At this year’s KUTENO from May 9 to 11, 2023, Haitian International Germany will present the electrical bestseller Zhafir Zeres series with certified medical pack.

“Cost reduction” and “resilience through flexibility” are currently important topics in the manufacturing industry. Requirements that are reliably met by the Zhafir Zeres series and help to justify its success in Europe and worldwide. “Efficient technology is very, very important in today’s economy, as is a high degree of flexibility in production. An electric Zeres with its integrated hydraulics naturally offers an excellent starting point,” says Niels Herz, Sales Manager Germany at Haitian International. ” When it then also brings other qualities to the table, such as the certified medical package, there are further advantages for the processor. Costs down, flexibility up, efficiency top! Technology to the point.”

In Rheda-Wiedenbrück, the Zeres can be experienced at the Haitian International Germany booth in Hall 5, K16. The sales team will be presenting the benefits of electric injection molding technology using the example of a ZE1200III with 120 tons clamping force, medical package and laminar flow box from Petek Reinraumtechnik.

Wide range of applications

The Zhafir Zeres series bridges the gap between electric and hydraulic machine technologies: identical in construction to the all-electric Venus series, it also features integrated servo hydraulics. This means that the main movements (clamping, injection) are electrically driven, while the lateral axes (nozzle movement, core pull, ejector) are servo-hydraulic. This offers plastics processors an unusually wide range of applications and increases production efficiency.

The Zhafir Zeres Series:

• Clamping force from 400 – 13,800 kN
• Application-oriented injection units up to 500 mm/s
• Integrated hydraulics for extended application versatility
• Customized servo drives by Haitian
• Intelligent mold protection
• Latest control technology

High flexibility

In addition to efficiency, flexibility is another important premise for Haitian International’s machine concepts. All series of the Haitian and Zhafir brands can already cover a wide range of parts with their standard equipment. In addition, industry-specific solutions and the integration of robotics and automation up to production cells or lines are available.

How the Dutch plastic injection molding company Smit Plastic BV has been swimming against the tide for many years and why it is still successful.

In business, it’s like real life: Between the turbines of the industries, the vast majority of businesses quietly turns their wheels. Inconspicuously and without any special features worth mentioning. At least it seems so. If you take a closer look behind the scenes, you will discover friendly people with heart and mind – and with the clear intention of reconciling profitability, sustainability and, above all, humanity. With a strong commitment and will to shape things in the interest of future generations. Smit Plastic BV in Tiel, the Netherlands, is such a company, a prime example in many respects.

The strategic location to the south of Utrecht, directly between the freeway junction and the canal port, gives an initial indication of what is important to the owner family: flexibility, independence, pragmatism. At first glance, the company headquarters itself suggests a “classic contract injection molder,” and indeed several million plastic parts have already been manufactured here. A huge “belly-shop” of more than 1,700 plastic products of the most diverse kinds. Technical parts, packaging, articles for the consumer goods sector – including the company’s own products and new ones still in development.

We are standing in the production hall with Mark de Krieger, he is the technical manager at Smit Plastic and also manages sales. His brother Marcel de Krieger is responsible for the commercial area. Both have taken over the family business from their father. But of course Gerard de Krieger, although officially retired, still assists his boys as a senior consultant. A man with his experience can still provide important impetus. And they all benefit from this, after all, new tasks, including challenges, are always being added. The machine park is correspondingly broad: 36 injection molding machines fill the room, with clamping forces ranging from 250 to 13,000 kN. The large Haitian machines immediately catch our eye – twelve in number, automated with robotics from Sepro.

As a matter of principle, they pursue a two-brand strategy, says De Krieger, if only to avoid being dependent on one supplier. The first Haitian arrived in 2006. “We had obtained a Haitian HTF, directly from China, on our own,” De Krieger smiles. “CE certification and robot adaptation were done at home in the Netherlands. We were able to do the service ourselves because the machine was quite simply built. But apart from that, the machine has run for 15 years without any major problems. We have invested just 1 valve and about 400 euros in labor in all these years. And the machine has been producing in 24/7 mode since 2010. New oil once a year – and that’s it.”

In 2-shift operation, they process all materials across the board, except PVC. Instead, they focus strongly on the area of bioplastics and develop packaging solutions for food & beverage in street vending (takeaway and to-go area).

