that MAKE LIFE EASY for our customers. Just like most companies in the sector, MAPLAN was also affected by the corona crisis in recent months. However, development activities continued unabated for the most part. Free capacities were utilized for new developments in order to alleviate the daily lives of our customers.

HIGHER EFFICIENCY
BY MEANS OF TARGETED DYNAMIC PRESSURE ALLOCATION

Our new software version enables plasticizing process defined in 5-steps with individual speed and pressure settings. Shear energy input to the rubber compound can now be done with much more accuracy and efficiency and thereby reduces the fluctuation range of the temperature progression within the plasticizing procedure. This results in a significantly greater process window whereby the parts quality is more consistent and vulcanization or cycle times are significantly reduced.

HIGHER PROCESS TRANSPARENCY
ENSURES THE QUALITY OF PARTS

Process data is clearly consolidated and visualized for all MAP.fifo injection units. Pressure and temperature progression of the plasticizing process is depicted in an easily comprehensible manner according to cycles on three screen pages of the machine control system. The pages show configuration parameters including a process graph (Fig. 1), hydraulic pressure at the hydraulic motor and the temperature progression graph. The second illustration (Fig. 2) displays the pressure progression during plasticizing via which a tolerance range can be established for process monitoring. The quality of parts can be improved with this simple tool. Moreover, curve progressions can also be exported and added to parts-related data quality documentation.

Fig 1. Overview page “Plasticizing” with graphic display of process parameters.

Fig 2. Pressure progression with generated envelope curve for tolerance monitoring.

MAP.COMPENSATE:
HEATING TIME MANAGEMENT
TARGETED, SIMPLE, EFFECTIVE

Various manufacturers have provided heating time calculation or process optimization systems for many years. However, most machine operators are overwhelmed by the multitude of material and machine parameters that must be entered in daily operations, which is why its usage has remained quite limited. MAPLAN is now introducing its own system in the form of MAP.compensate, which was developed with a focus on practicality. Up to 10 vulcanization times can be determined in advance per processed rubber mixture for various tool temperatures that are subsequently taken over in MAP.compensate. The control system uses this data to calculate the specific correlation between heating time and tool temperature. MAP.compensate returns the vulcanization process to the desired operating point by means of a calculated time correction if a deviation occurs in regard to this setting, e.g. due to an environmental drop in temperature. MAP.compensate determines a trajectory based on up to 10 mixture-specific and temperature-dependent heating times. These form the ideal basis for targeted heating corrections of environmentaloperating point deviations.

Fig. 3 MAP.compensate determines a trajectory based on up to 10 mixture-specific and temperature-dependent heating times. These form the ideal basis for targeted heating corrections of environmental operating point deviations.

MAPLAN is closely cooperating with producers and users to provide machine solutions for pioneering electrically powered mobility applications. The focus is on increasingly efficient battery/fuel cell technology, which can offer longer mileage range and drive power. For this reason, MAPLAN is developing a new modular and scalable large-scale machine series with vertical clamping unit: MAPLAN SPECIAL⁺ MR, with TWIN RAM 560 as the first model. Machines of this type are ideally suited for producing large gaskets for e-vehicle battery boxes.

PRODUCTION OF LARGE-DIMENSIONED HIGH-PERFORMANCE GASKETS

Initiated by the demand for machines that produce large-scale metal bonded rubber composite parts, engine gaskets and gaskets for battery boxes, MAPLAN has developed a new, vertical machine series. The functional specification highlights are large platen areas, ergonomic operation and at the same time accurate injection volume control. The Series name “SPECIAL⁺ MR” reflects the design principal, where combination of two (TWIN-RAM), four (QUATTRO-RAM) or even more clamping cylinders are used to distribute clamping force evenly across large platen areas and to ensure minimum deflection during moulding.

The new MAPLAN vertical machine series SPECIAL⁺ MR is stable, accurate & modular – and suitable for many challenging applications involving large size rubber parts with close tolerances.

SPECIAL MACHINE IN LARGE-SCALE FORMAT: MAPLAN TWIN-RAM 560

TWIN-RAM 560 (5600 kN clamping force) uses heating platens with size of 800 x 1500 mm designed for maximum deflection of 0.05mm at the center of the plate. For a specific project, the clamping unit was combined with two MAP.fifo injection units with injection volume of 50ccm located from the top of the machine. Two injection units can inject in parallel or independent of each other. These high-precision injection units make it possible to inject very small shot volumes with high precision.

In this specific case, rubber seals are bonded on cylinder head gaskets, using this special machine. The gasket consists of thin rubber lips injected around cylinder bores, fi xing holes etc. over the metal gasket. The entire injection volume of rubber is only 2 x 7ccm for one part. High-precision gaskets with vary large dimensions and that do not require post moulding operations like flash removal, can be produced with these machines.

TWIN-RAM machines are available with various shuttle systems to make loading and unloading of inserts and gaskets very easy. Moreover, various automation possibilities are also available from the MAPLAN portfolio.

