For the injection molding machines offered by KraussMaffei, an injection molding machine maker, variant models are available for processing a wide range of materials. A striking example is the EX machine in operation with Bernhard Kneifel Werkzeugbau GmbH in Bad Aibling, Germany, since spring 2010. It is being used to inject liquid silicone seals onto polyamide substrates.

The company, as the name implies, builds molds and tooling, and also runs a contract molding operation, supplying components, for example for the white goods sector. By moving silicone seal application in-house, Kneifel has reduced its logistics effort and increased the yield of good parts it produces.

To achieve its goals of high precision and low wear on the machine, Kneifel chose KraussMaffei's EX series as its technology platform. Hallmarks of EX machines are their speed and high precision. The three-platen electric clamp unit features a unique Z-toggle system. The number of moving parts has been deliberately reduced. The plasticizing and injection units are direct drive systems with high-torque motors. The force of two coupled electric motors is transmitted directly to the screw. Like the Z-toggle, the direct drives have been engineered to cut the number of moving parts for higher precision, more reliability, and lower wear.

Since spring 2010, Bernhard Kneifel Werkzeugbau GmbH has been operating a KraussMaffei EX 80-180 SilcoSet. The machine is tasked with injecting silicone seals onto substrates made of the polyamide Grivory HT1V with 40% glass fiber content. The substrates are produced on hydraulic machines 每 also from KraussMaffei 每 immediately prior to this operation. The outcome of the production process is a milk foaming nozzle for a coffee machine. Previously, managing directors Martin and Andreas Kneifel had outsourced the application of the seal. Their decision to bring this process step in-house was straightforward, "In this way, we are able to save substantial processing costs. We have eliminated the logistics effort and transport costs, and also the necessity for cleaning and reheating the substrates before applying the seal. Despite the extra effort involved, the yield of good parts never matched what we are now regularly achieving 每 our reject rate is now close to zero." The production cell now in operation at Kneifel is a custom solution developed as a joint project by Kneifel and KraussMaffei. Before going into production, the system underwent a comprehensive series of tests in KraussMaffei's TechCenter in Munich, Germany.

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