Coperion Optimizes Zsk 18 Megalab Extruder Design For Significantly Greater Flexibility 

Coperion has equipped its ZSK 18 MEGAlab laboratory extruder with numerous new functions that provide significantly greater flexibility and safety in handling. Pluggable cartridge heaters instead of hard wired ones now allow for rapid barrel reconfiguration as well as straightforward cartridge heater exchange. An electrically securable maintenance door on the gearbox lantern increases operational safety and at the same time provides quick access, reducing downtimes for screw changes and system maintenance. Moreover, feeders for this laboratory machine can now be placed on a newly developed patent-pending feeding platform which allows up to four feeders to be arranged with maximum flexibility for adding ingredients in myriad ways. 

The ZSK 18 MEGAlab, with a screw diameter of 18 mm, has a specific torque of 11.3 Nm/cm³ and achieves a maximum rotation speed of 1,200 min-1. It is ideally suited for use in research and development projects as well as for production of minimum quantities. 

Optimized feeding platform

The new, patent-pending feeding platform makes adding ingredients noticeably easier. It is firmly attached to the ZSK 18 MEGAlab extruder, allowing for flexible positioning of up to four feeders on all barrels of the process section as well as on the ZS-B side feeders. Moreover, the new feeding platform, which can be moved laterally along the machine, allows the feeders to be rotated and raised or lowered as needed. This feature creates enormous advantages particularly in the areas of research or recipe development, since feeding can be located flexibly at various points, in accordance with the process requirements. Elaborate, costly reconfiguration tasks and cumbersome additional frames for feeders are a thing of the past. Moreover, cleaning is simplified since the feeder can simply be pivoted away from the process section, thanks to the new platform. Where the previous model required a separate frame for each feeder, now up to four feeders can be mounted on the new platform. Time-consuming solutions for mounting additional feeders, or reconfigurations, have likewise become a thing of the past. This improvement significantly increases flexibility as well as efficiency in the production process.

New functions for safe, simple handling

Along with optimizing feeder positioning, Coperion has also incorporated proven functions from the ZSK series into the ZSK 18 MEGAlab. Among these, for example, are pluggable cartridge heaters. They are individually connected using IP67 plugs and can be removed for maintenance and barrel reconfiguration in no time, no electrician needed. Another improvement involves the gearbox lantern with easy access that can be equipped with an electronically secured maintenance opening. As soon as the screw shafts come to a complete stop, the door can be opened without tools. The screw shaft coupling is immediately accessible for maintenance purposes; machine downtimes drop significantly and completely safe servicing is assured. The machine can only be restarted when the maintenance doors are closed. 

As part of the ZSK 18 MEGAlab redesign, Coperion separated the mechanical and electrical machine components and recently mounted the control cabinet laterally onto the base frame. Thus, mechanical maintenance tasks on the base frame can likewise be performed without an electrician. The control cabinet is available in various designs: standard, stainless steel, or as a junction box if, for example, an external control cabinet is necessitated due to ATEX requirements. Coperion engineers have even improved the design of the base frame itself. Along with height-adjustable leveling feet, combined with casters, the cable routing has also been optimized to keep the floor around the extruder free of clutter and easier to clean. All supply lines have been centrally connected to the rear of the machine and distributed inside the base frame so that any possible impediments to working on the machine are reduced to a minimum.

“This optimized ZSK 18 MEGAlab extruder combines proven ZSK series functions and new developments specifically for laboratory operation that make its handling especially flexible and intuitive. This allows us to offer our customers a versatile extruder solution that is characterized by maximum efficiency, especially for small production batches and numerous recipe changes”, opined Johannes Heyn, Development Engineer with Coperion Research & Development.  

www.hillenbrand.com

Allrounder 470 H: Turnkey System Produces Adapters For Medical Technology

• Turnkey expertise: Customised solutions from the Arburg Technology Factory (ATF) Pinghu.
• Efficient: New hybrid machine technology at an attractive price-performance ratio.
• Exclusive: Flexlift for entry into automated moulded part production.

