Success stories

We spoke with Soon Liu, Director R&D of Pact Group Packaging Systems (GuangZhou) CO., Ltd, a subsidiary of Pact Group, about the challenges facing the industry and his experience with Kautex machines.

Mr. Soon, what do you produce in Guangzhou?

Soon Liu: In Guangzhou, we mainly produce bottles and closures for food, spices, healthcare products, medicines, detergents and beverages. Our partners are global players with extremely high demands on product quality, such as Amway, Infi nitus, Haitian, Blue Moon, Coca-Cola, Pepsi and Danone.

What challenges is blow molding production currently facing and how are you dealing with them?

Soon Liu: The demand for plastic packaging is stable and continues to grow especially in our market. At the same time the requirements for product quality and packaging design have risen to meet the demand
for more fl exibility needed for smaller batch sizes f global plastics restrictions, we currently see the reduction in the weight of blow molded products, the continuous optimization of plant effi ciency and the use of PCR plastics as the main challenges. Here, for example, we are investing in the development of PCR applications. But I also see a need for new blow molding equipment and standardized blow molding processes. Flexible production requires, for example, short mold change times and continuous and reliable performance of mold and equipment.

What makes a good partner from your point of view?

Soon Liu: A good partner delivers production solutions that are optimally designed to meet our requirements. This means uncompromising product quality while taking sustainability factors into account. In addition, we expect continuous improvements and innovations so that we can continue to optimally serve our customers‘ needs in the future.

How long have you been working with Kautex Maschinenbau and what has been your experience with Kautex extrusion blow molding machines?

Soon Liu: Our cooperation has existed for ten years. We highly appreciate the high quality of the machines, their advanced and reliable technology and the excellent service provided by Kautex Maschinenbau. We now use 3 Kautex blow molding machines especially for demanding bottle products. For this applications Kautex production lines offer decisive productivity and cost advantages. In the future, we will continue to rely on Kautex to continuously optimize machines and processes and to drive sustainable innovation.

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."

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.

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.

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.”

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”.

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.”

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.“

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.

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.

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.

Zibo Jielin began life as plastic pipe manufacturers in 2001, but since 2007 the company has also been producing intermediate bulk containers (IBCs) and plastic drums with volumes up to 200 liters. Its plastic pipe business concentrates on Northern China and Jiangsu-Zhejiang, whereas its containers are distributed throughout China. And with some success: this year General Manager Xu Yueming has expanded production with the purchase of a KBS241 from Kautex Maschinenbau.

Mr Yueming, what do you expect from your machinery?
In these times of scarce resources and volatile energy prices, when we purchase new machinery our main focus is on efficiency and low energy consumption. It is also important that the machines are simple to operate, so that they can be maintained by our own staff.

You have been using Kautex blow molding equipment since 2007. What motivated you to turn to Kautex once again?
For us, Kautex machinery means we can guarantee steady production of top-quality products. We have been operating our two existing Kautex machines for many years, and they have been extremely reliable.

How can suppliers such as Kautex help you to deal with the challenges of the market?
In the industrial packaging sector, the main challenge is constant price pressure. So I need our suppliers to provide cost-effective products with excellent after-sales service at relatively low prices. And when we are developing new machinery solutions, we want to be able to use our suppliers' expertise to help us continue with our program of innovation. We are currently working with Kautex on reducing weight and saving materials in our products.

What are your goals in the Chinese market?
If we increase our market share, the competition simply gets tougher. So at the moment our priority is to consolidate our position in the market. We ensure long-term customer loyalty by delivering first-class quality and service. The key factors here are our state-of-the-art machinery and, above all, our excellent, motivated team. In the long term, we would like to make even faster progress and be even more innovative. Kautex Maschinenbau is an important partner for us in this respect.

The market for composite cylinders is currently growing at a rate of 14 percent per annum, according to the Texan management consultancy Lucintel. It predicts a total market volume of $1,223 billion in 2015. Much of this growth in the market is due to the growing demand for transportation and storage containers for alternative energy sources such as liquid petroleum gas (LPG) and compressed natural gas (CNG). Composite cylinders offer a number of key benefits over traditional metal containers in terms of safety, corrosion and lighter weight.

This is why leading plastics processor Supreme Industries Ltd has been working with Kautex Maschinenbau to open its first full production line for composite LPG cylinders. This turnkey production facility has been designed to achieve annual production of 400,000 type IV composite cylinders in six different sizes. In an interview with K-News, the company's chairman SJ Taparia tells us more about the new facility.

Mr Taparia, what was the main reason behind your decision to become involved in the manufacture of composite gas cylinders?

It's quite simple – this is a real market of the future. Liquid petroleum gas and natural gas are becoming ever more important, particularly in the household installations sector. In India alone we are looking at an increase of 15 million gas cylinders per year, and the majority of existing gas cylinders are still made from metal. The outlook for the international market is the same. There is a growing demand within the automotive sector for more environmentally friendly LPG engines as an alternative to petrol engines.

