Kraussmaffei's 45 Years of Expertise Processing Polyurethane

Kraussmaffei's 45 Years of Expertise Processing Polyurethane

Press Release

KraussMaffei's 45 years of expertise processing polyurethane

Forerunner in high-pressure polyurethane processing in plastics production

(Munich, May 18, 2012) For more than 45 years now, KraussMaffei has been active in the area of processing polyurethane and has been building premium quality machines and systems for this purpose. The company has led the way along many paths to strengthen its position as the leading technological provider of machines, systems and procedures for reaction process machinery in core markets and to expand activity intensively in growth fields.

Starting machine production at record speed

The kickoff for processing polyurethane (PUR) at KraussMaffei took place in 1967. The company was active on the market as a machine supplier just one year later. "KraussMaffei is a forerunner for using this material in plastics production. Thanks to years of experience, an up-to-date, premium-quality machine portfolio and a large store of technology and procedure expertise, we've developed into a worldwide market leader," explains Nicolas Beyl, the Reaction Process Machinery Division Head at KraussMaffei since February 2012. KraussMaffei focused on high-pressure processing of PUR from the beginning. In close cooperation with raw material manufacturers and processors, new fields of application, machines and methods are still being developed constantly to this day.

Offering customers new and innovative solutions

"We want to strengthen our activity in the area of reaction process machinery globally and to demonstrate additional application and efficiency potential for our customers along their entire value chain. In particular, we want to draw them to us using combinations of machines and methods for injection molding and reaction process machinery and by using new technologies," explains Beyl. These strengths recently received positive feedback at the NPE 2012 trade show in Orlando (USA). The manufacture of an armrest using the SkinForm process was shown. In one machine, the injection-molded carrier was flow-coated with a foamed aliphatic type of polyurethane with pleasant surface characteristics and outstanding UV resistance. "KraussMaffei's extensive Technology3 expertise across the entire process chain was apparent at this machine. The machines, automation, mold technology, and custom solutions were all from our company and unified our expertise," explains Beyl. Furthermore, the company wants to advance new innovative solutions in growth fields, including the areas of lightweight construction and fiber composite technology. "In recent years we have been able to win numerous orders in these areas worldwide. We also have a worldwide one-of-a-kind expertise center in this area, the fiber composite technology TechCenter we opened in Munich in 2011," says Beyl.

Pioneering lightweight construction solution for trains distinguished

Thirteen companies were honored with a JEC Europe Innovation Award this year as part of the JEC trade show. The development consortium headed by the Fraunhofer ICT was able to distinguish itself among the companies. The SCS process (structural component spraying) premiered in the category of production processes. It is a manufacturing process for lightweight structures based on sandwich structures and spray processes for glass-fiber reinforced polyurethane resins. In addition to KraussMaffei, partners Bombardier, Fraunhofer ICT, Bayer MaterialScience DEC, the DLR Institute of Vehicle Concepts, the University of Stuttgart (IFB) and the Institute for Technology in Karlsruhe (wbk) were responsible for the manufacturing process and were distinguished for extensive developments along the entire value chain. Sandwich core materials, cover layer materials, manufacturing processes, fire protection systems, design principles and calculation methods were developed for this sandwich structure demonstration component with a length of 4.5 m and a width of 2.5 m. The innovative design with identical interfaces using glass-fiber reinforced polyurethane sandwich structures makes it possible to reduce the weight of the safety enclosure while simultaneously reducing the number of components. Despite this, all of the requirements of the requirements specifications are met, such as dielectric strength.

Personal details

Nicolas Beyl has been working for KraussMaffei since 2006. After spending three years as Director Corporate Strategy in the KraussMaffei Group, he took up the post of Director Technology in the Injection Molding Machinery Business Unit in 2009. The graduate in production engineering previously worked for nine years as a management consultant at the Boston Consulting Group. The focal points of his consulting work were the mechanical engineering and automotive industries. Beyl also gained a Master's Degree in Business Administration at INSEAD during this period.

An overview of KraussMaffei's performance and innovative strengths in the area of processing polyurethane:

  • First developments and trials for manufacturing polyurethane furniture
  • 1968First special clamping unit with two rotating axes, called "moon-swing"
  • 1970Presentation of the first KraussMaffei mixing head in successful production use
  • 1972First self-cleaning mixing head in the world with a recirculation groove
  • 1973Export of the first PUR bumper system for an automotive industry customer in the USA
  • 1974Delivery of the 100th PUR metering machine
  • 1981Delivery of the 2000th mixing head
  • 1982First transfer mixing head in the world and first twin-piston metering machine
  • 1984First dual-hardness soft foam system
  • 1985The 4000th mixing head of the families, which included 18 types at that time, is delivered
  • 1985Delivery of the 50 KK machine with metering outputs of up to 8000 cm³ per second
  • 1989Largest piston metering machine in the world with up to 16,000 g/s
  • 1991Development of the PUR recycling process; introduction of continuous gas charging
  • 1992The in-mold coating process for an undercoat in a foam mold is presented at the K trade show
  • 1993Systems for CFC-free foams
  • 1994Series system for carpet back-foaming
  • 1995Initial presentation of the LFI PUR process unit at K
  • 1996Start of lightweight design activities, first system for GRP components
  • 1999LFI production system for the smart roof
  • 2002Founding of the "white goods" expertise center in Abbiate Grasso, Italy
  • 2005First skin spray head in production use
  • 2004The SkinForm method is presented at K for the first time
  • 2005Start of mold-building activities for PUR, milling and custom solutions
  • 2006Development and presentation of the first small-quantity, high-pressure mixing head
  • 2007Large-scale SkinForm system for manufacturing interior door panel sections at K
  • 2010Presentation of the ColorForm process at K
  • 2011Opening of the world's largest TechCenter for fiber composite technology (lightweight construction) in Munich; complete HP-RTM system for manufacturing CFRP components
  • 201245 years of KraussMaffei reaction process machinery; first live demonstration of PUR processing at NPE in the USA

Enclosure: Pictures and more information can be found at

Press contact:

Markus Betsche

Press Officer KraussMaffei brand

Injection Molding Machinery and Reaction Process Machinery

Phone:+49 (0) 89 8899 4712


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About KraussMaffei

The KraussMaffei product brand is internationally recognized for its groundbreaking, multitechnology system and process solutions for injection and reaction molding technology and factory automation. With its standalone, modular or standardized machinery and systems, and a wide, customizable service offering, KraussMaffei is a full-system partner for customers in many industry sectors. KraussMaffei bundles many decades of engineering expertise in plastics machinery and is headquartered in Munich, Germany.

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About KraussMaffei Group

The KraussMaffei Group is among the world’s leading suppliers of machinery and systems for producing and processing plastics and rubber. Its products and services cover the whole spectrum of injection and reaction molding and extrusion technology, giving the company a unique position in the industry. The KraussMaffei Group is innovation-powered, supplying its products, processes and services as standard or custom solutions which deliver sustained added value along the customer’s value-adding chain. The company markets it’s offering under the KraussMaffei, KraussMaffei Berstorff and Netstal brands to customers in the automotive, packaging, medical, construction, electrical, electronics and home appliance industries. Continuing a long tradition of engineering excellence, the international KraussMaffei Group currently employs around 4,000 people. With a global network of more than 30 subsidiaries and more than 10 production plants, supported by around 570 sales and service partners, the company is close to customers around the world. KraussMaffei has been headquartered in Munich since 1838.

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