News

2017 – You will find us on following trade fairs:

2017_02_JEC_Paris_150x66

Date: March 14 th – 16 th, 2017
Location: Paris, France
Booth: M 54 (hall 5 a)
Website: www.jeccomposites.com

2017_03_SAMPE_USA_150x56

Date: May 22 nd – 25 th, 2017
Location: Seattle Washington
Website: www.sampeamerica.org

2017_04_CAMX_USA_150x46_Pixel

Date: September 11 st – 14 th, 2017
Location: Orlando Florida
Website: www.thecamx.org

2017_06_RubberExpo_USA_150x62

Date: October 09 th – 12 nd, 2017
Location: Cleveland, Ohio
Website: www.rubber.org

2017_07_HeatTreat_USA_150x18

Date: October 24 th – 26 th, 2017
Location: Columbus, Ohio
Website: www.asminternational.org

Rubber Expo in Cleveland, Ohio between October 09th -12th, 2017

2017_06_RubberExpo_USA_150x62

We would like to invite you to the Rubber Expo in Cleveland, Ohio between October 09th -12th, 2017.

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Automated production processes for molded rubber parts

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New elastomer compounds call for new technology

Elastomer compounds are becoming more sophisticated with more additives in order to satisfy end product properties. These new compounds are increasing base material cost while becoming increasing difficultly to process. These “high-end” elastomers can quickly push conventionally produced feed screws and cylinders to their performance limits. The reduction in performance comes from the degradation of materials by the feed screw. Wickert now employs feed screws that are extremely wear-resistant and that have service lives that, in some cases, are several hundred percent longer than conventional feed screws. Wickert’s ITM feed screw technology ensures that shear-sensitive compounds are not degraded in the screw feed section of the process. Shear heat, material residence time, and transfer velocity are all critical components to ITM processing. Wickert engineering has even determined finish of the screw is critical to the process. So we have the ability to recondition surface finishes on the ITM screw, which saves the substantial costs of investments for new screws. Wickert solutions provide technology to allow fine adjustment to eliminate processing issues while driving productivity and overall lower maintenance costs.

Injection Transfer Molding in the age of Industry 4.0

Injection Transfer Molding (ITM) has tangible advantages. Assuming parts are suitable, the ITM molding system offers an economic return on investment over other presses for compression molded parts and pure injection molding. Economies are driven by ITM which allows substantially more cavities in the mold plates than conventional injection molding. Selecting the right process controls for the filling unit, transfer pot, clamping, and demolding unit, provide swift material transferring, and vulcanization yielding better cycle times. The ITM procedure is very economical, particularly for systems with temperature regulated transfer pots. Additionally combining a vacuum chamber into this system virtually assures that you can increase quality and ascetics by avoiding flaws and burn marks.

Employing the proper automation solution solidifies the molding procedure including hardware, software systems that Wickert offers provide advantages in profitability and quality certification to your products. Manufacturing, quality assurance, and documentation of processes drive the automation requirements called for in Industry 4.0 by Wickert.

Vacuum, storage-pump combinations reduce mold cycle time

A standard injection molding system or configuration has vents but that does not guarantee a flash or burn free finished part. The ITM procedure is very economical particularly with tempered transfer pots, because there are no loss of materials from the transfer pots. Wickert’s system has combined the heated pot with the use of a vacuum chamber to eliminate entrapped air from the entire mold area. Burn marks and defects are things of the past. A storage-pump combination that is optimized with the latest PLC reduces evacuation time, which reduces cycle time to a level acceptable to the users. As a rule, this system optimizes the fill and overall cycle time to as much as half of a standard molding system.

Our filling unit is based on the established principle of first in – first out. The controller ensures that the transfer pot is filled only with the charge needed for the next shot. As a result, the material mixture residence time in the transfer pot is lower, eliminating hysteresis that degrade its properties. Innovative screw geometries allow optimal intake of the strip or cord. A feed guide system allows reliable feeding without tears in the material. Consistent input drives quality output.

System solution with intelligent automation components

The automation solution completes the finishing touches on the economics of the ITM system allowing for optimal processing. In a standard cycle a mold is driven into the automation system via the sliding table. The mold plates are fed onto the automation modules where first a hydraulic mold separator divides the mold plates. Plates then are actuated to the sides; on one side is a device to eject the articles and on the other is a brushing and/or spraying device. Completing a fully automatic system to that eliminates operator touch. If mold plates have to be rotated by 180° into a convenient ejection position or by 90° into a cleaning position, Wickert’s automation team consults with your process engineering team to provide custom solutions to increase profitability.

System networking (and animation) included

The WKP 5000 S, press system, demonstrated at the 2016 K and will be on the 2017 International Elastomer Expo in Cleveland, OH. This automation system presented the new generation of performance and system networking. External access to the system which includes real-time tracking of operator actions, material process, and cycle quality data as part of a new control concept. The Wickert Smart Factory concept allows secure plant users access to the complete factory via the Wickert Link. Alerts can be scheduled for preventative press maintenance during service intervals. As in the framework of “Industry 4.0”, Wickert provides total networking of multiple presses through the facility.

