Strategies for success – in Rubber Injection Moulding »

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MA

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Strategies for success

training center for customer and DESMA staff qualification. Our Sigma and Alpha models are offered from 250 kN to 5600 kN in Vertical series, C-frame Series and Horizontal Series. These modular machi-nes are equipped to hold injection units ranges from 130 cc to 12500 cc injection volumes. High quality optimized moulds are supplied as turnkey solutions. Our well equipped and experienced project depart-ment works with customers, to design the optimum process engineering. .

Commenced operation from 1996 in the industrial city of Ahmedabad. We offer Rubber Injection Moulding Machines, Moulds, Cold Runner Blocks , Presses and Turnkey Projects. Since 2009, DESMA has moved to state-of-the-art new factory with 12,000 sq meters area having 7,500 sq.mt production plant and offices. With this new factory DESMA now also provi-des in India a mould shop with adjacent engineering center for mould testing and optimization as well as a comprehensive

Since 1965, at Fridingen, Germany we are producing Rubber Injection Moulding Machines, Moulds and Cold Runner Blocks.We continue to be technology leader in the world, through our consistent development strategy. Quality of service, technical key qualification and process know-how are the strong points constituting the basis for the partnership with our customers.Our patented injection unit FIFO A and the Benchmark clamping system has set stan-dards for ergonomics.

2 Strategies for success

DESMA Germany DESMA India

DESMA Deutschlandin Fridingen

DESMA Slovakiain Považská Bystrica

DESMA USAin Hebron

DESMA Indienin Ahmedabad

DESMA Chinain Wuxi

We also offer value added services like training, production analysis, moulds, Cold Runner Blocks, and process optimization.Sales and service offices and service engineers are located strategically to provide prompt after sales service. In brief, we offer a total solution for eco-nomic production of high quality rubber parts. We are an ISO 9001:2008 company since 2009.

Vertical machines

ALPHA Series *Economic series with low cost automation. SIGMA Series * Optimized size of heating platen and injection volume. C Frame Series * For corner moulding of profiles and small rubber parts. (Injection unit for TPE is optional)

3 Vertical machines

Patented FIFO (First In First Out) injection system: Accuracy, speed, easy cleaning and higher injection volumes. Low strip feeding height.

Strong, parallel four column clamping unit design

Induction hardened, pre-stressed tie bars for long service life.

Large platen sizes and high opening strokes offer more space of extra cavities and easy demoulding operation.

Fully hydraulic and hydro-mechanical clamping.

Ergonomic operating height.

State-of-the-art microprocessor controls

Graphic display and real time trend curves (Optional)

Hydraulic pump with proportional pressure and flow for fast response and high power efficiency

Stroke measurement of injection volume and mould movements with high resolution accuracy and repeatability.

Heating platen with heat compensating design and close loop PID control, ensures uniform mould temperatures.

Flexibility to adopt variety of Manual/Automatic demoulding systems.

Machine enclosure isolating all hazardous machine movements for safety.

Light curtains or sliding safety gates (optional) provide additional safety

4 FIFO, Process Automation

FIFO - First In First Out Process Automation

Uniform rheology and heating time through out the shot volume allows higher injection temperature resulting in lower cure time.

Short flow path in injection piston, offers low pressure drop.

ZERO Back Pressure during plasticizing on rubber as plunger is horizontal.

Easy compound change as extruder can be retracted out of the barrel.

Our broad automation range offers various ejection possibilities for your applications. The modular and multifunctional design makes retrofitting at any time possible. For special requirements we can offer customized solutions.

Faster Cure time with Higher Injection Temperature Flexibility for vertical machines

Centre plate sliding device optionally for one or two centre plates. Availa-ble with ejector system. Can be used in front of or behind the machine.

Hydraulically driven demoulding table with 70% or 100% stroke.

Newly developed manual centre plate sliding device for two centre pla-tes, with hydraulic ejection. System decoupled from the clamping unit with excellent ease of operation and safety.

Wether two mould bottom halves or two complete moulds-optimum automation with our double-sided shuttle table is possible. Hydraulic lifting device on top and bottom at outside stations are available.

Alternating core plate sliding device, manual, suitable to produce parts like bellow with two core bars.

Multifunctional cetre plates sliding device, alternatively to be used in front of or behind the machine, with integrated splitting function and automated runner removal device.

1. Low Strip Feeding Height.2. Oil temperated plasticizing barrel.3. Constant screw length during plasticizing phase.4. Temperated injection cylinder and nozzle.5. Retractable injection nozzle.

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2

Best prerequisites for mass production

Stable structure of the clamping unit due to 4-column design.

Hydraulic lifting devices guided on tie bars.

As option, frame with guiding fitted around the tie bars for installation of central cold runner block for two-deck production.

Injection system FIFO-B or FIFO-C are available.

Electrically driven automation equipment with demoulding control. (Optional)

For manual operations easy access to all areas of the clamping unit.

In this case a maximum surface pressure per cm² is available due to compact machine dimensions. Ergonomic machine design combined with a wide choice of special clamping forces offers you the right solution for every application. Through needle-shaped shut-off cold runner and innovative DESMA-injection moulds, an article production without runners and/or without rework becomes feasible.

An extremely stable design of the clamping unit with four columns guarantees a minimum of deflections and a precise guiding of platens and hydraulic lifting devices. The models Alpha 100 H and 300 H are particularly suitable for the applications like precision seals, O-rings, gaskets etc.

Horizontal machines

5 Horizontal machines

FIFO B

FIFO C

Controls

DRC 1210 is exceptionally effective control system for controlling very complex machines and processes. Following are additional features possible with DRC 1210.

IPC based control generation DRC 1210, for complete Close Loop Control

Close loop control of complete injection process, mould movements and core lifter movements. Close loop PID control of multiple heating zones.

Comprehensive intermediate stop functions of core lifter movements

Modern for Telediagnosis

Data storage on hard disc or disc drive

6 Controls

DESCheck and Statistical Process Control Software (Option)

PC based efficient control system with 6.5“ colour display

Dynamic auto optimization of temperature controllers

Real-time operating system with multitasking

DESCONNECT: Connect all your DESMA machines to centralized server and monitor the process right from your desktop. Cure Time Optimizer: Monitors changes in mould temperature and adjusts cure time to keep the product quality constant.

With KDM 1000 and DRC 1210, following special softwares are available:

Feel what is happening with the new DRC 2020 HT visualization

Featuring a massive 19” high format screen, this system opens up a new chapter in simplified and logical control of rubber injection moulding machines. A new user prompting and the perfect display of processes set new standards. The operation panel is the first to integrate a Haptic-Touch screen which provides users not only with visual information, but also “touch” feedback. The new DRC 2020 HT operating panel is suitable for retrofitting to machine generations with DRC 1210 and DRC 2010 visualization systems. This means the state-of-the-art in control technologies is also available for existing units.

Controls

7 Controls

8 Moulds and Cold Runner Blocks

For years DESMA has been one of the leading suppliers of cold runner systems. According to the type of appli-cation, systems with open nozzles or our new, patented needle-shaped shut-off Cold Runner are available.Our Cold Runner blocks are single block design and thus offer high stability when used with high injection pres-sures. We provide training on maintenance and proper use of Cold Runner block. We guide you in the selection of optimum nozzle configuration as per your mould.DESFLEX® device which is patented by DESMA offers possibility of flash-free moulding of critical seals and small parts.

Our capable team has wide experience in various article groups and a large number of turnkey projects. We have in house testing facility for optimizing moulds and machines. We, therefore, have best combination of ex-perience, knowledge and facilities to meet your require-ments for high quality elastomer products.

Production know-how from one source

Innovative injection moulds for demanding articles

Success can be shaped

Moulds & Cold Runner Blocks

Save from Day One

In perfect form

Production concepts are transformed into quality moulds. Production moulds are made after validation with pro-totype mould. Based on specific product requirements, Product Concepts + Machine + Mould specification is designed.

9 In perfect form

Manufacturing facilities

Machine Assembly floor Mould ShopMould in Process

10 Manufacturing facilities

ALPHA series

11 Technical Data

Machine Type

Injection Unit-standard SizeInjection Unit-options SizeInjection Unit size - FIFOInjection plunger diameter mmInjection pressure barInjection volume cm3 Plunger stroke mmInjection Force kNInjection rate, calc.(1) cm3/sScrew diameter mmScrew length L:DScrew speed rpmScrew, torque, max. NmHeating capacity temp. control kWInjection Unit contract force kNStrip width mmClamping unitClamping force kNTransfer force kNTransfer stroke mmOpening force kNOpening stroke mmOpening speed mm/sClosing speed mm/sMould height min. mmSpace bet.heating platen,Max.(1) mmClearance between tie bars mmHeating Platen, standard mmHeating Platen, largest mmHydraulic core lifting device Lifting force kNStroke mmGeneral DataPump drive bar/LPM/kWTotal connected load kWMachine dimention LxWxH mmOil tank capacity IWeight with hydraulic oil (1) kg

Alpha 50 Alpha 100 Alpha 160 Alpha 250 Alpha 400 fully hydraulic fully hydraulic fully hydraulic fully hydraulic fully hydraulic 1C1 1A 2A 3A 4A 2C1 2A 1A and 3A 2A and 4A 3A,5A* and 6A* 1C1 1A 2A 3A 4A 32 I 40 55 I 65 75 I 85 85 I 95 105 I 115 2430 I 1560 2380 I 1700 2150 I 1670 2150 I 1730 2150 I 1800 85 I 130 350 I 500 800 I 1000 1600 I 2000 3300 I 4000 105 150 180 290 390 195 567 950 1227 1886 30 I 46 48 I 68 80 I 100 80 I 100 120 I 150 25 25 35 45 55 12:1 10:1 10:1 10:1 10:1 20 - 200 20-220 20-250 20-100 20-200 380 380 540 1260 1370 1 X 4.5 1 X 4.5 1 X 4.5 1 X 4.5 2 X 4.5 fixed nozzle 47 47 75 75 40 X 6 40 X 6 45 X 7 60 X 8 60 X 10 500 (550)2 1000 (1100)2 1600 (1700)2 2500 (2700)2 4000 (4500)2

500 1000 1600 2500 4500 fully hydraulic fully hydraulic fully hydraulic fully hydraulic Hydro - Mechanical 24 38 58 80 103 300 450 500 550 650 470 300 300 220 240 280 470 420 270 420 50 100 140 160 180 350 550 640 710 830 265 x 345 305 X 415 410 X 570 510 X 680 603 X 830 320 x 400 320 X 400 450 X 510 560 X 630 670 X 780 - 400 X 500 560 X 630 670 X 780 810 X 980 16 24,5 40,2 63 98 0-150 0-200 0-250 0-250 0-300 250(275)/28/7.5 263(289)/28/7.5 260(276)/41/15 250(265)/41/15 250(283)/65/22 20 20 34 38 56 1435 x 1360 x 2450 2215 x 1195 x 2925 2379 X 1255 X 3045 2570 X 1305 X 3430 3000 X 1660 X 3800 210 270 270 330 330 2000 4100 5700 8840 13800

Note : * For 2C1 injection unit size refer Alpha 25 C on page 12 * In case of 2500 kN, optional injection unit 4A is not retrofitable * In case of 4000 kN, optional injection unit * 5A and 6A is not retrofitable (1) Standard size (2) Increased clamping force Subject to technical modifications

Horizontal series C-Frame series

12 Technical Data

Machine Type

Injection Unit-standard SizeInjection Unit-options SizeInjection Unit size - FIFOInjection plunger diameter mmInjection pressure barInjection volume cm3 Plunger stroke mmInjection Force kNInjection rate, calc.(1) cm3/sScrew diameter mmScrew length L:DScrew speed rpmScrew, torque, max. NmHeating capacity temp. control kWInjection Unit contract force kNStrip width mmClamping unitClamping force kNTransfer force kNTransfer stroke mmOpening force kNOpening stroke mmOpening speed mm/sClosing speed mm/sMould height min. mmSpace bet.heating platen,Max.(1) mmClearance between tie bars mmHeating Platen, standard mmHeating Platen, largest mmHydraulic core lifting device Lifting force kNStroke mmGeneral DataPump drive bar/LPM/kWTotal connected load kWMachine dimention LxWxH mmOil tank capacity IWeight with hydraulic oil (1) kg

Machine Type

Injection Unit-standard SizeInjection Unit-options SizeInjection Unit size - FIFO-CInjection plunger diameter mmInjection pressure barInjection volume cm3 Plunger stroke mmInjection Force kNInjection rate, calc. cm3/sScrew diameter mmScrew length L:DScrew speed rpmScrew, torque, max. NmHeating capacity temp. control kWInjection Unit contract force kNStrip width mmClamping unitClamping force kNTransfer force kNTransfer stroke mmOpening force kNOpening stroke mmOpening speed mm/sClosing speed mm/sMould height min. mmSpace bet.heating platen,Max.(1) mmHeating Platen, standard mmHydraulic core lifting device Lifting force kNStroke mmGeneral DataPump drive bar/LPM/kWTotal connected load kWMachine dimention LxWxH mmOil tank capacity IWeight with hydraulic oil (1) kg

Alpha 100 H Alpha 300 H fully hydraulic fully hydraulic 1C 1B 1C1,2C1,1B,2B 2B and 2B HP 1B 1B 55 I 65 55 I 65 2200 I 1550 2200 I 158 0 350 I 500 350 I 500 150 150 523 523 52 I 74 78 I 108 25 25 10 : 1 10 : 1 20-220 20 - 170 380 380 1 X 4.5 1 X 4.5 58 58 40 X 6 40 X 6 1000 (1100)2 3000 1000 3000 fully hydraulic fully hydraulic 38 47,2 450 500 300 300 470 420 76 130 526 630 410 X 410 480 X 480 320 X 400 570 X 570 320 X 500 570 X 570 20,5 24,5 0-200 0-350 250/28/7.5 279/41/15 20 38 4120 X 1325 X 2135 4570 X 1460 X 2390 140 150 5550 7620

Alpha 25 C Alpha 50 C fully hydraulic fully hydraulic 1C1 2C1 2C1 1C1 + 1C 2 C1 1 C 45 I 55 55 I 65 2340 I 1570 2915 I 2085 220 I 330 350 I 500 140 150 373 691 78 I 120 42 I 62 35 25 10 : 1 12 : 1 20-180 20-200 540 380 1 X 4.5 1 X 4.5 - 40 X 6 40X6 C-Frame C-Frame 250 500 250 500 fully hydraulic fully hydraulic 8 20 300 350 110 110 70 240 100 130 400 480 320 X 320 320 X 400 16 16 150 150 250/41/7.5 250/28/7.5 20 20 1410 X 1220 X 2830 1410 X 1490 X 3070 190 226 2400 3000

Note : * For 2C1 injection unit size refer Alpha 25 C on page 12 * For 1C1 injection unit size refer Alpha 50 on page 11 (1) Standard size (2) Increased clamping force Subject to technical modifications

Sigma series

Machine Type

Injection Unit-standard SizeInjection Unit-options SizeInjection Unit size - FIFO-AInjection plunger diameter mmInjection pressure barInjection volume cm3 Plunger stroke mmInjection Force kNInjection rate, calc. cm3/sScrew diameter mmScrew length L:DScrew speed rpmScrew, torque, max. NmHeating capacity temp. control kWInjection Unit contract force kNStrip width mmClamping unitClamping force kNTransfer force kNTransfer stroke mmOpening force kNOpening stroke mmOpening speed mm/sClosing speed mm/sMould height min. mmSpace bet.heating platen,Max.(1) mmClearance between tie bars mmHeating Platen, standard mmHeating Platen, largest mmHydraulic core lifting device Lifting force TCL kNStroke mmLifting force BCL kNStroke mmGeneral DataPump drive bar/LPM/kWTotal connected load kWMachine dimention LxWxH mmOil tank capacity IWeight with hydraulic oil (1) kg

Sigma 250 Sigma 400 fully hydraulic fully hydraulic 3A 4A 2A and 1A 3A 3A 4A 85 I 95 105 I 115 2150 I 1730 2150 I 1800 1600 I 2000 3300 I 4000 290 390 1227 1886 80 I 100 120 I 150 45 55 10 : 1 10 : 1 20-100 20-200 1260 1370 1 X 4.5 2 X 4.5 75 75 60 X 8 60 X 10 2500 (2700)2 4000 (4500)2