As a prime contractor, Arburg very successfully realises turnkey systems in China and Asia. A perfect example of this will be a production cell centred around a hybrid Allrounder 470 H at Chinaplas 2024. The exhibit uses a family mould to produce two different adapters for medical technology fully automatically, including camera inspection and sample part storage. A Flexlift 10+2 linear robotic system, only available in Asia, performes the handling tasks.

The turnkey system, which was designed in the Arburg Technology Factory (ATF) Pinghu, China, and realised together with local partners, is a typical customised solution for the Asian market.

Hybrid machine technology reduces costs and cycle times

Launched on the market in 2023, the hybrid Allrounders from the Hidrive series with new hybrid machine technology combine an electric, energy-efficient and precise clamping unit with a powerful and dynamic hydraulic injection unit. They are available in sizes 470, 520 and 570 with clamping forces of 1,000, 1,500 and 2,000 kN and in the “Comfort”, “Premium” and “Ultimate” performance variants. Allrounder Hidrive machines are particularly good at saving energy and resources, and are also production efficient, reliable and user-friendly. They are particularly impressive due to their reduced purchase and operating costs, optimised energy footprint as well as reduced cycle times. Thanks to a wide range of options, the machines can be precisely customised to specific requirements. Smart assistants and robotic systems can be integrated into the Gestica control system.

The Chinaplas exhibit is an Allrounder 470 H with a clamping force of 1,000 kN and a size 290 injection unit in the “Comfort” performance variant. It is also equipped with an Arburg servo hydraulic system (ASH) as standard.

Automated production of medical devices

For the production of adapters for medical technology the hybrid Allrounder 470 H is equipped with a 2+2-cavity family mould from Chinese company Changshen. It produces two different components from PC for adapters in medical technology in a cycle time of around 25 seconds. A Flexlift 10+2 linear robotic system performs the handling tasks. After they have been removed from the mould and separated from the sprues, the moulded parts are fed to an integrated camera for inspection and deposited separately by cavity. In addition, a test sample can be placed in a sample part drawer at the touch of a button and sent for quality control.

Only for Asia: Linear Flexlift robotic system

Arburg has developed the Flex series of linear robotic systems specifically for the Asian market and tailored them to the needs of customers in the region. Thanks to its low height and telescopic design, it is also suitable for confined spaces. Powerful servo motors ensure that the vertical mould-entry axes are extremely dynamic and accurate – enabling fast removal, precise and vibration-free movements and short cycle times. Arburg is meeting the market’s demand for a reliable, fast and precise robotic system with an impressive price/performance ratio. The Flexlift is available in six different versions with loads of 5, 10 or 15 kilograms and with the option of one or two immersible axes.

A Flexlift 10+2 with a load of ten plus two kilograms is used for trade fair applications. For the gentle removal of moulded parts and sprue, a Freeformer 300-3X was used to additively manufacture the associated gripper quickly and cost-effectively. There are also easily accessible pneumatic and vacuum interfaces for end-of-arm tooling (EOAT) and peripheral technology.

https://www.arburg.com/en/

EXPO-NET Promoting Infusion Processing Flow Mesh Range And Technical Expertise At JEC World 2024

EXPO-NET Danmark A/S is once again exhibiting at JEC World, Paris (Hall 5, 5P76) to promote its extensive range of 100% recyclable extruded thermoplastic resin flow meshes. The flow mesh products developed and produced by EXPO-NET are extensively used in composite manufacturing as essential vacuum infusion processing aids; during the new product development stage for large parts, such as for a wind generator blade or a yacht deck, up to four different custom made resin flow mesh grades can be used in specific areas of an infused part to increase productivity and to avoid premature resin hardening and air voids. EXPO-NET has been supplying leading wind blade producers for more than 25 years, known for being a highly innovative, technically advanced, problem solving partner.

During 2023, EXPO-NET continued to develop its technical knowledge, working closely with TECHCOLLEGE, located in Aalborg; the college is a leading vocational education and training (VET) institute in Denmark, with over 3000 full-time students; one of college’s specialist offerings is the range of training courses on composite materials and processing. Testing of the 13 different resin flow mesh product grades supplied by EXPO-NET was completed last year using TECHCOLLEGE‘s facilities and support. The test programme, instigated by EXPO-NET to help customers to better understand the rheological impact of different flow mesh grades and types, was developed and conducted by Mark Holmgaard Christensen, EXPO-NET’s plant manager; he is also a composite specialist development engineer and one of the examiners for the TECHCOLLEGE composite training course.