What made you choose Kautex as your turnkey supplier for the new facility?

Our long-term success has always been based on an absolute commitment to quality, which is why we always work with leading suppliers in each of our different product segments. So it made sense for us to work with Kautex Maschinenbau on our first project involving blow molding technology. We also knew that Kautex have been pioneers in the development of composite cylinders.

What do you think are the other key factors for success in the market?

Along with excellent quality, it is also vital to have highly efficient production processes based on the very latest in machine technology. With this new production line, we are pioneers in the manufacture of composite cylinders.

Is there anything you have learnt from this project that you would like to share with our customers?

When you venture into a new area of business, it is vital to work with a partner who has in-depth knowledge and substantial experience in every area, from design and commissioning through to product optimization and production start-up. It’s also essential to have constant access to experts in the field. In this respect, our partnership with Kautex has been a huge success.

Siepe GmbH has been producing and selling premium quality metal and plastic packaging for over 135 years. 280 employees at three factories in Germany produce a wide range of packaging in all shapes and sizes, including bottles, canisters, lidded containers and barrels. They are used for all kinds of bulk materials such as chemicals, paint, varnish, glue, cleaning materials, mineral oil, foodstuffs, cosmetics and pharmaceutical products. In autumn last year, the company opened its new, high-tech plastic packaging production facility next to its main factory in Kerpen. It is now manufacturing standard and customised consumer packaging for customers in Germany and abroad. As part of this expansion, the company also decided to invest in a state-of-the-art Kautex machine.

A new generation of machinery
When he is selecting suppliers, Josef Siepe, the CEO of this successful family-run company, is looking to establish long-term relationships and work with firms who take a responsible approach to the use of raw materials and resources. So it is hardly surprising that his company is one of the first customers to buy the all-electric Kautex KBB machine. Electric blow molding machinery is much more energy-efficient than hydraulic solutions, and the new lightweight clamp unit means energy consumption can now be reduced even further. The all-electric KBB machines are set up to handle single or multi-layer production and container volumes of between 50 and 5,000 ml. They also offer maximum flexibility in the number of cavities.

A smooth start-up
The KBB60D has now been operating at Siepe GmbH since autumn 2013. It has been configured to run 2 x 4 cavities with an output of 2,400 items per hour and is supplemented by a fully-automatic packing machine which bundles the products directly onto trays, cartons or palettes. Siepe GmbH is currently using the all-electric machine in the production of multi-coloured one-liter round bottles with handles and different neck sizes for household cleaners – at a rate of 57,000 pieces per day. It is planned to start production of 1.5 liter bottles in the near future.

Procter & Gamble, Avon, Amway, Unilever, Johnson & Johnson – SAP’s customer list reads like a Who’s Who of the consumer goods industry. From its three locations in Zhongshan, Tianjin and Suzhou, the company supplies the whole of China with high-quality packaging materials, making it one of the country’s leading manufacturers.

SAP was founded in 1999 in Zhongshan and production began in the summer of 2000. Since then, the company has experienced the kind of growth that is not an everyday occurrence, even in the booming Asian markets. This success is based on SAP’s comprehensive service package and its focus on always providing its customers with added value. The company is always there to help and advise the customer, from the initial design of the packaging and labels, through the manufacturing process, right up to the final delivery. It also provides a high degree of flexibility, fast reaction times and the unwavering desire to supply top-quality products.

Kautex supplies the cutting-edge technology that is essential to meet these demands. Since 2001, SAP has been relying on this market leader’s expertise
and engineering solutions. “We are not prepared to take any risks, so we made a conscious decision to turn to the global market leader in extrusion blow molding technology”, says Rondy Liao Deputy Technical Director SAP. “If we are to compete in today’s markets, it is essential for us to have a totally reliable partner with the highest quality standards on the production side. ”Now 26 Kautex machines are in operation in SAP factories. The multi-layered customer service package includes intensive training courses, ongoing process optimization and regular maintenance. “Kautex has helped us to build a highly-efficient production line in every respect, and in this way it has made a major contribution to SAP’s growth.”

This is why SAP is keen to continue working closely with Kautex in the years to come. It is planning to expand its business into the pharmaceutical area in the near future. But its main goal is to become China’s number 1 in the packaging industry in the course of the next 5-10 years, followed by expansion into the global market. Rondy Liao sees the greatest challenges in this respect as being the customers’ insatiable desire for new, innovative packaging solutions and the unrelenting price pressures: “We need to make more use of multi-layer processes and reduce energy consumption and run times. But with Kautex by our side we are optimistic that we will achieve our ambitious goals and continue to write the SAP success story.”

