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Wittmann Group 2013-10
Company presentation
WITTMANN BATTENFELD GmbH
Introducing ourselves

The WITTMANN Group
First supplier worldwide with a complete product portfolio for injection molding
application needs, consisting of:
 Injection Molding machines
 Robots and Automation systems
 Temperature control units
 Material handling systems and dryers
 Dosing units
 Granulators
 Flow control units
 Inmould Labeling equipment and Molds

PRODUCTION
Vienna
(2)
Kottingbrunn Hungary France USA Canada China
WB WITTMANN GROUP
HOLDING GMBH
WITTMANN
Kunststoffgeräte GMBH
(Headquarters Vienna)
WITTMANN
BATTENFELD
(Headquarters
Kottingbrunn)
SUBSIDIARIES
Austria Germany Hungary Turkey France UK Benelux Italy Spain
Switzerland Russia Romania Bulgaria
Czech
Republic
USA Canada Mexico
Brazil China Taiwan Singapore Indonesia Malaysia Thailand India Australia

The WITTMANN Group
WITTMANNN BATTENFELD GmbH WITTMANN Kunststoffgeräte GmbH

WITTMANN BATTENFELD Injection Molding
WITTMANN BATTTENFELD develops, manufactures and supplies Injection Molding
machines, Automation solutions and robot systems for the production of plastics parts.
With a comprehensive, diversified range of machinery, including
all equipped with the latest technology – optimized for customer‘s needs in horizontal
or vertical design – WITTMANN BATTENFELD stands ready to meet any future
demands of the market. State-of-the-art process technology to solve a variety of tasks
are at the disposal of our customers.
Thanks to WITTMANN BATTENFELD‘s global presence, we are in a position to offer
our customers in a quick and competent way the necessary support and service
anywhere in the world.
 modular Toggle machines
 hydraulic machines
 all – electric machines

MISSION STATEMENT
We want to offer our customers an advantage when they work with us in
mastering their jobs.
HOW ?
 With our products and technologies,
through innovation power, flexibility, reliability.
 With our services,
fast, uncomplicated, globally close to customers.
 With the sustainability and long-term commitment of
a family company with international business
orientation and quick decisions.
 All from a single source:
from machines, robots, periphery, moulds,
up to complete plants.

Milestones of the WITTMANN BATTENFELD History
 Founded in 1876 by Ernst Battenfeld
 First injection molding machine built in 1949; since then more than
80,000 IMMs built and delivered
 BATTENFELD expands on a global scale in the 1960s
 Acquisition by Schloemann Siemag AG (SMS) in 1977
 Today worldwide more than 25,000 machines in operation
 In 2005, the production is concentrated at the facility in
Kottingbrunn / Austria
 In 2008, BATTENFELD is taken over by the WITTMANN Group.
 2008-2012 development and market launch of the PowerSeries
 2013 opening of the new assembly hall for the large machines

The WITTMANN BATTENFELD Support Network
Worldwide activity
with 31
subsidiaries and
26 agencies

Quality Products for the Plastics Processing Industry
WITTMANN is a Leading Supplier of Molding Machines & Peripheral Equipment:
Total Employees: 1750
2012 turn-over: € 275M / $360M

WITTMANN BATTENFELD GmbH
Kottingbrunn, Austria
Kottingbrunn Production Site

 Production of Injection Molding Machines
 Production of precision parts such as plasticizing
units, tie bars, toggles, locking systems, flat jack
barrels
 Gas nitrating equipment for screw barrels and
plunger units
 Total Manufacturing Space of around 18,000 m²
 DIN EN ISO 9001:2008 certified company
WITTMANN BATTENFELD – Production
Assembly at WITTMANN BATTENFELD
in Kottingbrunn
MacroPower locking
system
Screws Platen production

 New assembly hall for large machines
 Opening April 2013
 Assembly of machines of the MacroPower series
 Increase of the existing production and stock
space of 15,000 m² to 18,000 m²
WITTMANN BATTENFELD – Production

Machine Product Portfolio - Overview
Hydraulic models
35 - 300 t
Vertical models
40 – 270 t
t
Toggle line
180 – 500 t
EcoPower
55 – 300 t
Fast runner
160 – 450 t
MicroPower
5 – 15 t
MacroPower
400 –1.600 t

MicroPower 5 t, 15 t
 for the production of highly precise micro parts
 designed for smallest part down to the single digit
milligram range
 highly economical
 two-step screw and plunger injection unit
 extendable to complete production cell
 specialized peripheral equipment and robots for
small and micro parts
Power Series
Machine Product Portfolio

Design-Concept
without
rotary table
with
rotary table
Injection Process
2-step plunger injection

Machine Product Porfolio
basic version
tempering unit
material feeder
monitoring
camera
handling
device
rotary
plate
more modules to follow
material dryerclean
room
stacking
module