Social responsibility on a broad basis

Currently, Smit Plastic BV employs about 90 people, almost half of them with handicap and no full-time employees. A fully-fledged inclusion company. The atmosphere is family-like, everyone gives their best. They’ve been doing this since 2007, says De Krieger, “out of free will, out of conviction.” They do not receive any financial support from the state for this. Nevertheless, the decision in favor of inclusion means a considerable amount of extra work, because these employees need additional support and assistance due to their disabilities. In Tiel, they are gladly given it, because “everyone has the right to develop their talents.”

We come to the current economic situation and the worrying price developments for gas and oil, for energy par excellence. While Haitian was chosen for its cost advantages and efficient consumption rates, electric machines have not been an issue. “We haven’t needed electrical performance so far. However, given the energy prices, we are in discussion with Mark Waterreus.” (Managing Director of Haitian Representation Netherlands). After all, contract moulders usually line up broadly, he says. If one industry gets into a slump, others can make up the dent. “But in times of energy crisis, it just hits everyone.” And then we’re on the subject of environmental policy, one of the central themes at Smit Plastic, “an integral part of the company’s policy.” Not as mere theory, but rather as lived practice – quite pragmatically. Without chemical cleaning agents. With waste reduction wherever possible. And of course, energy efficiency continues to be a big issue for them, “so energy-saving technologies are essential.”

When asked where he sees the company in five years, De Krieger says, “A year ago, I would have said we wanted to double it. But because of the crisis mood, I’ve become cautious.” He looks thoughtful for a moment, but then adds, “We bought another building next door that we want to fill.”

Read more: www.smitplastic.nl

Household products like these storage boxes are part of Smit Plastic’s crisis-proof core business.

One of the own products is a stackable flower pot

Ease of operation plays an important role in the purchase decision, along with the attractive price/performance ratio

Since 2006, a Haitian machine of the HTF Series has been producing without significant problems

Premium Sound Solutions – the name says it all. The company develops and manufactures high-quality audio boxes, speaker systems and innovative sound solutions for ultimate entertainment and safety on the road. For efficient manufacturing solutions, PSS pursues its very own strategy to optimize its value chains around the globe: the vertical integration of its own injection molding machines based on the Haitian Jupiter series.

Premium Sound Solutions (PSS) is a global leader with extensive expertise in the research, development and manufacture of innovative sound products for the automotive industry and end consumers.
The company employs approximately 3,000 people worldwide in product development and state-of-the-art manufacturing. Every year, around 80 million loudspeaker systems leave the company’s 7 locations worldwide, from Europe to North America and Asia.

The Esslingen site, with approx. 70 employees and sales of EUR 30 million, sets the pace in the future concert of PSS sites worldwide in the injection molding sector. While Belgium, Hungary, China, Malaysia and Mexico mainly manufacture loudspeakers, the focus in Germany is 100 percent on the automotive sector, specifically subwoofer boxes and pedestrian warning systems. These systems, which have been an integral part of the body design of e-mobility for some time, generate artificial driving sounds so that electric and hybrid vehicles can be perceived by pedestrians, cyclists and other road users in good time in road traffic.
For Pedestrian Warning Systems, PSS is a market leader in terms of unit sales, revenue and quality.

We chatted with Jens Maschkiwitz, Managing Director Germany and Team Leader Global Process Engineering at the PSS Group, and Ingo Fischer, mold and injection molding expert at PSS in Esslingen.

Felix Rudelt (right), sales representative at Haitian partner Färber-KT, inspects a sound system housing together with Jens Maschkiwitz (center) and Ingo Fischer (left) – straight off the production line of a Haitian Jupiter machine.

Mr. Maschkiwitz, Mr. Fischer, you have expanded the local production to include injection molding machines. How did this development come about?

Maschkiwitz: Our strength is our innovative power. We want to drive the market forward with innovations and consolidate our position through differentiation. In 2020, for example, we took on two new products in Esslingen, the subwoofer and the Pedestrian Warning System (PWS), sound systems in electric vehicles to better protect pedestrians. For these products, the vertical integration of injection molding machines simply made sense. Both products are now the focus of PSS in Esslingen.