2500 4000 fully hydraulic fully hydraulic 58 93 500 600 300 240 420 300 100 180 600 780 410 X 680 490 X 830 560 X 630 670 X 780 670 X 630 810 X 780 40,2 98 0-250 0-300 63 98 0-250 0-300 250(265)/41/15 251(283)/65/22 38 56 2760 X 1305 X 3320 3170 X 1685 X 3970 330 450 7400 13900

Note : * For 2C1 injection unit size refer Alpha 25 C on page 12 * For 1C injection unit size refer Alpha 50 C on page 12 * For 1C1 injection unit size refer Alpha 50 on page 11

13 Technical Data

(1) Standard size (2) Increased clamping forceSubject to technical modifications

SIGMA SE series

Machine Type

Injection Unit-standard SizeInjection Unit-options SizeInjection Unit size - FIFO-AInjection plunger diameter mmInjection pressure barInjection volume cm3 Plunger stroke mmInjection Force kNInjection rate, calc. cm3/sScrew diameter mmScrew length L:DScrew speed rpmScrew, torque, max. NmHeating capacity temp. control kWInjection Unit contract force kNStrip width mmClamping unitClamping force kNTransfer force kNTransfer stroke mmOpening force kNOpening stroke mmOpening speed mm/sClosing speed mm/sMould height min. mmSpace bet.heating platen,Max.(1) mmClearance between tie bars mmHeating Platen, standard mm

Hydraulic core lifting device Lifting force TCL kNStroke mmLifting force BCL kNStroke mmGeneral DataPump drive bar/LPM/kWTotal connected load kWMachine dimention LxWxH mmOil tank capacity IWeight with hydraulic oil (1) kg

Sigma 250 SE Sigma 400 SE fully hydraulic fully hydraulic 3A 4A 1A, 2A, 3.2 A, 4A 3A, 3.2 A, 5A, 5,3A 3A 4A 85 I 95 105 I 115 2150 I 1730 2150 I 1800 1600 I 2000 3300 I 4000 290 390 1227 1886 80 I 100 120 I 150 45 55 10 : 1 10 : 1 20-100 20-200 1260 1370 1 X 4.5 2 X 4.5 75 75 60 X 8 60 X 10 2500 (2700)2 4500 2500 4500 fully hydraulic fully hydraulic 58 93 500 600 300 240 420 300 100(1) 180(1) 600(1) 780(1) 410 X 680 490 X 830 670 x 1000 670 X 1500 38 98 0-250 0-300 63 98 0-250 0-300 250/41/15 283/65/22 46 62 2760 x 1305 x 3320 3870 X 1685 X 3970 330 450 8500 15500

Note : * For 2C1 injection unit size refer Alpha 25C on page 12 * For 1C injection unit size refer Alpha 50C on page 12 * For 1C1 injection unit size refer Alpha 50 on page 1

14 Technical Data

(1) Standard size (2) Increased clamping forceSubject to technical modifications

Optional features

Selection Guide Machine Type ALPHA SIGMA Control System KDM 1000 DRC 1210 KDM 1000 DRC 1210Modem for telediagnosis Cure optimization software for machine Preparation for DESconnect Swiveling operator panel Additional heating control for mould, 1 phase, max. 3 kW Heating element monitoring for all heating elements 3 Zone heating for top and bottom heating platens 8‘‘ color TFT operator panel10‘‘ color TFT operator panel Injection unit Oil temperation units for injection and cold runner block Water temperation units for injection and cold runner block ITM Programme with additional valve Stock temperature indication for injection unit Strip guiding device incl. strip sensor Back pressure valve (proportional) Back pressure valve (mechanical) Spring loaded shut off nozzle LSR conversion kit Silicone stuffing device Vacuum function Vacuum device complete with pump. Digital display of vacuum with PLC interlocking Preparation of vacuum, only signal Demoulding and shuttle table Demoulding table with two hand operation Central ejector for demoulding table or shuttle table 2-sided shuttle table, with additional longer heating platen hydraulic lifting device, at shuttle table from Top / Bottom Stroke measurement for core lifter on either side of shuttle table. additional heating and insulation plates, fixed to the upper core lifter in outer stations. Air Blow function, only Signal and valve Outside actuation of ejectors (valve and signal) Sliding Devices Hydraulic sliding device for middle plate sliding. Outside ejector device on hydraulic sliding device. Outside ejection station with manual middle plate sliding. Manual core plate sliding device, with bearing slide. C-Rail frame one side or two side extended. E-Rail with bearings one side or two side extended.

