Space, time and material – these variables determine how efficiently a processing plant can manufacture plastic. How many machines should be set up in the production hall? What are the possible cycle and setup times? How can the need for electricity, compressed air and masterbatches be reduced? The new CX from KraussMaffei takes advantage of savings potential in all three areas.

From hydraulics to control software to automation, every component in the tried-and-true CX machines in the small clamping force range was subjected to testing and desired improvements were defined. Dr. Hans Ulrich Golz, Managing Director and President of the Injection Molding Machinery segment for the KraussMaffei Group, stated, “Our objective was to take the already successful CX line and orient it even more consistently to customer needs. Plastics processors should have the option of producing plastic with outstanding cost efficiency and flexibility.” The new CX in the series of small machines up to 1,600 kN has become top of the class thanks to a large number of individual innovations. Götz Scheibe, Product Manager, says with enthusiasm, “We were in fact able to technically implement all of our customer requirements: 10 percent less energy, 15 percent faster, 30 percent quieter, oil volume reduced by 20 percent – 25 percent greater efficiency means 100 percent added value for the customer! Additional highlights specifically for small machines include the new sprue picker and the Blue-Power Vario drive concept.” Like all machines from KraussMaffei, the new CX is equipped with the new Adaptive Process Control system (APC), which can immediately compensate for fluctuations in the injection molding process.

Space advantage: Two-platen design, sprue picker, removable tie bars

The CX has always cut a fine figure; its two-platen design takes up less installation area than longer three-platen models. In addition, a cantilevered clamping unit provides enough space underneath for mold temperature controllers or removal equipment. As a result, the extremely compact manufacturing cell is also ideally suited for use in locations such as clean rooms. The new servo-sprue picker from KraussMaffeiʼs automation division also features a very compact and stable design. The telescoping stroke makes the picker particularly well suited for use in low halls. It forms one unit together with the machine, providing the best solution on the market as a result. The detached sprue is stored within the standard machine’s housing. This means that a side expansion in the form of a protective fence is not necessary. These way four machines can be installed in the same installation area instead of three. The servomotor enables the sprue picker to operate extremely fast and saves on maintenance time and expensive compressed air compared to wear-prone pneumatic drives. The all-in-one MC6 control system and the optimized parked position for the mold change round out the user-friendly features.

Molds are becoming ever larger and more complex in the small area as well. Contract manufacturers in particular have to make fast changes, even with complex molds, in order to facilitate cost-effective production. A simple manual bar-pulling device is an ideal option here for changing complex molds faster. For frequent changeovers, customers can also use a fully automated bar-pulling device. The newly developed ejector coupling makes it easier to change molds and is capable of compensating for small axis offsets between the mold and ejector. The standard CX already provides more space for molds. Since KraussMaffei is not satisfied with just the standard, you have the option of choosing between different platen sizes and spacing. This makes it possible to enlarge the mold volume by another 40 percent.

An additional advantage is that for some applications, the machine can even be sized smaller than before. The complex design of molds for multi-component injection molding machinery often makes them too large for a machine that has sufficient clamping force. The 13 percent wider platens enable such applications to be produced on a CX 130, while the competition needs a 160 t machine. Scheibe emphasizes, “The 20 percent benefit for efficiency is plain to see: Reduced machine hourly rate and lower operating costs.”

New time calculation: Fast clamping unit, screw less cover, sound insulation

In a nutshell, the new CX clamps about 15 percent faster on average. For high-volume projects, this fact alone pays off. This is achieved thanks to optimized interaction between the new valve technology and hydraulic switching concepts. Service access has been substantially improved by the new click function of the cover for the most important hydraulic components. Moreover, the new cover is also soundproof and reduces noise emissions by 30 percent. This not only creates pleasant working conditions, but also makes it possible to mesh injection molding production and assembly workstations closely together.

Best consumption values: Drive, oil volume, adapter for the injection unit

Less electricity, less oil, fewer masterbatches. The new CX con serves all consumable materials. The drive concept has been energy-optimized and requires ten percent less electricity than before thanks to smart battery management with a disconnectible battery. The BluePower Vario drive option can do even more: a variable-speed asynchronous motor improves efficiency and reduces idling capacity. The longer the cycle times, the greater the savings of up to 30 percent compared to the traditional hydraulic variant.

We put effort into reducing oil volume by 20 percent due to high oil prices. This was achieved through fine filtering and oil treatment with an eye toward conservation during preheating. In addition, the service life of the oil is increased by up to 40 percent reducing how often changes are needed. Customers benefit from a lower investment for initial filling and oil changes. The majority of injection molders are familiar with the problem: a small part is to be manufactured and the minimum material throughput of the available machine is too high. The only workaround is to use a large sprue, wasting resources in the process. This is why the plasticizing unit of the CX series features adapters that enable the ma chine to be adjusted for smaller shot weights. The tried-and-true high-performance screw also conserves material. Its good homogenization performance means that the color masterbatch amount can be reduced by up to 30 percent, which – at prices as high as 20 euros per kilogram – easily adds up to a few thousand euros per year.

You can visit KraussMaffei`s web site for more detailed information: www.kraussmaffei.com