And you run both products on Haitian machines.

Fischer: That’s right. We had been involved with injection molding technology for quite some time, so we already knew Haitian. For the Pedestrian Warning System, we set up a fully automated assembly line and inject the parts in-house, as an in-line process, to completely manufacture the PWS. The second new production is the subwoofer for the Tesla (Model Y) from Brandenburg. Here, the process also starts with injection molding and then leads to complete final assembly.

Pedestrian Warning System – that sounds quite novel?

Fischer: Yes, that’s right. We helped develop the products here in Esslingen and then also worked out the technical implementation. I dare say that we are already the market leader in terms of unit numbers and quality.

Maschkiwitz: Demand will certainly continue to rise, in line with the increase in the e-mobility trend. And quite independently of subsidies for e-cars from the government, we also see the electric trend developing strongly internationally. Even if the current situation is very uncertain, especially for e-mobility, because of the energy cost crisis. However, we see ourselves as relatively broad and well positioned, and we plan for the trend to continue to rise in the coming years.

And that’s where the choice fell on Haitian for injection molding machines. Why?

Maschkiwitz: Our goal is to consolidate the local site. The focus is on vertical integration and a “one-piece flow” with the goal of 100% automation.
We were convinced by a few key factors at Haitian. The global footprint, for example, the price-performance ratio, the availability worldwide, also the consistent specification. The machines are the same everywhere, and they have many languages in the HMI. A good sales and service contact. Mr. Fischer will have a more differentiated view of this, since he comes from an injection molding background.

Fischer: What I like about Haitian is their expertise. They have developed so many machines that the maturity level of the machines is already very high, also because a lot of feedback from the market flows in.
There is little to report on support, because the machines run smoothly. And operation is relatively simple. We received a short training course at the time, free of charge and good.

Subwoofer box for Tesla in 60-second cycle, with maximum shot weight at 0.35 kWh/kg

For the Pedestrian Warning System, the entire production line runs completely automated, except for material filling.

How are the production processes set up on the machines?

Fischer: Each machine runs a certain group of products, we then change the product daily. In terms of material, we mainly process PP with various additives, such as glass fiber.
We produce the subwoofer box for Tesla in a 60-second cycle, with maximum shot weight at 0.35 kWh/kg. For the Pedestrian Warning System, the entire production line runs completely automated, with the exception of material filling.

Maschkiwitz: We operate automation with “heart and mind”. That means we try to achieve 100 % depth of added value. But with a sense of proportion.

And if I have understood you correctly, you will also transfer this concept to other sites?

Maschkiwitz: That is indeed our intention. We still see great potential in the penetration of our value chain. The vertical integration of injection molding machines is only logical. As Mr. Fischer has already said, technical products such as sound boxes simply lend themselves to this.

What dimensions are you planning?

Maschkiwitz: We operate around 80 production lines worldwide, but of course this will take some time; we in Esslingen are the spearhead of global process engineering at PSS. Ultimately, there will probably be around 50 injection molding machines in operation worldwide. However, it remains to be seen whether these will all be Haitian machines. We are still in the early stages, currently working here in Esslingen with two large Jupiter machines, the third has already been ordered. The fourth machine is planned for the end of 2023, which would mean that the site would be exhausted for the time being. But here, too, we appreciate the advantages of Haitian International’s good global presence in the various markets, which is why we have currently classified Haitian as a “Preferred Supplier” – also due to its expertise and cost-effectiveness.

In the upcoming generation of machines, Haitian plans to integrate numerous “Smart Features” into its machines. What role does smart technology play at PSS?

Fischer: Audio boxes are basically relatively simple products, hardly any visible parts. The top priority is process stability. Our machines have to produce on a reliable basis, and they do.

Maschkiwitz: Sensibility is paramount, quite clearly. Our Haitian machines run stably, but we are of course curious about innovations, insofar as these are part of the standard scope of the machines.

How important is sustainability in the strategic planning of the PSS Group?

Maschkiwitz: All in all, sustainability starts with local production – local for local. This means that we also invest vertically in all locations in order to save logistics costs and not have to drive everything around the world. In this respect, we think along similar lines to Haitian International.

