- Noticeable cost benefits with consistent component quality
- ROI less than one year
- Patented screw geometry for fiber-friendly compounding and maximum efficiency
- More formulation flexibility for component-specific applications
- Live at the K 2025: GX 650-4300 with new LRXplus 350 linear robot
With the new Chopped Fiber Processing (CFP) process, KraussMaffei is setting a milestone in the processing of fiber-reinforced thermoplastics. For the first time, this innovative process enables direct, fiber-friendly compounding of polypropylene (PP) and chopped glass fibers in the injection molding process. Visitors to K can experience the CFP process live at the trade fair stand: A GX 650-4300 with the new LRXplus 350 linear robot produces a complex tailgate component for the automotive industry.
“With the unique CFP process, we offer our customers the game changer to significantly reduce their material costs in the production of fiber-reinforced components. We are particularly proud of the heart of the new CFP process, the patented screw geometry, which was specially developed for the KraussMaffei process,” says Jörg Stech, CEO of KraussMaffei Technologies GmbH.
Technological edge through flexible direct compounding
In contrast to conventional processes with pre-compounded long glass fiber granulate, the CFP process allows PP and glass fibers to be added separately. Both components can be fed directly into the machine via the conveyor system, homogenized in the cylinder and processed particularly gently using the new CFP screw. This has the advantage that no fiber clusters are created during processing and therefore optimum component properties can be guaranteed at significantly lower material costs.
Recipes can be individually adapted – with cost savings of 30
The CFP process enables plastics processors to individually dose and mix polymers and fibers. This allows them to develop their own formulations for components and build up material expertise, giving them a targeted competitive advantage. At the same time, the savings in material usage lead to a cost reduction of up to 30 percent and a noticeable reduction in the product carbon footprint (PCF) thanks to inline compounding.
ROI of less than 12 months – easy to retrofit
Other highlights of the new CFP process include compatibility with the KraussMaffei series and easy retrofitting – even for existing, older systems with the KraussMaffei retrofit program. Due to the achievable material savings and process advantages, the return on investment (ROI) is less than one year.
Live demonstration at the K 2025
Visitors to K 2025 can experience the CFP process live on a GX 650-4300 (clamping force 6500 kN) with an LRXplus 350 linear robot. The production of a complex functionally integrated tailgate component with realistic 3D geometry and high functional integration will be demonstrated – without reworking and ready for assembly from the machine. This opens up new possibilities for the production of structural and carrier components as well as reinforcement elements.
In keeping with the trade fair motto “Perfomance. Perfected. For You.”, the GX 650-4300 is equipped with the proven BluePower options such as servo drive and insulating sleeves. With the BluePower energy and performance recording system, plastics processors can call up the exact energy consumption at any given time. In addition, the BluePower ecoAssistant allows the machine to be switched to an energy-efficient mode at the touch of a button while maintaining performance.
The component is filled in cascade via three injection points. The tried-and-tested APCplus machine function impresses with new functions at the K. For example, cascadeX ensures seamless filling behavior and improved mechanical properties in applications with cascades. The APCplus function materialX uses material-specific compression curves to control the injection molding process. This achieves a particularly high level of component precision.
Complete process documentation – available at any time
The weighing unit integrated in the gripper of the LRXplus 350 determines and documents the weight of the components cycle by cycle. All production data and quality features are documented online. All parts are printed with an individual QR code when they are removed. In this way, KraussMaffei offers plastics processors the opportunity to call up the quality of a component and its production data online at any time, e.g. for quality assurance purposes.
Wide range of applications: From automotive to aviation
Whether in the automotive and aerospace industries or for technical consumer goods, the new CFP process from KraussMaffei offers a high degree of flexibility in the production of structural and carrier components as well as reinforcing elements – and at significant cost advantages.
Partners in the trade fair exhibit are: Borealis Polyolefine GmbH (material), Siebenwurst GmbH & Co. KG (tooling), motan gmbh (material handling), Audia Plastics s.r.o. (color batch), Helm AG (glass fiber).
Read the entire press release here: