The next generation of the KTR 5.2 Speed cup-forming system from Kiefel

Optimizations along the entire KTR 5.2 Speed cup-forming system ensure considerable performance enhancements and process improvements: Starting with film transport via the heating, forming station, forming air supply, tool cooling, tooling and tool change through to the new stacking system with downstream automated carton packaging.

Forming Station Upgrade

A planetary gearbox with a water-cooled servomotor improves drivetrain rigidity whilst reducing vibration throughout the system. In addition, the new motor-gearbox combination permits up to 50 cycles per minute and increases the punching force to 400 kN. The new backlash-free upper yoke adjustment rounds off the new robust forming station. The enlargement of the usable molding surface results in an increase in the number of cavities in the tool; Optimized rapid tool change reduces downtime.

Flow-optimized forming air lines fill the cavities consistently and reduce the filling time by 25 percent and the venting time by 30 percent.

Focus on Efficiency

Seven complete heating steps ensure precision heat distribution. The nominal heating capacity has been reduced by about 15 percent whilst maintaining the heat input. Christian Stockinger, Head of Engineering & Design at Kiefel Packaging, explains how this was achieved: "In order to optimize the heat output, we have reduced the distance between the heating elements and the film, insulated the heating elements even better and improved the temperature and process control."

The new tool cooling system is fully automatic and sensor-controlled, reducing energy losses. This innovation also has a positive effect on tool life and product quality. The KTR 5.2 Speed utilizes two separate cooling circuits for the upper and lower tool and an extended sensor system for optimum control. Two high-pressure pumps and mixer valves supply the two circuits with cooling water; the integrated temperature control ensures optimal tool protection. Start automation is sensor-controlled, completely preventing overshooting of the lower tool.

The new, gentle film guide avoids scratches, particles on the film and the loss of contact heat. The threading of the film is greatly improved thanks to excellent ergonomics and the new geometry at the infeed table. Start automation prevents cold film from spreading. The linear guides ensure optimum film spreading, strain relief is provided by separable movements, manual height adjustment and position control are handled by the initiator. Spreading increases before the forming station. The system also works robustly in case of film shrinkage.

The SPEEDSTACKER is designed to stack a wide variety of plastic articles. It achieves a remarkable increase in maximum article height compared to the previous model. In addition, the system has achieved a significant increase in cycle speed.

New Intuitive User Interface KMI2.0

Simple and intuitive, that is the motto of human interaction with the KMD 78.2 Speed. Pictograms and graphics support the input of machine parameters and aid fault diagnosis and rectification as well. The display shows the entire forming process at a glance, important functions are just a click away. This makes the complete process easy to understand, even for non-experts.

Stockinger is completely satisfied with the result of the new development: "Not only have we made a multitude of little improvements, but we can offer our customers genuine innovation. In practice, this means more output for the customer in combination with lower resource consumption.