EcoPower 55 – 300 t
 all-electric machine
 lowest energy consumption through use of
breaking energy within the machine
 clean machine, suited for clean room
 ultimate repeatability
 low noise level
 small footprint
 open design
 integration of peripheral equipment
 fast barrel and screw change
 integrated servo-hydraulic for ejector,
core pull and nozzle
Power Series

EcoPower 55 – 300 t – servo-electric machines in 2 versions
Injection unit
 Standard:
 servo-electric closing, injection and metering
 integrated servo-hydraulics for ejector, nozzle movements and core pulls (optional)
 All-electric:
 servo-electric closing, injection and metering
 servo-electric direct drive for ejector
 servo-electric twin drive for nozzle movements
Clamping unit Injection unit
to 70 130 350 750 1330
55 ● ● ●
110 ● ● ●
180 ● ● ●
240 ● ●
300 ● ●

Power Series
MacroPower 400 – 1,600 t
 2-platen technology, small dimensions
 highest precision
 shortest locking build-up time through QUICKLOCK®
 easy lateral mold insertion
 modular design
 energy saving servo drive technology (optional)

Hydraulic machines (also in Multicomponent technology)
HM 35 – 300 t
 central hydraulic clamping system up to 300 t
 3-platen technology
 highest precision
 powerful injection unit
 energy saving hydraulic system
HM ServoPower
 low energy consumption and excellent ecologic
balance through servo drive technology
 easy accessable open injection unit
 compact, room-saving design

 Variety of configurations
 Complete range of clamping force
from 35 – 1,600 t
 For all multicomponent technologies
The BATTENFELD COMBIMOULD is
 compact
 flexible
 multipurpose
Multi-Component Machines

Combimould Technology
 Long-term experience
 Various models in 2- and 3 color design
 Rotary table with servo-electric drive for
quick and precise movements
 Application technology consulting for the
selection of the best process
 Integrated operation via highly efficient
UNILOG B6P control system

Toggle machines
TM 180 – 500 t
 5-point toggle system
 high precision
TM Xpress 160 – 450 t
 highest performance fast runner
 for high speed Inmould labeling
applications
 for closures, boxes and thin wall

TM Xpress 160 – 450 t - Applications

VM R 40 – 270 t
VM 60 – 200 t
CM 40 t
 open design for good access
 hybrid version with servo injection unit and
servo rotary table
 parallel function of ejector/core pull
 modular concept machine for 2 and 3 c
 modular concept peripheral equipment
Vertical Series
3-colour
application

B6P – One superior control for all machines
 universal operating system Windows Embedded
 high user comfort and functionality
 easy connectivity to IT- and customer networks
 BATTENFELD K4 process data capturing
 WEB Service remote diagnosis, service and training
 15“ Color-TFT-Touchscreen
 freely configurable
 comprehensive event protocols – quality recordings
 online help system – online language switch over
 access control via USB – online user manuals
 hull curve monitoring – cycle time analysis – user page
functionality

Processing Technology Product Portfolio
 AIRMOULD®, AQUAMOULD®
 Multi-component technology
 CELLMOULD®
 BFMOLD®
 IML
 IMD
 IMWOOD (wpc injection molding)
 Insert Technology
 LIM
 PIM
 Overmoulding Technology
 Thermoset
 Elastomers
 Variomould
 Co-injection (sandwich)
 Process combinations

Process Technology Sample Parts

AIRMOULD®/AQUAMOULD®
 High quality.
 Avoidance of sink marks.
 Reduction of frozen stresses.
 Reduction/avoidance of warpage.
 Reduction of required clamping force.
 Reduction of cycle time.
 Weight reduction.
Fluid injection process:
Gas or liquid is injected in a way
that cavities are formed in the
molded part.

BFMOLD® – New Variotherm Process
Technology
 perfect „High gloss parts“
 reduction of sink marks
 no weld lines
 increase of product quality
 reduction of cycle times
“BF” = Ball Filled

BFMOLD® – New Variotherm Process
Technology
Function
BFMOLD® combines multi-functional
properties
 ball filling takes over mechanical
support function
 ball filling allows high flow rate of
temperature control medium
 temperature control medium comes
very close to the surface
 application for straight parts and
parts with contours
TEMPRO plus C 2/160 VARIO

Physical blowing agent
Very fine cell structure
CELLMOULD®:
The new WITTMANN BATTENFELD direct gassing technology

Advantages: Weight reduction 15 %; Cycle time reduction 18 %
Conventional injection moulding:
Sink marks opposite to ribs
CELLMOULD®:
No sink marks
Foam structure
CELLMOULD®:

Example: Support, PP TV 20
CELLMOULD®:
Very fine cell structureCompact
Weight: 94,0 g
Cycle time: 36,0 s
CELLMOULD®
Weight: 88,9 g:
Cycle time: 30 s