Fischer: Lightweight construction and saving resources are other topics. How do you manage to reduce large-volume sound boxes in terms of space and materials without compromising the sound? Of course, recyclability and the circular economy are also key topics. For example, how can alternatives be created for loudspeakers, which are often glued several times, in order to return the material to the cycle?

More information at www.premiumsoundsolutions.com

A customer visit to Emperor Mouldings B.V. in Alphen aan den Rijn, the Netherlands.

Brothers Maarten and Peter Keijzer, heads of Emperor Mouldings B.V., embody a new generation of injection molders: focused, efficient and relaxed – with a new understanding of work-life balance. In the Zhafir Zeres Series, they see the best prerequisites for making injection molding processes as efficient as possible and driving production automation forward.

Growing up in his parents’ injection molding business, Maarten Keijzer knew very early on that he wanted to run an injection molding company. The fact that his father then sold the business turned out to be a good decision in retrospect, as Maarten quite inevitably had to found and build up his own company. He took this step in 2019, initially alone, but since 2022 his brother Peter has been completely on board.

Both had precise ideas from the start: “No employees for as long as possible, but to bring production to the maximum, so far that we can still manage everything with just the two of us.” The main products are clips of agricultural use; the end customers are greenhouse operators. In addition to the agricultural industry, they still supply the commodity sector and technical parts. The bottom line is that they focus exclusively on small shot weights in high volumes. This is because highly efficient processes, “production-friendly” products and automation in places where it is worthwhile and serves the work-life balance are important to them. Maarten Keijzer: “I certainly experienced many things in my father’s company that I wanted to do differently. The principle ‘Only those who work hard will make it’ may have had its justification in those days. Today, we have other options. In the age of digitalization and its tools, it’s easier to design efficient and lean processes.” The recently introduced automated foiling of cartons is a good example of this, he said. “This robot saves us a lot of valuable time.” They are currently considering an AGV, which would then take the full cartons out of the magazines at night, increasing piece counts.

Passion for technology: Maarten (left) and Peter Keijzer with a Venus model made of Lego that they added robotics and peripherals to.

About meaningful growth and scalability

Since its founding in 2019, Emperor Mouldings B.V. has grown steadily, in output, turnover, set-up. “If the demand is there, it would make no sense not to grow,” the Keijzers agree. “But always with moderation and purpose.” Nevertheless, growth is not generally the big goal, they say; rather, they are concerned with the “sporting challenge” of spraying the maximum number of products with the existing machines and their 2-man power. “There is room for eight machines in our production. That’s still a size we can handle with two people. And should the market require more, we’ll see how far we can go with our manpower.”

Growth in this, their sense, presupposes that processes are optimized for maximum efficiency. That cycle times are reduced to the maximum and 24/6 non-stop operation runs smoothly to the maximum, with a clearly focused product group: simple small parts in large quantities.

Accordingly, they have aligned their machinery and supplemented it with pinpoint accuracy. The heart of production is currently formed by five electric Zeres machines with four times 900 and once 1,200 kN clamping force (another is on order). All run with integrated controls (Success Series 7 and 11) from Sepro Robotics. The molds are equipped with external hotrunner systems from PSG, and a specially programmed error-stop function intervenes if the temperature in the metering unit is too high. This also guarantees them near-zero error production at Emperor Mouldings. Original quote Maarten Keijzer: “We’ve had just 1 carton of rejects so far in 2022.”

“The electric Zeres fits very well with our philosophy: technology to the point for production to the point. The price-performance ratio is also unbeatable in our eyes. Our first 90-tonne Zeres has already gone through more than 6 million cycles without a significant malfunction.” Maarten Keijzer, Emperor Mouldings B.V.

Performance against rising energy costs

While the young company has come through the pandemic relatively well and relaxed, the energy crisis is having an even more serious impact on its core market, the Dutch agricultural industry. Rising energy prices are likely to bring many greenhouse owners to their knees, by next winter at the latest. “Our warehouse is full and the market is saturated for now. That means that of our machines, only two out of five are currently running. The reason for this is that the agricultural industry is suffering extremely from rising energy prices and many end customers have already announced that they are closing their greenhouses for the winter.” The two brothers nevertheless take the situation calmly: “A crisis is also always an opportunity. Up to now we’ve had full capacity utilization, now we’re using the quiet phase for new customer acquisition, internal projects that have fallen behind, or we’re happy to have more family time.”

