Success Stories

Kautex technology and service convince ShiJiHeng

ShiJiHeng Plastics is North China’s largest manufacturer of plastic hollow packaging. Its products boast an excellent reputation. The company chose a Kautex machine for the first time in 2017 and has since then ordered three more machines.

The company operates six factories with 40 production lines in China, which can manufacture a total of 5 million hollow packaging items, such as plastic canisters and drums, 400,000 blow molded pallets, and 500,000 IBCs per year.

First Kautex machine purchased after much hesitation
Company founder and general manager Song Yuping had long found it difficult to invest in a Kautex machine, despite having valued the brand for some time. His hesitation came down to the price difference compared with Chinese machines. Today, he tells himself that he should have bought a Kautex machine sooner.

After making initial contact with Kautex Maschinenbau in 2010, he spent seven years pondering his decision before ultimately being convinced that the investment would pay off in 2017. A short time later, ShiJiHeng commissioned a KCC25D, manufactured at the Chinese Kautex plant in Shunde, which replaced five of the older machines.

Impressed by performance and reliability
The Kautex machine quickly impressed with its high level of automation, high performance, and reliability. It consumes just half the energy and produces 40 percent less flash than the machines being used previously. Added to this is the consistently good product quality. By contrast with previous production, there have been no customer complaints about products manufactured on Kautex machinery. Company founder Song was impressed, as customer satisfaction is the top priority for the entrepreneur. He recently ordered three more state-of-the-art extrusion blow molding machines from Kautex Maschinenbau, a KCC20D, and two KCC25D for the production of plastic canisters.

Special Kautex advantage: local service
The fact that Kautex, unlike other European manufacturers, has its own plant in the Chinese district of Shunde, with Chinese employees and its own spare parts service, also played a role in the decision to go with Kautex. Chinese customers are assisted directly from here in their native language, which not only facilitates communication, but also shortens delivery times when spare parts are urgently required.

Song: “We were won over by the overall package: the technology and performance of the machine itself, but also the professionalism, reliability, straightforward service, and Chinese support that Kautex offers us. Not only are we saving on staff, material, and energy costs, but above all we are ensuring stable production with high product quality.
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Innovation needs partnership

Kautex has supplied a KEB10 extrusion blow molding machine as a laboratory machine for the new technical research center of the Russia´s leading petrochemical company SIBUR. Research is carried out in close cooperation to develop innovative products.

The key figures of the largest petrochemical company in Russia and Eastern Europe are already more than impressive. Around 27,000 employees at 22 production sites generate annual sales of the equivalent of 6.2 billion euros. SIBUR covers the entire production cycle from gas production, the manufacture of monomers and plastics to synthetic rubbers and plastics processing. The market leader in Russia and Eastern Europe supplies more than 1,400 major customers from wide variety of industrial sectors in around 80 countries worldwide.

Even more impressive is the corporate mission to which the economically highly successful company is committed: ”Our products make a better quality of life accessible to everyone. They transform the world around us and change people‘s lives for the better.“ That‘s what it says on the company‘s website. To achieve this, SIBUR invests a large part of its revenues in scientific research and the development of new knowledge potential in order to reduce the dependence of the Russian economy on natural resources and facilitate the transition to a more sustainable and competitive manufacturing economy.

New research and development centre
An important milestone on the way to achieving this ambitious goal is the new Polyolefins Application and Development Center (PADC), which SIBUR plans to open in the first half of 2019. The new research and development centre is located within the Skolkovo Innovation Centre in the Moscow region and is open for cooperation with all interested parties, says Ilnaz Zaripov, expert for the development of the product portfolio at SIBUR. ”The functionality of the PADC is based on cooperation with customers in order to develop optimal processes for the production of end product samples from polymer granules and to test the raw materials and finished products for compliance with quality standards with the aid of our research equipment.

Strong partnership
In its search for a partner for extrusion blow molding technology at the Technical Center, SIBUR has chosen Kautex Maschinenbau. An important and decisive aspect here was once again the good and close cooperation with the Kautex Technikum and the exchange on a technical level. Since the PADC is also planned as a training centre, Ilnaz Zaripov attaches great importance to the technical know-how of external partners. ”If you want to develop advanced solutions, you must not close your eyes. Innovation needs openness and strong partnerships.“

The technical features of the compact KEB series, which is ideal for testing PP and HDPE applications, were also convincing. Kautex supplies a KEB10 extrusion blow molding machine with two blow molds for tests with 1-liter round PP bottles and 10-liter HDPE Eurocans. SIBUR has little experience with HDPE to date, but sees enormous market opportunities in the development of products from this material due to the great demand in Russia and other countries.

“We are very much looking forward to the opening of the SIBUR Technology Center and to passing on our expertise,“ said Hubert Moritz, Kautex Sales Manager for Russia for many years.
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The highest product quality as the highest priority

Thanks to uncompromising quality in production and service and a high level of innovation, China Wonderland Nursery Goods has developed into a truly global player. The company relies on Kautex’s know-how.