The latest ‘Vacuum Infusion Resin Flow Mesh Technical Processing Guide 2024’, which has now been published, provides comparative data on all the EXPO-NET flow mesh grades currently available. The guide enables an OEM or Tier 1 composite part producer to select the best flow mesh grades to use in different areas of a mould to consistently obtain the desired resin infusion speed and final part quality. Visitors to the EXPO-NET stand during JEC World 2024 will be able to hear about future developments, find out how EXPO-NET can assist customers in more detail, and obtain a copy of the updated 2024 technical processing guide.

EXPO-NET is a key preferred supplier to a wide variety of customers and markets worldwide, supplying both directly and via approved supply chain distributors and kitting partners. The EXPO-NET team prides itself on providing a flexible, responsive customer service, customized products, innovative technical support and a reliable supply chain delivery service. EXPO-NET is committed to its ongoing programme focused on sustainability and net zero.

www.expo-net.com 

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Exciting Line-Up Of Side Events With An Attractive Mixture Of Lectures, Info Slots, “Eco And High-Potential Trails”

Countering skilled labour shortages

Some 2,300 exhibitors on more than 118,000 square metres of net exhibition space – with these numbers wire and Tube 2024 are setting a powerful agenda. For the first time, the innovations showcased by the industry players in the exhibition halls will be accompanied by an extensive programme of supporting events tuned to the market – and what’s more – on all five trade fair days!

Premiere for the wire & Tube BME Einkäufertag / Buyers’ Day  on the Forum stage of Hall 1 A47 on Monday, 15 April. Everything revolving around Due Diligence Supply Chain Acts, sourcing and logistics, transparently compiled and presented by the Federal Association of Materials Management, Purchasing and Logistics (Bundesverband Materialwirtschaft, Einkauf und Logistik).

On Tuesday, the wire & Tube Convention 2024 will follow with entirely different exhibitor insights for the Green Steel theme and its implementation in their own manufacturing halls. The organiser is the “Agentur  Stahl-Kommunikation“.

From Monday, the SawExpo Forum will present news and trends from the multifaceted field of sawing and milling technologies in daily snapshots in Hall 6 G07. SawExpo GmbH is the organiser.

Publishing house Vulkan Verlag will organise a varied line-up of different focal topics on the Forum stage of Hall 1 A47 and in the conference rooms  14/15. Be it the Destination Green Summit by ecoMetals, the H2 Summit by ecoMetals or the Green Jobs Forum – exciting content presented in an infotaining way plus the mega theme Green Jobs are all aimed at attracting visitors.

In the Special Area Plastic Tubes & Pipes (Hall 1 C35) exhibitors will be showcasing the complete supply chain for plastic tubes and pipes and provide impressive demonstrations of possible processing and finishing methods for plastic tubes and pipes.

At the BDS Forum (Hall 1 A47) the Federal Association of the German Steel Trade (Bundesverband Deutscher Stahlhandel) will provide information on global trends in the steel trade. Here, experts will analyse the impact of current economic policy trends in the steel trade. Steel traders will also discuss sourcing and sales markets, economic framework conditions and the mega themes digitalisation and AI.

The ITA Forum (also on the Forum stage in Hall 1 A47) will address the global economic challenges for the industry in lectures and will project concrete impact scenarios for the tube and pipe industry.

The last two trade fair days will be all about the so-called High Potentials – i.e. promising skilled workers and young talents. Be they trainees, students or potential career changers – they will all have the opportunity in Hall 6 G07 to learn about vocational training and career opportunities in the versatile field of cutting technologies in numerous talks and information slots. Organised by SawExpo GmbH.