“Flexibility” is the key word when describing the reasons for AIP’s success. Since its foundation in 1978 in Fairfield, Iowa, the company has consistently worked to expand its customer base – which could hardly be more diverse. Whether it is fuel tanks, soundproof screens or shelf systems, AIP supplies customised solutions to meet every requirement and works closely with the customer from the initial design idea right through to the finished product. But this is not the only reason
why customers remain so loyal to the company. AIP is also the watchword for excellent quality, fast reaction times and on-time delivery. Over the years, the company has grown from a tiny four-man operation to one of North America’s leading manufacturers of extrusion blow molded components. It has relied on the expertise of Kautex right from the start and it continues to invest in technical innovation.

Mick Stielow, AIP’s Director of Sales and Marketing, comments: “Cutting-edge technology is essential if you want to survive in this business. As the world’s
leading supplier of extrusion blow molding machinery, Kautex helps us to be constantly pushing the boundaries in terms of flexibility, efficiency and quality.” 21 Kautex machines are currently operating at AIP. The trend is increasingly moving towards multi-layered production processes.

“Single-layer tanks have largely become obsolete, particularly for biofuels. It is now essential to have additional barrier layers in order to meet emission standards”, says Geoff Ward, Engineering Manager at AIP. At the same time, the company is countering growing price pressures by increasing automation levels in its production area and by reducing run times. Kautex Maschinenbau remains the supplier of choice in this area. “For us, Kautex is much more than just a
supplier of high-quality manufacturing solutions”, says Mick Stielow. “Instead, we think of the company as our strategic partner and we believe it has played a major part in AIP’s success.”

Clean water is a somewhat scarce commodity in China, whether for large-scale industrial usage or for supplying to people’s homes and public buildings. It is this latter area that is the main focus of Shanghai’s Canature Environmental Products Co., Ltd.

The company, which was founded in 2001, provides filter and water treatment solutions for apartments, office buildings, schools and private houses and so makes a significant contribution to supplying the Chinese population with clean drinking water. And its business is growing steadily, helped by public funding due to the fact that its work is classified as one of the governments “National Key Projects”

In 2011, Canature was the first Chinese manufacturer in this sector to be listed on the country’s stock market.

The company naturally has high expectations for the future. “We have enjoyed an annual growth rate of 30-40 percent over recent years and we obviously want to maintain this tempo”, says Qiao Huoming, Vice General Manager of the Production Department at Canature. The company is also keen to extend its range to include industrial solutions in order to fully exploit the market for water treatment systems. To achieve these ambitious goals, the company has enlisted the help of the experts at Kautex Maschinenbau. “We need to improve the efficiency of our production lines while reducing operating costs” explains Qiao Huoming, “So Kautex’s advanced technology and services make it the ideal partner for us.”

Currently, the first KBS61 machine is being installed and commissioned in Shanghai. But this is not the only reason that Qiao Huoming is feeling optimistic. “Canature’s success is built upon a constant quest for
perfection. Kautex is no different. So we look forward to continuing our fruitful exchange of ideas in order to keep improving our processes.”

„Cupac“ – with this innovative product, Con Plax New Pac set new industry standards and established its reputation only a year after the company was set up in 1961.
The futuristic-looking plastic container with its rounded corners has been a top sellers for many years and is even incorporated into the company‘s logo. But this is not the only reason why the family business from Zingonia in Italy can look back on an eventful past. At the beginning of the 1980s, the company became pioneers in the industry by starting to produce Intermediate Bulk Containers (IBC) by blow molding using Kautex equipment.

Until 1988, it even produced its own blow molding machines. However, as a result of ever-growing specialization on the part of its competitors and faced with increasing cost pressures, Con Plax New Pac decided to re-focus on its core business by producing canisters
and plastic containers for a wide range of different industries. Today, much of its production relies on Kautex equipment and between 2008 and 2012 alone, the company integrated five new Kautex machines into its existing production lines.

„If
we are to be leaders in our key markets, it is vital for us to ensure high availability, fast production, corresponding cost savings and the ability to change colors quickly“, explains Walter Bestetti, who runs the company with his two sons Filippo and Jacopo. „In this respect, Kautex is the best partner in the market.“ Added to this is the need for energy efficiency. Electricity is more expensive in Italy than in neighboring countries. „We’re currently planning to install a photovoltaic system that will allow us to reduce our energy consumption by around a third“, says Bestetti. 

„In this context, energy-efficient machines are absolutely vital. Here too, Kautex is in a league of its own.“ This is why the Italian company wants to maintain its close relationship with Kautex and in the future. The customer sums it up: „Kautex gives us a real sense of security thanks to its first-class machine technology and excellent customer service, and we want to continue having this guarantee of success. My visit to the new factory opening in Shunde strengthened this feeling of security still further.“

Seit 1988 produziert das US-amerikanische Unternehmen Fulcrum Incorporated aus Minneapolis erfolgreich extrusionsblasgeformte Behälter für Konsum- und Industrieverpackungen. Der Branchenführer im Bereich Plastikcontainer mit Volumina zwischen 1 und 10 Litern hat sich auf die Herstellung maßgeschneiderter Verpackungslösungen spezialisiert.

Increased product throughput and quality

Increased product throughput and qualityIn 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”.