THE MARKET DEMANDS FLEXIBILITY – MAPLAN RESPONDS

OEMs and machine producers are challenged by the complex special requirements of e-mobility. New challenges will emerge regularly as various future applications are developed driven by E-mobility. MAPLAN is ready for this challenge and, in addition to the existing and proven machine program, has developed another new machine segment by which the large gaskets can be efficiently produced with high precision. This is how MAPLAN takes challenges positively and will be there for our customers to depend on us. Electromobility is important for the future of all people on the planet and also a major concern for MAPLAN. e-mobility is practiced within our organization as the part of MAPLAN’s sustainability strategy.

TWIN-RAM 560 with 2 x 2800 kN clamping cylinder and 2 50-cm3 MAP.fifo injection units that are injected from the top.

Mexico provides a low-cost supply base for many manufacturers in North America and around the world. Among others, the automotive industry has long enjoyed the cost advantages of sourcing from Baja California – the northern-most state in Mexico, just across the border from San Diego. But lowering costs isn’t everything, and in the wake of the global supply chain disruptions of 2020, purchasing directors are even more sensitive to one critical element: stability.

By partnering with Morgan Polymer Seals (MPS), automotive OEMs benefit from a reliable supplier that is privately-owned, debt-free, and experienced. And like MAPLAN, Morgan Polymer is a family company that provides personal customer service for its global partners. However, it is not easy to meet the demands of heavily-regulated car makers, so auto suppliers must deliver goods that adhere to strict quality standards. Starting with a single MAPLAN press in 1997, founder and CEO Kevin Morgan has quietly built a reputation as the innovative, on-time leader in precision rubber molding. Now, over two decades later, MPS continues to partner with MAPLAN for its Injection Molding, with seventeen machines that have helped the company earn distinguished quality awards from OEMs like Ford and General Motors, for several consecutive years.

(Left to right) Alex Borboa, General Manager, Kevin Morgan, President & CEO, Mark Conlee, Director of Engineering, Todd Tesky, VP of Sales

ON-TIME DELIVERY WITH CUTTING-EDGE INJECTION MOLDING TECHNOLOGY

MPS has benefited from three generations of MAPLAN presses. “We’ve partnered with MAPLAN for our vertical-style injection molding presses since we started production. Their world-class machines help us achieve an industry-leading low scrap rate, which saves material,” says Alex Borboa, General Manager. MAPLAN has helped us increase our capacity, improve quality, and reduce costs.” Executives also highlight the machines’ long lifespan and range of refurbishing options. “The MAPLAN presses utilize a ‘full-stroking ram’ to evenly distribute the clamp tonnage over the entire surface of the mold, which helps to maximize the life of the tool and protect the customers’ tooling investment,” confirms CEO Kevin Morgan.

“For our company, MAPLAN presses are the best in the world”

Kevin Morgan, Founder and CEO

To support its promise of on-time delivery, MPS commits to the continuous improvement of its strict internal quality controls. Engineering Director Mark Conlee explains, “On-time delivery is the natural result of quality manufacturing. MAPLAN machines employ a FIFO (first in, first out) injection process to ensure only fresh rubber is injected in the mold. The result is high-quality, flawless articles without any cured residual material. At the same time, the vacuum technology helps eliminate air traps from the finished product. And with the vertical presses, we can maximize our capacity by operating two presses in the same space that it takes to run a single horizontal press. These benefits save cost and matches our processes perfectly. And when we save money, our clients save money.” And its dedication to the customer goes far beyond reducing costs. Morgan Polymer’s full-service logistics includes ’safety stock’ agreements, so customers enjoy peace of mind during seasons of unpredictable demand.

THE HARMONY OF GREAT PEOPLE WORKING WITH THE RIGHT TECHNOLOGY

CEO Kevin Morgan affirms, “There’s a right way to make every part – and it takes lots of experience to manufacture quality rubber seals.” Thus, it’s no surprise that Morgan Polymer Seals values enthusiasm, further training and positivity in its workforce. “We take care of the good people we’ve got. Good people want to be part of a winning team, so we track achievements and reward superior performance. From management to maintenance, everyone is essential and deserve an individual development program.”, says Sandra Martínez, HR manager. With centuries of combined engineering experience, Morgan Polymer’s engineers keep up with the latest advancements in precision rubber molding, robotics, and vision inspection. “MAPLAN always fully supports our new ideas for an even better production process”, adds Conlee. With the smart MAP.commander C6 control unit, MAPLAN supports every new production process introduced by its engineers. Furthermore, the userfriendly interface makes sure the machines are easy to operate.

A COMMON PHILOSOPHY BEST PRACTICE FOR THE FUTURE

MPS and MAPLAN share a common philosophy: continuous improvement. And the basis for this philosophy is a culture of discipline to support today’s goals and pave the way for a better future. Morgan Polymer’s Chief Revenue Officer, Sean Morgan, lays out the company’s plans: “Our future sees us expanding into new product segments, new markets, and exploring other exciting opportunities. These are uncertain times for many mid-sized companies, but we’re fortunate to be thriving from a strong financial position and experienced leadership. We’re excited to see what the future holds.”

Morgan Polymer Seals is a full-service, precision rubber molding company based in Baja California. To learn more, visit www.morganpolymerseals.com.