Also new are the daily digital ecoMetal and high potential Trails, allowing visitors to put together their personal itineraries online or by QR code to meet exhibitors from the fields of ecoMetals (producing sustainably and in a resource/environment saving way) and High Potentials (introducing themselves as attractive trainers/employers).

https://www.wire-tradefair.com/

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Vianode Appoints Howard Ormonroyd as CFO Bringing Extensive Experience in Financing Large-Scale Materials And Infrastructure Projects

Vianode, an advanced battery materials company providing sustainable anode graphite solutions, has appointed Howard Ormonroyd as CFO. As a member of the executive management team, he will focus on financing and value creation as Vianode establishes itself as a leading supplier to battery and EV value chains in North America and Europe.

Ormonroyd assumes the position effective 14 February, coming from J.P. Morgan where he was an Executive & Technical Director in the Global Metals & Mining investment banking division for over 10 years. He will oversee the execution of Vianode’s phased multi-billion-dollar investment program for developing industrial scale production of high-performance synthetic anode graphite with a 90% reduction in CO2 footprint.

“Howard adds a unique combination of financial expertise and extensive experience from the energy, industrial and renewables markets, together with global managerial competence. He will play a key role in bringing together strong owners and partners to finance Vianode’s growth strategy and our ambition of delivering high-performance anode graphite solutions to 3 million EVs per year by 2030,” says Burkhard Straube, CEO of Vianode.

Ormonroyd has a proven track record of facilitating large and attractive financing for rapidly growing companies. He has industrial and managerial experience from three continents from companies including WestLB and Rio Tinto. He holds a BEng in Mining Engineering from the University of Nottingham and an MSc in Mineral Project Appraisal from Imperial College London.

Vianode is positioning to meet increasing demand for batteries and anode graphite solutions driven by global electrification and EV deployment. Vianode intends to scale through a strategically phased expansion with production sites in North America and Europe and to decarbonise mobility and create significant stakeholder value. The completion of the USD 200 million industrial customer qualification plant at Herøya, Norway later this year will mark the next scale-up milestone.

“Vianode provides a unique opportunity to drive the energy transition through the supply of efficient, low-emission materials to battery and EV manufacturers in North America and Europe. I look forward to applying my skills and experience to help bring Vianode’s large-scale graphite production facilities from the planning stage into real life, and to becoming part of this very impressive team,” says Howard Ormonroyd.

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The MDS Volumetric Feeder

Movacolor launches the all new MDS Volumetric Feeder, an additional solution to her modular dosing and blending concept. This innovative feeder sets the standard in volumetric dosing. It targets plastic manufacturers in search of a cost-effective solution to optimize their material handling and increase their operator efficiency.

Movacolor’s first volumetric unit was introduced in 1997 and has proven its worth in a variety of applications. Over the past decades, Movacolor engineers have continuously improved its functionality to ensure it meets the changing industry needs. Now, it’s time for the next phase of innovation: the all new MDS Volumetric Feeder.

This new volumetric dosing solution – backed by the tagline ‘Volumetric Dosing Done Right’ – is developed for plastic manufacturers that require a high performing dosing unit at a cost-effective price. Klaas Talsma, Product Manager at Movacolor states: “We believe this product will become the new standard for volumetric feeding across the plastics industry. With its new intuitive touch screen in combination with the latest controlling software technology, we have developed a unique solution for this market segment.”

The MDS Volumetric Feeder allows for reliable dosing, with the capability to handle a wide variety of materials, from granular to microgranulate and free-flowing powder up to 70 degrees Celsius. It proves its value in easy operation, minimizing overdosing and as a result saving on material and process costs.

The MDS Volumetric Feeder comes with an efficient and reliable stepper motor, a rigid dosing house, a stainless-steel hopper and a robust neckpiece. Optimal blend homogeneity is accomplished through inline dosing using a centralized insert within the neckpiece.

All the dosing tools from Movacolor’s MDS Balance product range will also be available for the MDS Volumetric Feeder, providing customers with the flexibility to choose the most suitable dosing tool for their specific process. The stepper motor and selection of dosing tools offer an RPM range from 0.1 to 200 in 0.1 RPM increments and the capacity to dose up to 72 kg/h.