Wickert Service team embraces predictive maintenance and proactive service reports for preventive maintenance, driven via remote maintenance and system monitoring through Ethernet/Intranet/Internet. Wickert Link means central formulation management and backup of the formulation data in the Cloud. A Wickert system log includes the backup of the process and production data in the cloud. With process tracking in real-time, and component tracking and mobile data mirroring. Wickert Eco offers energy management monitoring for the entire system, energy use measurements, model calculation, and integrated system networking for factory efficiency.

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Seminar “Fixture and Hardening Presses in Operational Practice” on 11 and 12 May 2017

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This year the WICKERT “Fixture and Hardening Presses in Operational Practice” seminar was again presented for a second time at the beginning of May, due to the large interest from the first event, that took place in 2015.

This conference was presented on the edge of the Palatinate Forest. WICKERT gave all the visitors the opportunity to participate the seminar in this relaxed and peaceful setting.
The focus of this seminar was on press hardening. Presenting the new production technologies, including the innovations in this area, with lectures about the agricultural sector, metallurgical and structural aspects were further enhanced by the viewpoint of a furnace manufacturer.
The program was rounded out by introducing the attendees to new tool and machine concepts of press-hardening in reference to construction and wear parts.

Representatives from all areas of the heat treatment branch were among the participants and complementing, the lectures, it was also very interesting having an exchange of experiences in heat treatment by the attendees.

WICKERT Maschinenbau GmbH, founded in 1901 with headquarters in Landau in der Pfalz, Germany, manufactures hydraulic presses and fully automatic press systems for the press- and fixture hardening industry. Wickert also builds presses for hot working of wear parts and components in agricultural engineering. WICKERT covers a wide spectrum ranging from simple presses with manual loading through to fully automated systems. As well as fixture hardening presses, feeding systems, workpiece buffers, cleaning machines and blasting machines are also integrated into the fully automatic systems.

Supported by 160 employees, WICKERT manufactures presses up to a total pressure capacity of 110.000 kN. The primary market locations are Central Northern Europe and North America. WICKERT is a vertically integrated manufacturing center, from engineering department, which represents a quarter of the workforce, with integral machining of critical components, control cabinet construction, hydraulic system construction, to final assembly and machine certification for critical systems.

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Wickert Composite Press for TU Chemnitz: from 0 to 25.000 kN in one second

2017-04 TU Chemnitz

Production of structural lightweight components made of thermoplastic composite materials and hybrid plastic-metal materials for electromobility

Landau/Pfalz, February 13, 2017. A Wickert composite press, with a press force of 25,000 kN that builds up within one second, was purchased by the Institute for Lightweight Structures (IST) at the Mechanical Engineering Faculty of the Technical University of Chemnitz. Directed by Prof. Lothar Kroll, the faculty researches new processing technologies for thermoplastic composite material as well as hybrid materials made of fiber-plastics composite and metal. The objective is to develop mass production processes for manufacturing light-weight components for electromobility.

At this time, automotive structural components in particular are being produced on the WKP 25000 S type press. It was engineered for laboratory operation for a period of many years, making it is suitable not only for use in a wide variety of applications, but also as an automation solution. The fast build-up of the press force is an important prerequisite for its ability to process a variety of materials, for example for glass-mat-reinforced thermoplastics (GMT). This is because the mats, which are heated to 230 ºC in a preheating station, must be processed in the press immediately at a temperature of 190 ºC.

Fast press force build-up, high closing speed, high precision

The WKP 25000 S is a four-column type upper piston composite press with fully hydraulic closing system and active parallel control. It has a 1,500 x 2,000 mm clamping plate and is characterized by its highly dynamic opening and closing speed of 300 mm/s, a press speed of 10 mm/s and an opening force of 360 kN. The press is impressive not only due to its high speed, but also because of its high precision: Thanks to an active hydraulic parallel positioning, the configured deviation to the parallel position during the pressing process is a mere 0.05 mm.

Not only did TU Chemnitz require a fast pressure build-up, it particularly specified the build-up without press basement. Moreover, only minimal dynamic forces were to act upon the hall floor. In addition, the new press was to be accessible from three sides and be fully controllable from two sides. Due to their limited accessibility, frame presses were out of the question. Here as well, Wickert was able to score big with its four-column press that can be set up on a flat surface and is accessible from all sides.

Close-to-production development of structural automotive components

IST required a new composite press due to the size of the structural automotive components that had to be produced. “In the past, we had to have the prototypes manufactured elsewhere. However, for close-to-production development of components and for a successful collaboration with industrial partners, it is absolutely critical to be able to monitor and control all production processes of close-to-application 1:1 components”, explains Prof. Wolfgang Nendel, Deputy Director of the Lightweight Structures & Polymer Technology professorship.

All Wickert presses are custom designed

Wickert was awarded the contract after a European-wide tendering process. In addition to the composite press, the contract also included the integrated peripherals with preheating oven, plasticizer for manufacturing compounds plus four temperature conditioning units.
Just like all Wickert presses, the WKP 25000 S is also configured as a custom design. All machines are made specifically to order and consist of high-quality components based on a modular system made in Germany. This manufacturing process makes it possible to implement all of the TU Chemnitz requirements, despite the extremely short lead time. The researchers placed special value in keeping the applicability flexible with interfaces for an RTM injector, a PU unit and an injection unit as well as ensuring compliance with highest safety standards, even under laboratory conditions.

Institute for Lightweight Structures plays a leading role in research

The Institute for Lightweight Structures is an international leader in research with regard to lightweight plastic components. The top performer is represented at the first and only Federal Excellence Cluster of the German Research Association, a nationwide event held on the topic of lightweight construction, “Technology Fusion for Multi-functional Lightweight Structures – MERGE” and at “MERGE Europe”, the corresponding globalization concept. In addition, IST is a member of the European Alliance for Lightweight Construction and Prof. Kroll is in charge of the STEX project group at the Fraunhofer Institute for Machine Tools and Forming Technology IWU in Chemnitz.

Excellently positioned within the Federal Excellence Cluster with the Wickert press

Prof. Lothar Kroll, director of the professorship for Lightweight Structures & Polymer Technology is very happy with the composite press and the collaboration with Wickert. “In research, we depend on high precision and in allowing the press to have the greatest amount of latitude, which is why only very few machines were even considered. With the Wickert composite press, we are excellently positioned within the Federal Excellence Cluster.”

About Wickert Maschinenbau GmbH

Wickert Maschinenbau GmbH develops and manufactures hydraulic press and fully automatic press systems. All machines and equipment are modularly constructed, available with press forces between 20 and 100,000 kN and are each designed based on customer specifications. They are used to process elastomer, composites, polymers and powder materials, in the production of brake and clutch linings as well as grinding wheels, as fixture hardening units and in labs for research and science.
Partners and executive directors Hans-Joachim Wickert and Stefan Herzinger manage the family-operated company that was founded in 1901, which manufactures exclusively in Landau/Pfalz and supplies its customers from there to locations in Europe, the Americas and Asia. In 2016, its staff of 150 employees generated revenue of close to € 30 million.

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Promising JEC show in Paris

JEC 3

Wickert Hydraulic Presses looks back on a successful show in Paris. The JEC World exhibition is one of the major exhibitions worldwide for lightweight materials.
Good new contacts as well as interesting projects had been discussed within the 3 day show. The high frequency of international visitors ends up in an interesting and significant exhibition.

We would like to thank all the visitor on our booth for spending time with us.

For questions please contact Mr. Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Wickert Hydraulic Presses is assisting customers to move Out of Autoclave (OoA)

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WICKERT HYDRAULIC PRESSES (Landau, Germany) – A global manufacturer of custom Hydraulic presses and Systems for the molding industry, has developed a line of precision High-Temperature Vacuum Heating (HTVH) Presses.

Aerospace and Automotive suppliers are embracing this system who are looking to meet the next production ramp cycle, offer price reduction suggestions with manufacturing processes that can deliver faster throughput cycles while providing improved process quality. Since autoclaves continue to be expensive to operate, lacking in consistent A/B part surfaces, tighter thickness tolerances and are slow in cycle turn times. Wickert Hydraulic Presses has developed another solution beyond the standard.

The HTVH press vacuum, heating, and parallelism, controls are designed to offer our customers superior OoA results with faster turn times. Our current offering has maximum product dimensions that can be processed 1,100 mm x 1,100 mm. With a heat output of 2 x 50 kW, the maximum temperature of 425°C can be ramped very quickly from room temperature due to a focused heating area. Both heating plates are equipped with 6-zone temperature control designed specifically for this purpose, making it quick and easy to make material-specific adjustments. The control accuracy of the heating element zone monitoring system is +1.0°C. The wide variety of operating modes offers maximum flexibility: the contact heating press can be time- or temperature-controlled, which results in extremely high product reproducibility. The system can use shop air for lower cost.

A HTVH press with its wide variety of operating modes offers maximum flexibility. Wickert’s single press control allows programing of multiple variables that can be locked, which results in extremely high product reproducibility. All process data is logged, such as the target/actual temperatures of the heating plates, mold, product temperatures, ramp/hold times, and the entire pressure cycle.

This new system is applicable for producers of High-performance fiber composites (HPFC) , TS or TP, HPFCs (such as PPS, PEI or PEEK) or conductive polymers including structures, made from TP pre-impregnated uni-directional fiber-reinforced tape, or specialized plastic or elastomeric components where high processing temperatures and improved A/B surfaces are crucial regulating factors for reliable properties.