The name of the company indicates their area of activity fairly clearly. China Wonderland Nursery Goods Co., Ltd manufactures products for babies and small children. Since its establishment in 1993, Wonderland has produced more than 40 million child safety seats and 90 million play yards. Young parents on every continent rely on products from the NUNA and Joie lines, which the company uses for the distribution of their products around the world. Beyond that, Wonderland also produces products for other well-known industrial manufacturers such as Graco.

Quality is the highest priority Renee Wang, Executive Vice President at China Wonderland, is well aware of her special responsibility towards her customers. “Millions of mothers and fathers trust the most valuable things in their lives to our products. Because of that, the highest product quality, safety and innovation are our highest priorities.” Continuously expanding their high standards for quality is one company goal. In addition, several of the products in the Nuna and Joie lines have already won the well-regarded Red Dot award for exceptional design.

Wonderland trusts Kautex
Wonderland has collaborated with Kautex Maschinenbau since 2012. Several KCC30 machines have been reliably used for production without any problems. However the stabile performance of the machines is not the only point that Renee Wang made with this comment about their collaboration with the extrusion blow molding experts from Kautex. “We truly appreciate the many years of experience in blow molding and the broad spectrum of technical support that Kautex provides. Currently, we are collaborating on solutions for reducing the weight and wall thickness without changing the details and properties of the products.” In addition to collaborating in the product development, Kautex technicians provide Wonderland’s engineers with support in the design of molds and on-site start of production.
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A high-performance partnership

Europe’s leading producer of industrial packaging, AST Kunststoffverarbeitung GmbH, has high requirements when it comes to both the quality and energy efficiency of its machines. For the production of stackable jerrycans, the family-run company relies on the new, all-electric KBB400 from Kautex Maschinenbau.

AST Kunststoffverarbeitung emerged from the company Albrecht Strohmann in 1977. With approximately 160 employees, the family-run company based in Erndtebrück near Cologne records revenue in excess of 100 million euro. As Europe’s leading producer of industrial packaging, AST specializes in the manufacture of plastic jerrycans and drums. The company’s primary focus is on the production of containers with UN hazardous materials accreditation. The main customers for the company’s products are in the chemicals and oil industries, while the pharmaceuticals and food and beverage industries are also important markets.

State-of-the-art production facilities
AST manufactures plastic packaging, stackable jerrycans and drums with volumes ranging from 2 to 220 liters at its locations in Germany, the UK and Belgium. The company relies on high-performance, state-of-the-art machines. “Kautex approached us in 2016 when they were working on the new all-electric KBB400 machines in Bonn,” relates Martin Schack Staffeldt, Managing Director of the AST facility in Wales. “As one of Europe’s most high-tech jerrycan manufacturing machines, the KBB400 meets our high expectations in every technical detail. We also collaborated closely with Kautex to bring our own ideas and requirements to reality.”

In August 2016, the first KBB400 machine, equipped with a Kautex three-layer head for a cost-efficient ReCo process, left the plant in Bonn for delivery to the AST facility in Hoogstraten, Belgium. After a brief stopover on the Kautex stand at the K Trade Fair in Düsseldorf, another KBB400 reached its destination in Wrexham, Wales, to commence production in January 2017.

Smooth commissioning process
“New technologies always bring new challenges,” comments Martin Schack Staffeldt. “But we have to commend Kautex Maschinenbau for the support they provided. The company dealt with the challenges we faced during installation with the utmost efficiency, great expertise, and no fuss.” Since then, the machine has been running in continuous operation with no problems reported. “This confirms that our trust was well-placed and that we made the right decision to go with Kautex as our supplier,” according to the plastics specialist.

“We have also been receiving very positive feedback from our customers when we show them around our plant and point out the new KBB machine. We have already put in orders for additional Kautex machines to meet the ever-growing quality requirements of the industrial packaging market.”
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Clack Corporation: Made in the USA

As one of the leading names in water treatment systems and blow molding, the US based Clack Corporation has been relying on quality equipment from Kautex Maschinenbau for 40 years. Its most recent acquisition is a KBS61 for the production of water treatment pressure tanks and water treatment brine tanks.

Clack Corporation was founded in Madison, Wisconsin, in 1946 as a small family-owned company. It quickly established itself as a leading manufacturer and supplier of water softener components with the claim: “Made in the USA”. In the 1970s, Richard Clack further expanded the blow molding segment of the business, acquiring the first Kautex machine in 1977. The following two decades saw further orders for a total of 20 machines. “Thanks to the great precision of the Kautex equipment, we have been setting benchmarks in the sector for 40 years,” declares Richard Clack.