Thanks to its intuitive design, this dosing solution allows a swift 60-second cleaning and material change through a discharge valve and easy motor, hopper and dosing tool release. As a result, downtime and changeover time can be minimized.

The VoluTouch
The MDS Volumetric Feeder includes a dedicated newly developed 4.3” VoluTouch controller. This capacitive touchscreen controller can manage up to two units and is equipped with intuitive functionalities such as easy recipe management. A wireless web interface allows for data and recipe transfer. The VoluTouch controller can seamlessly connect with an extruder’s tacho signal, initiate the injection molding machine in timer mode, and features a relay mode. This ensures smooth integration with any production line.

The MDS Volumetric Feeder is part of Movacolor’s modular dosing concept and can be combined with other units and/or specifically tailored to fit the requirements of your production process.

Availability and delivery time

The availability of Movacolor’s new MDS Volumetric Feeder will vary by region. The product has been launched in the Asia-Pacific region on January 25, 2024 and will be introduced to the North- and Latin American market on May 6, 2024 during the NPE exhibition in Orlando, FL. The EMEA launch will follow shortly after. The delivery time will be approximately 2-3 weeks from the date of purchase.

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Aurion – The New Era Of Clean-Tech Machining

• Aurion Machining Technologies Oy (“Aurion”) has developed new technology – using ionized air – as a trailblazing clean-tech alternative for metal working fluids and emulsions in parts manufacturing.
• Ionized air is ideal for achieving high quality machining results – and it is safe for employees and environmentally friendly.
• Aurion technology is fully compliant with modern sustainability regulations which require end-to-end clean-tech solutions.
• Aurion technology is the response to increasing concern that metalworking fluids contribute significant carbon emissions on global basis.

Disposal of used cutting fluids causes significant environmental contamination. Global annual consumption of cutting fluids is estimated to exceed 2 billion liters – although the actual amount of cutting fluids waste is assumed to be up to 10 times higher, as most fluids are diluted before their use. Cutting fluid treatment and their release to the environment leads to significant oxygen depletion and nutrient destruction in surface waters.

Aurion Technology
The core of the Aurion technology is in the ionized air which generates an electrochemical process resulting in electron loss and atomic level transformation of Aurion gas medium at the cutting surface. The electrochemical process acts as a dry lubricant in the cutting process, penetrating the cutting zone and optimising the interaction between the tool edge and the workpiece. This process accelerates oxide layer formation and significantly reduces the friction, thermal stress and tool wear.

The Aurion system consists of three components – ionizer, controller and air-cooling unit. The system is connected to the factory compressed air network and machinery CNC. There is no need for any special safety precautions as ionized air pressure remains at 2 – 3 bar and temperature in the -10°C to +10°C during machining operations.

Aurion technology is the result of years of industrial research and development work. Its technical properties have been proven in thorough tests conducted by authoritative institutions and industrial partners. Most recently the respected Advanced Manufacturing Research Centre (AMRC) of the University of Sheffield in England achieved excellent results in titanium milling trials.

Economically Compelling Solution
Aurion reduces manufacturing costs and cutting lead times in workshop processes. Thousands of validation runs have proven that Aurion technology delivers at least the same machining quality and performance as cutting fluids – measured by cutting speed, tool life and surface quality. Ionized clean air is safe for its operators and the relevant machinery and meets the highest standards for workpiece residuals.

Easy to use and integrate
Aurion technology is suitable for all machining applications and materials. It is easy to integrate to both existing and new machines, either by using the external piping to the cutting zone or by using existing coolant channels in standard toolholders and tools.

High integration flexibility and the possibility to use existing machine tool features minimises the up-front investment and limits the transition costs for introduction of the Aurion technology.  The payback for the Aurion system is typically 3-6 months.

Aurion adaptation is moving to full industrial scale – Join for the journey
Following years of successful development work, Aurion is now ready for full scale industrial use. Attracted by the recent positive tests and validation runs, a number of high-quality manufacturers are engaged as partners in the next steps of the Aurion journey to transform their profitability and accelerate their carbon net zero plans.