Wickert Hydraulic Presses operates a North American facility in Hebron Kentucky that is dedicated to engineering, field service and customer support. Wickert can assist customers in overall system planning, including capacity calculations, feasibility studies as well as detailed production layouts.

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

All process steps networked to save time

Forming and hardening in a single manufacturing chain

The manufacturing chain developed by Landau-based Wickert combine component forming and hardening in a single work process. Using controls to network all steps in a process not only allows comprehensive component tracking, but also provides continuous process data acquisition. Comparison of this data with target values is a given in these production lines. Fluctuations in the production process are quickly detected as a result, allowing the plant operator to make a rapid response.

Manufacturing chains of this type generally comprise a component feed with a component buffer, a high-temperature furnace, and forming presses with integrated quenching. Forming and hardening are followed by component batching and the output buffer. Depending on the plant operator’s requirements, a tempering furnace and a cooling section can also be integrated. The quenchant can consist of water, polymers or hardening oils.

During the combined forming and quenching process, a semi-finished metal sheet part is heated to around 950 °C in a furnace and placed in the forming press. Once forming is complete, it is then quenched in the forming tool in direct contact with the hardening agent. The forming tool is modified to allow this to happen.
This means that lower investment and reduced costs are required to manufacture wear parts for agricultural machinery in comparison with a conventional process, for example. In the standard process, the component is first formed and then, after a suitable time delay and in a separate step, placed and hardened in what is known as a quench press.

Hardening process assured

The combined process offers another advantage in the fact that components come into contact with the quenchant very swiftly, thus ensuring that quenching takes place within the designated temperature range. This usually prevents ferritic structures from forming – a particular great advantage for thin blanks between 2 and 4 mm thick.

Permanent monitoring of process data guarantees the required quality level for the plant operator, especially when producing safety-relevant components such as those for fast-rotating blades. The monitoring system in these Wickert combined production lines pays special attention to the handling time between the furnace and the forming tool until contact with the first hardening agent and also to the component temperature directly in the tool before forming.

The manufacturing chain proposed by Wickert comprises five individual processes:

  • The trimmed blanks are placed in a fully automatic handling system and fed into a heating unit, which heats the component to between about 900 °C and 950 °C.
  • As a general rule, the blanks are uniformly heated up in roller passage furnaces.
  • Forming takes place in presses with a pressing force between 1,600 kN and 8,000 kN using high-response proportional technology. The system includes hydraulic die cushions and component lifters.
  • The components are quenched with a liquid quenchant, which is channeled to the forming tool via the clamping plates with large cross sections.
  • The last step in the process is when the formed, hardened component is removed from the press. The component temperature is recorded during this stage of the process and monitored to ensure it remains within a selected tolerance range. The setting time is 1 ms (90 %).

Shorter hardening times by 50 % or above

The return grooves containing the quenchant are bounded into the clamping plates to ensure a guided return flow into the filtering systems. Full filtering ensures that the system remains almost completely free of scale.
The bounded return grooves allow a typical constriction of drainage, which creates an adjustable internal pressure within the forming or hardening tools. This internal pressure offers a decisive advantage for the plant operator: the Leidenfrost effect, which produces a vapor layer, is overcome more quickly than in a hardening quench thanks to the internal pressure in tools and the constricted flow. The cooling process changes over to what is known as the simmering stage earlier and the vapor layer dissipates. This is when the quenchant first comes into contact with the component, achieving a maximum cooling effect. The result is dramatically shortened process times. Hardening time can be halved – or even more than halved, depending on the component.

Good parts guaranteed

Process-relevant data for all work steps can come together in a process engineering diagnosis and archiving system in Wickert LOG. Derived over the entire process, this information helps to optimize the system and detect any deviations in individual manufacturing parameters in good time. Components which have experienced deviating parameters can be discharged for inspection before they are returned among good parts.

The intelligent process sequence ensures that these combined forming and hardening production lines can deliver optimum product quality and time savings in the manufacturing process. They not only increase cost efficiency in the manufacture of highly precise components, but also provide traceability for quality-relevant parameters.

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Production line layout

For further question please contact Marc Jordan, Email: m.jordan@wickert-presstech.de

2500 tons in ≤ 1 sec for research and developments of new materials and processes

Wickert was able to install a WKP 25 000 S press with a maximum pressure build up to 2500 tons in ≤ 1 sec at the Technology University in Chemnitz.
The press with a platen size of 1 500 x 2 000 mm includes an active plan parallelism control as well as a wide variety of additional options for the
R & D environment. In order to illustrate the precision of the installation of such at technic Wickert had been able to prepare a detailed video of the installation.
See yourself:

2500 tons in ≤ 1 sec for research and developments of new materials and processes

For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

K 2016 a great success!