Of course, rising energy costs are also making themselves felt in their own injection molding operations, but their stringent decision to use electric machines and the low shot weight of the small parts keep their energy consumption within limits. In any case, they optimize their injection molding processes for maximum energy savings to keep their carbon footprint as small as possible.

First certified industrial compostable clipring made of PLA’

Apart from that, they keep on working on continuous automation of production, keyword: increasing efficiency. “The electric machines are a tremendous help for us to produce in this high efficiency. Our father had hydraulic machines, he still had to ramp them up with some lead time and wait until the oil temperature was right, sort out some cycles of scrap and so on. We turn our Zeres family on Monday morning and don’t turn them off until Saturday night. Machines and the Success line from Sepro are an ideal match. From the first shot, production is error-free,” explains Maarten Keijzer.

In his opinion, another important building block for higher efficiency is material-optimized processes, in which he gained valuable experience in his previous job at a material supplier. “Our injection units are all equipped with a shut-off nozzle, so we can maximize parallel functions during energy-intensive plasticizing. Every second saved has an immediate impact on energy costs.”

In addition to all their commitment to energy savings and efficiency, they are equally consistent in working on their production-side sustainability. From starting with 100% virgin raw material at startup time, they are now at nearly 100% recycled and compostable material.

When asked about concrete visions or dreams for the near future, the answer is rather down-to-earth: “Two days away from the company, but everything continues to run” – that’s a good vision. But of course they are well aware of the challenges ahead and want to face them. And who knows, “maybe we’ll become the smallest smart factory in Europe.”

Info box

Production profile of Emperor Mouldings:

• All Zeres machines run smoothly in 24/6mode;
• All machines are equipped with automation;
• During the day, the machines are serviced and processes optimized if necessary; at night, they produce unmanned;
• Only small parts with a high number of pieces are produced.

Solution for Technology and Performance Enhancement: About the Successful Cooperation between Haitian and Dongfeng Nissan.

Dongfeng Nissan is a joint venture between Japanese automaker Nissan and China’s Dongfeng Motor Corporation, a leading group in the construction of trucks, buses and passenger cars, as well as in the manufacture of engines and automotive components. With annual sales figures of more than 1 million vehicles, Dongfeng Nissan is a major player in the automotive industry in the People’s Republic of China.

Since Haitian began intensive cooperation with this manufacturer in 2009, ten automatic production cells with injection molding machines of 33,000 kN clamping force each have already been installed at the Guangzhou, Xiangyang, Zhenzhou and Wuhan plants. The latest plant in Wuhan-Yunfeng plays a prominent role and poses great challenges to its business partners due to the highest standards and strictest specifications at Dongfeng Nissan.

Turnkey solution for the highest demands

To ensure smooth operations from the very be- ginning, Haitian established a special team specifically for the Yunfeng project, consisting of senior executives from the application, engineering, manufacturing, customer service, marketing and other departments. In joint efforts, they overcame all challenges and accomplished their task even in the most severe pandemic phase. Despite many difficulties, the project goal was achieved on time.

This unwavering commitment with the goal of successful delivery was highly recognized by Dongfeng Nissan. During the final summary and appreciation conference of the Wuhan-Yunfeng project in August 2022, Haitian was awarded the “Excellent Project Manager” and “Excellent Supplier” awards.

Haitian will continue to cooperate and develop with Dongfeng Nissan in a targeted manner in the future. Last but not least, to seize the strategic opportunity to accompany and promote the development of the domestic automotive industry through high-quality solutions with more precise machines, faster cycles and higher energy efficiency.

With the development from a means of transport to a symbol of prestige and status, the requirements in automotive engineering have changed fundamentally. Not only have the number and size of components increased, but more and more functionalities are calling for increasingly complex geometries, more material combinations, and more demanding properties. Energy efficiency benefits (or lightweight construction) and even greater driving pleasure are particularly high on the agenda.

Consequently, the quality and performance requirements for plastic injection molding have also increased significantly. Haitian has implemented a comprehensive customer solution for Dong- feng-Nissan: A Turnkey Solution that leads to technology and performance enhancement and serves the market needs to the point.