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Planned change at Zeppelin Group Management Board – Matthias Benz follows Peter Gerstmann

Matthias Benz, currently Managing Director of Raufoss Technology, a company of CAG-Holding, will become a member of the Management Board of the Zeppelin Group on July 1, 2024. He will succeed Peter Gerstmann as Chairman of the Management Board on October 1, 2024. This was decided by the Supervisory Board of Zeppelin GmbH at its last meeting in December 2023.

“We are delighted that we have been able to appoint Matthias Benz as Peter Gerstmann’s  successor,” emphasizes Andreas Brand, Chairman of the Supervisory Board of Zeppelin  GmbH, Mayor of the City of Friedrichshafen and representative of the shareholder Zeppelin  Foundation. “Matthias Benz has many years of national and international management  experience and faces entrepreneurial challenges in a strategic, focused and decisive manner  – and always manages to take his team with him.” 

“Peter Gerstmann is passing on an excellent, committed and motivated team to me,” says  Matthias Benz. “I am very much looking forward to my new role and would like to thank the Supervisory Board for the trust they have placed in me. And I am delighted to be able to take  on responsibility for a Zeppelin Foundation company again.” 

In the ZF Group, Matthias Benz took on management responsibility early on in various  positions at national and international locations. Among other things, he was Chief Financial  Officer at ZF North American Operations, Managing Director of ZF Services in Schweinfurt, a  member of the Executive Board of ZF Marine in Padova and thereafter, as Executive Vice  President Sales & Customer Development at ZF in Friedrichshafen, a member of the first  management level below the ZF Executive Board. Since 2020, Matthias Benz has been  Managing Director of Neuman Aluminium / Raufoss Technology and a member of the top  management level of CAG-Holding, an owner-managed company. Neuman Aluminium / Raufoss is one of the leading international manufacturers of aluminum components for  automotive and industrial applications. 

Peter Gerstmann (62) has been Chairman of the Management Board of the Zeppelin Group  since 2010 and has worked for the company for 24 years. He informed the Supervisory Board  at an early stage that he would not be available for a further appointment and would like to  hand over responsibility after 15 years as CEO of the Zeppelin Group. 

In 2002, Peter Gerstmann initially took over the management of Zeppelin Systems and thus  overall responsibility for the globally operating plant engineering with its headquarters in  Friedrichshafen. From 2007, Gerstmann was also Managing Director for Controlling at  Zeppelin GmbH – until he was appointed Chairman of the Management Board in 2010. “I’m  leaving at a time of economic and geopolitical upheaval, so for me it’s indeed quite difficult to  step down,” says Peter Gerstmann. “With a view to my successor, our management team and  the committed employees throughout the Group, our company has proven its resilience in all  crises and the course has been set very well.” Following his stepping back from the Group  Management Board, Peter Gerstmann will be available to advise and support his successor  and the Supervisory Board until the end of the year.  

The Chairman of the General Works Council of Zeppelin Systems GmbH and Vice Chairman  of the Supervisory Board, Heribert Hierholzer, sees the unanimous election of Matthias Benz as a sign of continuity: “Successful cooperation between the employer and employee sides  has characterized the Zeppelin Group for many years and decades, which is what makes us  so successful in the market.” The task now is to continue this success story. 

Andreas Brand, Chairman of the Supervisory Board, emphasizes: “It is still too early to say  goodbye, but we owe Peter Gerstmann a great debt of gratitude. During his time, the Zeppelin  Group has developed enormously and above all successfully in both the industrial and  commercial sectors. Peter Gerstmann shaped the Zeppelin Group into an extraordinarily  successful and broadly diversified company. For the owners Zeppelin Foundation and  Luftschiffbau Zeppelin, he impressively increased the value of the company. Peter Gerstmann  is handing over a financially stable and profitable company. Over all the decades he has been  part of the Zeppelin Group, Peter Gerstmann has always remained a person, approachable,  present, listening, team-oriented and decisive for the people of Zeppelin, the Supervisory  Board and me.” Group sales rose from around 2 billion euros in 2010 to 3.8 billion euros in  2022. In 2010, there were around 6,000 employees worldwide – the Zeppelin Group now has  more than 10,000 employees in 26 countries. 

https://www.zeppelin.com/

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