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8 days of interesting discussion and good meetings are over. The K 2016 show in Düsseldorf was a full success for Wickert. The main topics we transferred on the show, “Industrie 4.0” as well as “Wickert Turnkey press system” attracted approximate 30 % more visitors to our booth in comparison to the show in 2013.

In a pleasant environment, quiet often also with the glass of wine, we had be able to discuss good projects together with our visitors out of more than 20 different countries.

Again the Wickert show team would like to thank everybody, which visited our booth and spent time with us!

Development press for lightweight technology delivered to Japan

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Wickert Hydraulic Presses was able to successfully deliver the WKP 4700 S Composite press to the development center of Kurimoto LTD. in Japan. Kurimoto just recently held the opening ceremony at their facility in Japan. The Wickert press WKP 4700 S is optimized for the development and research on new materials as well as processes for lightweight design specially in the automotive industry. Traditional high-precision-compression as well as high pressure RTM processes can be realized on this press. In order to preform tests during LFTD moulding in a vacuum atmosphere the press is equipped with a Wickert vacuum chamber including a 700 mm over all stroke.

Installation and commissioning of the Wickert WKP 100000 S

The time lap video sequence on the installation and commissioning of the WICKERT WKP 100000 S with a total heating platen size of 3.500 x 3.500 mm and a total pressing force of 100.000 kN makes it clear, that it is absolutely necessary to install also large single press units with a total weight of over 50 tons very precise during such an assembly. After the final commissioning and start up Wickert was able to prove the specific parallelism with full load lower than 0,1 mm/m for this large elastomer press.
For further question please contact Thomas Klimpl, Email: t.klimpl@wickert-presstech.de

Large scale Composite Press left the factory in Landau

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Successfully we run of a Composite Press with a platen dimension of 3.500 x 3.500 mm. Based on the specific accuracy of the press including the necessary options, Wickert decides to design this press with a single piece welding concept. According to this design a transport into the building trought the facility door was not possible anymore. The installation into the building for run of and test of the overall machine took place via the open sealing of the building. The decision to fully run of the machine in Landau was made based on the new process developments for the customer. After disassembling a total of 7 special transports carried the press to closest harbor.
To ensure the 100 % process reliability and quality this decision was throwing for.

New support for Wickert Sales in the States

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As a result of the growing Wickert business in North America we recently hired a new DIRECTOR OF NORTH AMERICAN WICKERT SALES. His name is Mr. Randy Schuster.

Mr. Schuster has a diverse and impressive background in corporate management, capital equipment sales and new market development. Randy previously worked at Flow Aerospace that produced CNC waterjet machines uses in composites. Mr. Schuster served as the CEO of LAP Laser of German based laser equipment company. He also spent over 20 years at Parkway Products a composites, plastics, rubber and other exotic materials molder.

His experience is a great fit for us. 2014 was a big year for Wickert USA.
2015 will also be a big year for Wickert in North America.

Wickert is a Hidden Champion in Germany – one of the World Market Leaders

The family-run company from Landau in the Palatinate region manufactures hydraulic presses, press systems and fully automated systems for moulding processes. It is a global market leader in the production of elastomer presses for individual production and a leading manufacturer of vacuum compression presses. WICKERT places great emphasis on optimisation and problem solving, which explains why the innovations from WICKERT have won numerous awards.

With approximately 2,000 hectares of cultivated vineyards, Landau is one of the largest wine-growing regions in Germany. It is therefore no coincidence that Landau-based Wickert Maschinenbau GmbH, today the world market leader for elastomer presses, was originally involved in wine. The company’s success story began on 4 May 1901 when the artistic master fitter Jakob Wickert founded the machinery factory J. WICKERT. Together with eight journeymen and five apprentices, he began building presses for wine and fruit growing. The first products were spindle and down-stroke wine presses – manufactured with state-of-the-art hydraulic pressing mechanisms.

But Jakob Wickert soon thought about how his first experience in press construction could be applied to other fields, and in 1939, he began developing large drainage presses for cotton. Meanwhile, the founder’s two sons had also joined the company and, in 1948, the seminal decision was made to develop presses for the rubber and plastics processing industry. Since then, the ideas of Wickert Maschinenbau GmbH have continually enhanced press technical manufacturing processes. Today the company produces between 80 and 120 presses each year for various industrial applications – 80% of them are exported.

WICKERT presses are at home all over the world. Whether in Europe, the USA or Canada, wherever rubber and thermosets or thermoplastics are processed, where brake, friction and clutch linings are manufactured, presses from the Palatinate region are in operation.

Throughout its almost 115-year history, WICKERT has continually provided its customers quality- and productivity-enhancing machinery, equipment and processes with a whole range of innovative developments. The processes developed in Landau, for instance, shorten cycle times significantly, thereby making the parts suppliers competitive. Even if the layman does not realise it, things made on WICKERT machines accompany his daily life: Presses for cleanroom applications produce, for example, sealing plugs for pharmaceutical products. Fabric-reinforced brake linings for trucks are produced on vulcanisation presses from the Palatinate. Brake and clutch linings as well as gaskets produced on automatic presses provide reliable service in all kinds of vehicles. With dryers and Duroline presses, thermoset moulded parts such as toilet seats, light switch and socket covers are manufactured with high surface quality. Handrails for escalators and banisters, expansion joints and sealing profiles for tunnel segments, dam and power plant construction – the machines from Landau are used in many areas of application.

Over the years, WICKERT has evolved into a development partner, e.g. when it comes to micro technology in plastics processing or specific things such as membranes for fuel cells. This also applies to automatic presses for materials in powder form. Today more than 150 employees of the family-run company design and manufacture hydraulic presses, press systems and fully automated systems for the global market. A 2,000 m² extension (2008) and an enlargement of the outer area in the form of a logistics access road (2014) also document the company’s growth externally.

The recipe for success is as simple as it is effective: WICKERT focuses on niche markets and is systematically geared to the needs of its customers. “Searching for the problems of others” has always been the company’s guiding principle. After all, problems fill the order books. “We try to uncover the optimisation potential of existing products and offer corresponding solutions,” says Dipl.-Ing. Hans-Joachim Wickert, who now runs the company together with Dipl.-Ing. Stefan Herzinger in the 3rd generation. The importance of problem and solution appears in a single company figure: More than a quarter of the employees work in research and development. The annual expenditure in this area amounts to some 8 per cent of total revenues. Wickert Maschinenbau GmbH has already received several awards for its pursuit of high-quality products, faster responsiveness and maximum helpfulness. For instance, the Investment and Development Bank (ISB) Rhineland-Palatinate has honoured the Landau-based company four times since 1999 as a particularly successful and innovative company. Wickert has also received the Innovation Award Rhineland-Palatinate six times. Most recently in 2013 for its idea, the “Lab on a Chip”. This is a process by which biochemical analyses are possible in the smallest space – on a chip, which is between a square millimetre and a few square centimetres in size. Thanks to the system developed by WICKERT, it was possible to reduce the production costs for the capped “Lab on a Chip” by more than 90 percent compared to the previous production process.

WICKERT also has big plans for the future: As a market-driven global company, it is not only focused on strengthening its market position, but also on value-driven growth. This is to be achieved primarily through the development of new markets, through successful innovations and active portfolio management. At the same time, a stronger market and customer orientation as well as the targeted expansion of its international presence are essential milestones on the way to this goal. Wickert is already looking forward to the new challenges. Because one thing is true for the next 115 years: A long tradition can only be beneficial for finding reliable and economical solutions to produce plastic and rubber parts. Thus not only does the truth lie in wine, but in the case of Wickert also the beginning of a unique success story.

Source: Deutsche Standards, edited by Florian Langenscheidt and Bernd Venohr
The Best of German Mittelstand

Review on DKT 2015

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Successful and high frequented would be a good summary for the DKT 2015 in Nürnberg for WICKERT. Not only new contacts also existing customers grab the opportunity to have a discussion on new projects and new developments. The amount of visitors was quiet successful and a certain trend on international companies could be recognise.

The WICKERT team is happy to work on several new discussed projects and would like to thank all visitors, which took the time during the exhibition to discuss with us.

For more information on the show please contact Mr. Thomas Klimpl.
Email: t.klimpl@wickert-presstech.de

Specialist seminar “Fixture- and press hardening in practice”

on May 7 – 8 th 2015

Bild zu Pressebericht Wickert Fachseminar

The heat treating of steel continues to play an increasingly important role in the automotive industry, machinery and plant construction and tool construction – especially since it allows superior performance at lower weights. The area of fixture- and press hardening has evolved in recent years and decades, receiving particular attention in the industry.

It was therefore almost to be expected that the specialist seminar organised by Wickert Maschinenbau GmbH in cooperation with IBW Dr. Irretier GmbH in Landau on 7 and 8 May “Fixture- and press hardening” was met with great interest, attracting visitors from the field. Over 30 experts from Daimler, Magna, SKF or ZF, for example – from Germany and Austria – took the opportunity to learn about process and plant technology in fixture- and press hardening in practice-orientated lectures. The opportunities and advantages offered by this process in particular in terms of dimension- and shape stability of the components were the subject of lively discussion among participants.

WICKERT Maschinenbau GmbH, founded in 1901 with headquarters in Landau in der Pfalz, Germany, manufactures hydraulic presses and fully automatic press systems for the press- and fixture hardening industry. Wickert also builds presses for hot working of wear parts and components in agricultural engineering. WICKERT covers a wide spectrum ranging from simple presses with manual loading through to fully automated systems. As well as fixture hardening presses, feeding systems, workpiece buffers, cleaning machines and blasting machines are also integrated into the fully automatic systems.