The relationship of trust between the two well established companies was further strengthened last year, when Clack Corporation ordered yet another machine from Kautex Maschinenbau. The new KBS61 will be used to increase production of water treatment pressure tanks as well as water treatment brine tanks for the North American market. KBS series models are regarded as the all-rounders among blow molding machines. As well as being highly flexible, they also deliver impressive output rates. “We are extremely pleased to continue our successful partnership with Clack Corporation,” confirms Andreas Lichtenauer, Managing Partner at Kautex. With this new acquisition, Clack products will be able to continue boasting the claim “Made with Kautex” in addition to proclaiming all blow molded water treatment components “Made in the USA”.
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Lifetime Kayaks for the World

Lifetime Products Inc. is the world‘s leading manufacturer of blow molded polyethylene folding chairs and tables, picnic tables, and home basketball equipment. In 2015, six Kautex machines were ordered for the production of kayaks.

Lifetime uses polyethylene blow molding and metal forming technology to manufacture a variety of consumer and industrial products. The company has one of the largest blow molded plastics facilities in North America. Lifetime Products occupies over 3,000,000 square feet (278,000 m2) at its USA Head- quarters and employs over 2,200 people worldwide.The company started its molding business in rotomolding and in 1995 purchased their first Kautex extrusion blow molding machines. From 1997 to 2001, another 13 machines, built in the US at that time, followed. During the next 15 years, Kautex worked to supply Lifetime with retrofit accumulator heads for legacy machines. Since the acquisition of Emotion Kayaks in 2015, Lifetime has become one of the largest blow molded kayak manufacturer in the world.

Kautex-Maschines for kayak production
Finally in 2015, with Lifetime’s plans to open a new production facility in Mascot, TN, Kautex received an order to build three machines each of the model series KBS241 mono and KBS480, all intended for the production of various Kayak models.

”Kautex is our preferred supplier for blow molding machines,” explains Bob Adams, Vice President Lifetime Products Inc.. ”Their machines are technically superior and better built than competitive machines in the industry. When faced with the challenge of starting up a new facility, we chose to partner with Kautex because of their capacity to design and build multiple machines and to provide technical support, service and training for our personnel.”
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Toray Industries does research together with Kautex

With the substance polyphenylene sulphide (PPS), the Japanese chemical corporation Toray has developed an ideal material for the production of feed and exhaust air ducts for modern turbo-charged engines. New materials are being developed in close cooperation with Kautex Maschinenbau.

Toray is a corporation in the chemicals industry with business activities in 26 countries and regions and has about 45,700 employees all over the world. In addition to the main business areas of fibers & textiles as well as plastics & chemicals, Toray is also involved in the development of IT products, carbon fiber composite materials, pharmaceutical and medical products, as well as in the environment & technology areas.

Starting in August 2016, Toray will use a KBS20-SB in the company's own technical center at the factory in Nagoya for testing the production of various 3D ducts using the suction blow molding process. The focus lies on the development of especially heat- and pressure-resistant air ducts made from PPS. Kautex Maschinenbau has provided the Japanese corporation with an extrusion blow molding machine for research and development purposes.

PPS for turbocharger ducts
A current development trend in the car industry is the downsizing of car engines. Turbochargers are used in order to be able to achieve the same performance with fewer cylinders and smaller displacement. However, these require heat-resistant air ducts in the engine. Toray achieved very good results here with polyphenylene sulphide (PPS). This plastic distinguishes itself with especially high and durable heat-resistance up to 220°C. The Kautex machine with high-temperature equipment can process this material without problem.

A development partnership
Jürgen Moitzheim, Sales Director at Kautex Maschinenbau, is looking forward to working with the Japanese plastics manufacturer. ”The latest developments in car engines always create new challenges for car industry suppliers. This is particularly true for the interplay between materials and engine technology. For this reason we like to work very closely with our customers on the development of new solutions.“

This also convinced Toshiteru Nishijama, Manager Automotive Products Business, Resins Global Marketing Dept. at Toray: ”We were looking for a provider who not only produces good machines, offers high process reliability and good service, but who will also support us with their know-how in the R&D field. It became clear quite quickly that we would use a Kautex machine.“
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Elmeg shapes its future with Kautex machines

In the international automotive business, the name Elmeg has enjoyed a good reputation for more than 30 years. The Italian automobile supplier has specialized in the blow moulding process and has been the official supplier for suction blow moulded 3D parts since 2013 as they are used, for instance, in turbo-charged engines.

Elmeg purchased its first Kautex machines 10 years ago. Since then the two companies have developed a virtually friendly relationship. Salvatore Giordano, the recently deceased founder of the family company, compared the cooperation of the two companies with the successful cooperation between Ferrari and Michael Schumacher: ”It is very nice to work with Germans when you want to develop new ideas.“

Automotive in the DNA
In the meantime the son of the company founder, Gianluca Giordano, has taken over the management of the company and conducts business in the same manner his father did. Values such as technical competence, willingness to improve one's performance, and especially appreciating one's own values are part of the company mission. And not to forget, a passion for automotive which is passed down from generation to generation in the Giordano family. ”Being fascinated with automobiles is deeply engrained in our company DNA,” says Gianluca Giordano.