 Machines of series TM, HM,
EcoPower and MacroPower
 Chemical blowing agents:
 needle type shut-off nozzle
 special software
 Physical blowing agents:
 needle type shut-off nozzle
 accumulator, quick injection
 special screw and barrel
 CELLMOULD® box
 gas injector(s)
 pressure generating unit
 software
Equipment for CELLMOULD®

Inline-Thermography
 Permanently optimized cycle times by having a constant mold temperature control.
 Easy start-up, reduction of start-up scrap.
 Quality improvement through constant temperature distribution.
 Improvement in quality by having a constant temperature distribution.
 Immediate detection of scrap.
 Statistic process control inform in time about necessary maintenance of the cooling
channels.
 Traceable „finger print“ of relevant process parameters.
Advantages

SKZ-Software for Inline - Thermography
Reference
picture done
during
approval run
Actual
picture
shows the
current
temperature
distribution in
the mold
Online visualization of the difference  Input
parameter for control of the TCU

Up to 6 views are shown in each
injection molding cycle In each view, the temperature
deviations are assigned to the
temperature control circuits.
The software generates the variables
for the control of the magnet valves.
WFC systems which are directly
attached to the tool reduce the effort
for adjustment.
 Control active

Integrated Molding Work Cells –
Production Monitoring
Kistler CoMo Injection – visualization by UNILOG B6P
System with
Kistler Monitor
CoMo Injection  System to Switchover,
process monitoring and scrap separation
with B6P control, no
external Monitor needed

Integrated Molding Work Cells –
Production Monitoring
Detection of surface failures by integrated vision system
 sink marks
 weld lines
good part
bad part

Energy consumption in plastics processing
Machine concepts (2) – electric machines
recovered energy 400 W
production hours 6000 Std.
price / kWh 0,13 EUR
savings / machine 312,00 EUR
recovery of braking energy
hydraulic vs. electric driven machine
connector 4-cav., shot weight 27,48g, cycle time 13,2s.
2,237
4,032
0,000
0,500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
HM 65 Eco Power 55
energyconsumption[kWh]
cycle time 30,09 s
shot weight 109 g
active power 3,684 kW
material throughp 13,04 kg/h
energy / kg 0,282 kW/kg
energy / kg > 0,85 kW/kg
Eco Power 110
hydraulic machine

Drive systems of the benchmark machines
 Hydraulic machine HM 240 DFEE:
 Standard hydraulic
 drive system with energy saving Hydraulic –
 electronical adjustable pump
 Hydraulic machine HM 240 ServoPower:
 Servo electric driven drive with constant pump
 Servo electrical machine EcoPower 240:
 Servo drive for all movements
Machine benchmark – clamping force 240 t

Specific Energy consumption, power, cos phy
0,65
0,44
0,27
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
[kWh/kg]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
specific energy consumption
12,30
8,31
5,267
0,00
2,00
4,00
6,00
8,00
10,00
12,00
14,00
[kW]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
power consumption
0,49
0,80
0,766
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
cosphy
mould VTA 208
 shot weight 106g
 cycle time 20sec.

0,65
0,44
0,27
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
[kWh/kg]
HM 240/750 DFEE HM 240/750
ServoPower
EcoPower 240/750
specific energy consumption
Cycle time 20sec., shot weight 106g
HM 240
DFEE
HM 240
ServoPower
EcoPower
240
100,00% -32,44% -57,19%
- 2,94 Jahre 2,31 Jahre
- 7,06 Jahre 7,69 Jahre
- 23.720 € 45.600 €amount of coverage with lower energy costs (10 years)
remaining live time after ROI (basis 10 years)
ROI (higher investment costs)
effective energy costs - difference
Specific energy consumption – economic comparison

Servo Robots – Customized solutions
W 823 D
for stack molds up to 2* 10kg of
payload
W 828
for long kick reach and easy
mounting of sub-arms
Clean Room Kit
Special execution for lowest particle
emission and easiest cleaning
W 821-831
Universal servo robot for a great
variety of applications
W 837
Side entry robot for shortest
overall cycle times
Insider
Highly compact solution, free
access to the mold

IML – In-Mold Labeling Systems
Top entry robots
for flexible solutions
W827 F/W
side-entry system for up
to 300t machines
W837 F/W
side-entry system for up
to 800t machines
W837 FLEX
Dual production for flat
and wrap-around labels
on unique frame

Service Portfolio
 Battenfeld offers its customers a comprehensive, highly efficient service portfolio
 WEB SERVICES: leading in online service on internet basis
 Inspection & maintenance packages:
- Preventive service
- Calibration service
- Full service
 Service Help Desk: available from
7:00 am to 10:00 pm, 7 d/week
 Processing Technology counseling to optimize processes
 Wide range of (individual) training seminars
 Web-Service 24/7 – around the clock and worldwide

Striving for your success
Reference customers
Automotive
Electro
Consumer goods
Others
Medical

Striving for your success

With almost 60 years
experience in building injection
molding machinery, we offer
efficient, innovative solutions for
all applications.

Thank you for your attention.

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