Supported by 150 employees, WICKERT manufactures presses up to a total pressure capacity of 100,000 kN. The primary markets are in Central and Northern Europe, USA and Canada. WICKERT has everything you need in one place; in addition to an engineering department, which represents a quarter of the workforce, there are also divisions for mechanical processing, control cabinet construction, hydraulic power packs construction and final assembly.

If you are interested, WICKERT Maschinenbau GmbH will be happy to send you the seminar documentation.

Get in touch via: k.theobald@wickert-presstech.de

NPE 2015 Show Review

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The NPE Trade show was held March 23 – 27 th in Orlando, Florida. Over 60,000 industry professionals convened in the Orange County Convention Center for a weeklong showcase of plastic and technical innovations.

DESMA USA and WICKERT took the opportunity to showcase their new booth design. Modern, eye-catching and functional the booth held multiple meeting areas that were put to beneficial use for customers engagements.

Remarks on New European Standard 289

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Hans-Joachim Wickert CEO of Wickert Maschinenbau GmbH
Charimain of the Working Commitee on Presses Rubber and Plastic
Machinery Division of the German Engineering Association (VDMA)

The safety and well-being of employees is of major importance to all industrial enterprises and takes top priority. This necessitates the creation of effective safety regulations.
These safety regulations must be practice-oriented and must contain clear definitions that leave as little room for interpretation as possible.

All those involved – operators, manufacturers and supervisory bodies – should be provided with a uniform understanding of how to implement the guideline.

In the new press standard an attempt is made to specify previously disputed or unclear definitions and, furthermore, to adapt the standard to contemporary technological conventions. With advances in development, new elements are continually being used in compression and transfer moulding presses, so Standard EN289 is intended to evaluate and safeguard these new elements.
To cite an example of this, the magnetic potential difference in compression and transfer moulding presses has been re-addressed. A further point was access control for machines with safety guards. This was brought into alignment with standard EN201 in order to create homogeneous safety requirements together with similar machines, in this case injection moulding machines.

All participating parties who collaborated on the revision of Press Standard EN289 in the committee hope that the new press standard will provide users with greater clarity and that newly developed elements can be safely employed.

Special solution with double injection unit

Presse_DLR

Horizontal injection molding machine for abrasive media

WICKERT Maschinenbau, Landau, world market leader in elastomer presses, has developed a horizontal injection molding machine for large-volume plastic moldings. In use by FRIATEC AG, Division Rheinhütte Pumpen in Rennerod, this machine processes polypropylene (PP) and polyvinylidine fluoride (PVDF) with significantly greater economic efficiency.

The WPM 10000 S injection molding machine can produce impellers, volutes, housing covers and circular parts for chemical applications. There are no standard ‘off-the-peg’ machines available which are capable of processing media such as very abrasive PVDF in injection volumes of more than 24 liters (24,000 cm³). To meet the challenge of enabling this, WICKERT has designed and built a horizontal injection molding machine with a locking force of 10,000 kN. The working area measures 1,200 x 1,200 mm and plate distance and stroke is 1,500 mm. The system contains a double injection unit to enable two different media to be processed. The press has two autonomous injection units, the positions of which can be adjusted by sliding. The capacity of each unit is 24 liters.

The reduced need for cleaning is not the only advantage of this design. Dipl. Ing. Achim Görres, Production Manager at Division Rheinhütte Pumpen, notes that “The double injection unit removes the need for cleaning when the media are changed. This gives us a significant cost advantage because, with some granulates costing up to € 40 / kg, there are no media losses. We also save time because the second medium can be pre-warmed, a process which can last up to 4 hours, while we are using the first medium.”

The media themselves are particularly resistant to aggressive acids and substances. PP can be processed at temperatures of up 200 °C and PVDF at up to 360 °C. At these processing temperatures, aggressive acids are released by the media in the sealed machine. This shows that the injection molding process places great strains on the quality and surface properties of the injection unit. To be certain that the necessary media can be processed, WICKERT has designed the injection units to withstand 400 °C. The design also provides protection against wear for parts in contact with media in their plastic states.

The previous machine always needed to be cleaned each time the medium was changed. It had only one injection unit, and at approx. 16 l, the extruder had a lower capacity than today’s 24 l capacity. Producing pump parts in low-number production runs required removal of the screw for cleaning at each change of medium – a process taking some 5 to 6 hours. A second injection unit makes the production of small batch sizes a much more economic proposition.

As regards pressure, temperature and time control and regulation, the machine uses cutting edge technology and features all the necessary quality assurance information. The system also features the standard injection molding and ejector options, connection to tempering units for tools, etc.

Achim Görres regarded production flexibility and media savings as particularly important. Providing customers with short turnaround times for their orders ranks above productivity gains. WICKERT solutions enable both. Given the many years of positive experience as regards service, availability and durability of the smaller presses in operation in the factory, it was an obvious move to contact WICKERT and ask for the type of solution which otherwise was not available on the market. Manufacturers of standard production-line models had no solution to offer. Ultimately, the decisive factor was the convincing design of the new (special) machine. Moreover, it took only 6 weeks to get from the initial idea to the basic concept, which then led to discussion of details and eventually to production. WICKERT Marketing Manager Thomas Klimpl says with pride, “The WPM 10000 S once again demonstrates our company’s performance level as regards special solutions for all types of presses.”