The Italian automobile supplier uses a total of four Kautex machines. They include a KB260 for the production of plastic fuel tanks and a Kautex K3D-SB8 suction blow moulding machine which Elmeg loves because of its reliability and flexibility. This compact machine can be used for suction blow moulding and for conventional blow moulding applications and various materials. This allows Elmeg to process different materials alternatingly, such as Hytrel, Zytel, or PA6.6.

Specialists for 3D blow moulded parts
Its specialization in components created using blow moulding has allowed the company (which has an additional factory in Serbia since 2012) to acquire a great wealth of know-how. In contrast to most other competitors, and in addition to doing the engineering, Elmeg also makes its own moulds. This allows them to realize customer wishes quickly, flexibly, and cost-effectively but also to perform short-notice optimizations in the process.

Gianluca Giordano feels that this high level of customer support positions his company very well and adds: ”An important criterion for success is the optimal interplay of know-how, materials, and mechanical engineering. Kautex Maschinenbau is a partner which always supports us actively in the development of new solutions.” In the future Elmeg plans increasing international expansion under the motto ”Shaping together” – especially as expert for 3D suction blow moulded components.
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MPE s.r.l. - A sustainable partnership

MPE S.r.l has been a top international supplier to the automotive industry for 30 years. One of the key factors in its success is its excellent relationship with our team at Kautex Maschinenbau, along with our blow-molding technology.

MPE are specialists in the development and production of precision components for the global automotive industry. With five production facilities in Italy, the USA, Mexico and Serbia, the company sells almost  200 million vehicle components per year to the world's leading vehicle manufacturers. “It is a very demanding market. Suppliers have to be flexible and set high standards while still offering competitive prices”, explains MPE’s President, Giorgio Battagliotti.

Foto: Giorgio (l.) and Riccardo (r.) Battagliotti, MPE srl

Focus on customer needs
In order to meet these challenges, MPE understands the importance of maintaining close relationships with its international customers. Regular visits and invitations to customer audits and the continuous development of products and strategies are all vital factors in this respect. Mr. Battagliotti describes his company’s philosophy as follows: “Good suppliers never rest on their laurels but are always striving to improve.” This is why MPE believes it is essential to work closely with customers from the very beginning. As an experienced businessman, Battagliotti is well aware that “the acquisition phase is where we can really make an impression. This is where we can set-out our stall, show the customer that meeting their needs is our number one priority and explain how we can work together to find the perfect solution.”

Continuous improvement
MPE also expects this kind of service from its own suppliers. This is where Kautex Maschinenbau has a major advantage, thanks to its tried-and-tested mix of innovation, reliability and customer focus. MPE currently operates 13 Kautex machines that have already provided many years of reliable service. But sound, reliable engineering is only part of the story. “Of course we expect to see continuous improvements in terms of performance and efficiency”, explains Battagliotti. The bar has already been set very high, because the company has to satisfy leading vehicle manufacturers such as VW, BMW and Daimler “In Kautex, we have a partner who can help us to achieve our goals – making continuous improvements to production processes and developing exciting new products.”

MPE and the Kautex team already enjoy a lively exchange of ideas, and in future this will be even more rapid and effective. MPE is growing in the Nafta region and is now concretly examining the opportunities and potential that the Asian market has to offer.  Kautex-Maschinenbau will be there to accompany Giorgio Battagliotti and his team every step of the way.
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Fulcrum Inc. - Tailormade packaging with Kautex quality

Started in 1988 Fulcrum Inc. is a custom blow molder in the US focusing primarily on consumer and industrial packaging. Fulcrum is an industry leader in the custom blow molding of high quality plastic containers ranging from 32 oz to 2 ½ gallons.

Increased product throughput and quality
In early 2011, Fulcrum’s management team ordered a Kautex KCC 20D to replace an ageing blow molder.  Says Director of Operations Dan Gilroy, “we identified opportunities to grow our business with new and established customers that we could not make happen with our existing equipment”.  The results exceeded expectations and Fulcrum realized a dramatic increase in product throughput and quality.  Additionally, the significant decrease in material loss added to the overall viability of the machine purchase.


New machinery supports growth
Also a benefit of adding this highly efficient machinery is the resulting growth Fulcrum experienced.  Owner Samir Mehta explains it this way: “the decision to purchase a Kautex machine has been an excellent investment for our company.  Our experience with their team was smooth and the results lucrative, so much so that we recently ordered a second machine.  We look forward to our continuing relationship with Kautex”.
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