Machine Type ALPHA SIGMA Control System KDM 1000 DRC 1210 KDM 1000 DRC 1210 Lifing devices Hydraulic lifting device for moving / fixed platen Mechanical ejector device for moving / fixed platen Stroke measurement for hydraulic lifting device Tie bars surrounding for hydraulic lifting device 2 fold synchronization for top and bottom hydraulic lifting device Safey devices Edge monitoring for sliding gate and injection unit Light guard palm safety in front / rear side Light guard palm safety with mirrors Additional sliding safety gate or safety cage Further accessories Quick clamping for heating platens and core lifters Light in mould carrier and control cabinet Tie rod extension Insulating plates for 220 deg. cels. temperature. Machines as per EN201 safety norms CE Certification

15 Technical Data

Retrofitable options at extra cost Not available Features included in standard supply

16 The complete package

The complete package

Innovative mould concepts Service and practical training Expert projectmanagement

Due to the DESMA-owned technical mould centre, new ideas are implemented in a hands-on and process-adapted way. This proximity is another key to quick success.

Modular machine concepts

Ground breaking machines lay the foundations for successful turnkey packages. An open control architec-ture allows the integration of even complex automa-tions.

A project-orientated training forms the basis of an effective introduction into your production, particularly in case of extensive turnkey packages. An experienced service team is globally at your disposal and keeps your manufacture running.

Development of new procedures

In our new technical rubber centre, equipped as per the latest standards, skilled application technicians and project engineers come up with new procedures and get them ready to go into production. They stay in close contact with the customer during the development stages.

From project engineering to final acceptance our knowledgeable project engineers are at your side. During the implementation stage the engineer in charge of the project is your contact. Thus, a direct communication is ensured.

CHINADesma Rubber Injection Machinery (Wuxi) Co. Ltd. No. 227 Chengnan Road, Hall No. 5, Whangzhuang Industrial New Area, Wuxi, Jiangsu Province, P.R. 214028 China Phone +86 510 85 36 11 18 Fax +86 510 85 36 29 92 info@desma.biz www.desma.biz

USA AND CANADA KDE Sales & Service, Inc. 2195 Arbor Tech Drive, Hebron, KY 41048 / USA Phone +1-8 59-5 25-6610 Fax +1-8 59-5 25-8972 sales@klocknerdesma.com www.klocknerdesma.com

Mumbai Office:Mobile: +91 - 99677 68099dinesh.kurhade@desmaindia.comHyderabad Office:Mobile: +91 - 97046 65826n.vittalmurthy@desmaindia.com

GERMANY DESMA Elastomertechnik GmbH An der Bära, 78567 Fridingen / Germany Phone +49 (0) 74 63-8 34-0 Fax +49 (0) 74 63-8 34-186 info@desma.biz www.desma.biz

Superior technologies, progressive innovations

DESMA. The world leader in turnkey injection moulding technology

INDIA Kloeckner DESMA Machinery Pvt. Ltd. Plot No. 10, Road No. 1, G.I.D.C., Kathwada, B/h. Torrent Power Sub-Station, Ahmedabad - 382 430. India. Phone +91-79-2290 1782 / 6619 0000 Fax +91-79-2290 1785 sales@desmaindia.com Delhi Office : Phone +91-11-2341 1162 / 5152 8152 Telefax +91-11-2341 1161 sundeep.gupta@desmaindia.com Pune Office : Phone +91-20-3062 1635 Telefax +91-20-2744 2717 suhas.pol@desmaindia.com Chennai Office : Mobile +91-98840 79670 sk.nathan@desmaindia.com

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Kloeckner DESMA Machinery Pvt. Ltd. Plot No. 10, Road No. 1, G.I.D.C., Kathwada, B/h. Torrent Power Sub-Station, Ahmedabad - 382 430. India. Phone +91-79-2290 1782 / 6619 0000 Fax +91-79-2290 1785 sales@desmaindia.com