WICKERT introduces itself as a potential employer

WICKERT constantly put proactive efforts in the recruitment of well trained potential trainees, skilled employees and managers. Far beyond the regular job advertisement WICKERT tries to be one step ahead in contacting potential employees. To get a first feeling on the daily business of the company and the interesting industry WICKERT work with and cooperate with the new recruiting video has the launched lately.

Curious? Have a look!

<p”>For more information please do not hesitate to contact us anytime. We would be happy to get your message:

karriere@wickert-presstech.de

Jubilee press produces energy-saving high tech couplings 1000. WICKERT vacuum-chamber press from the world market leader for elastomer presses

Drive specialists want the lightest possible connecting and coupling components, and an allnew coupling represents an outstanding example in this context. The elastomer coupling features a composite membrane on both sides, which forms the mechanical interface to the drive train in place of the otherwise customary steel discs. Thanks to a weight reduction of up to 50%, this results in a highly responsive coupling with torsional elasticity, high damping and minimal maintenance. For the production of these high-tech couplings, WICKERT delivered the 1000th vacuum-chamber press built in Landau (Pfalz), a WKP 12.500 S in four-column construction delivering a press force of 12.500 kN and round heating plates. These heating plates are adapted to the geometry of the products and lead to energy savings of up to 30% compared with rectangular heating plates. Consequently, the 1000th WICKERT vacuumchamber press also marks the beginning of a new generation of especially energy-efficient machines. The optimized thermo-oil heating with a thermo-oil tempering device per heating plate allows savings on heating energy of around 15 – 20 %. This includes a contribution from the heating plate which matches the geometry of the tooling. As the part of the surface which is not directly used in production has been reduced to a minimum, less heat energy is needed.

WICKERT composite press for Airbus A 350
Weight-saving carbon-fiber aircraft doors in RTM and L shapes in thermoforming process

The highly resilient (carbon) fiber composite component is manufactured at Eurocopter in Donauwörth by the Resin Transfer Molding (RTM) process. This process allows the production of structural components with relatively high volumetric fiber content and good impact qualities, while ensuring low weight at the same time.

The case considered involves the application of the injection process with the use of the WICKERT WKP 2500 S composite press. The WKP 2500 S composite press is based on the proven modular system of the WICKERT downstroke presses. Since exposure of the carbon parts to even the slightest hint of oil mist has to be rigorously excluded, the complete absence of oil leakage by the hydraulic press system was an essential requirement. This was achieved by the complete enclosure of the press area, as well as all the press technology peripherals including hydraulic plant and electrical systems. The press, with a closing pressure of 2.500 kN, has an upper and lower form installed for each job. The mounting plates measure 2.400 x 1.800 mm. The controller and process visualization integrates the injector, the heating/cooling system and the press shuttle. The latter performs the fully automatic loading of the raw work piece brought from the high-bay warehouse, as well as the return transport after the process. The cycle time per aircraft door is about 6 h.

WICKERT built a press cell for L-shapes especially for the aircraft components industry. These Lshapes serve as reinforcements for the Airbus A 350 XWB fuselage. While the aircraft doors are manufactured from highly resilient (carbon) fiber composite components in the Resin Transfer Molding (RTM) process, the L-shapes are produced with the thermoforming process. With its working area of 660 x 370 mm and a press force of 600 kN, the column upstroke press for the L-shapes is significantly smaller than the “aircraft door press”. On the WKP 600 S, L-shapes are formed from various matrix materials such as PPS or PEEK with carbon fibers. In order to be able to process the PEEK material, the machine is equipped with an infrared preheating oven, which heats the carbon laminate to a precisely regulated temperature of up to 425 °C to cool in the press to 250 °C. The required temperature accuracy in the infrared preheating oven is + 5 °C at 425 °C.

The reinforcement angle follows the cylindrical geometry of the fuselage, which is why there are only a few identical components per aircraft. In total about 4,500 of these reinforcements are built into each Airbus A 350. This means that more, and in particular faster tooling changes have to take place. Simultaneously with the pressing process, two form preheating ovens bring two tool pairs up to the processing temperature of 300 °C. The transfer of the heated material up to the closing of the press and the buildup of pressure takes less than 5 seconds.

The very comprehensive data recording program necessary for application in the aerospace industry presented a challenging hurdle in the overall concept. Every part demands detailed documentation of the production process including the traceability of all processing steps. Consequently, each L-shape is labeled directly on the press after production, for example. A barcode printer produces a label which is adhered to the particular component and which makes the part-specific process data permanently available directly on the component.