Kiefel – Higher quality and lower costs

21 Dec 2017

New FLF vacuum laminating process from Kiefel with the potential to save millions

What would the interior of a vehicle be without visually appealing surfaces on the doors, center console and dashboard? The higher the vehicle class, the higher the quality of the interior trim. Structured surfaces, a pleasant feel and everything manufactured at a high production quality are demands that the industry takes for granted. At the same time, the cost pressure for interiors continues to increase. A redesigned Kiefel vacuum-lamination process is the answer to these challenges.

 

Vacuum lamination applies the films to the interior linings. In order to significantly reduce component costs, KIEEFL GmbH, Freilassing, has developed a holistically innovative technology, taking a close look at and optimizing all process steps. The result is a unique vacuum lamination process - Flexible Lamination Frame (FLF) technology. With the help of FLF technology, the Freilassing specialists have managed to reduce material consumption and thus film costs by around 40 percent compared to conventional vacuum lamination processes. Also, the degree of film separation is significantly reduced and film stretching rates of only 10 to 15 percent are reached. Thus, the FLF vacuum lamination process comes close to the surface quality achieved with InMold-Graining laminating technology and is obviously a more cost effective alternative.

 

But what's the secret of the new FLF process? The innovation lies in the use of precision film blanks for each component, leaving hardly any waste in the laminating films. The heart of the process is a specially developed gripper system capable of 3D movement. This positions the film on the carrier part without any stretching, before the tool closes and the film and carrier part are glued.  

 

The process at a glance

A highly flexible, modular system concept with a high level of automation enables low-personnel production. The materials, such as precision blanks and carrier parts, come from upstream processes, and wherever possible are already positioned - robots handle subsequent further steps.

 

By integrating subsequent work steps such as punching and edge-folding, a finished component is available at the end of the line. Compared to conventional manufacturing processes, the total footprint is significantly lower - saving up to 50 percent of costly production space.

 

Millions of cost savings

 

“The highlights of the new technology are undoubtedly film savings together with improved surface quality. This is combined with a reduced component cost, which quickly adds up to several million Euros over the production lifetime of a model series”, explains Kiefel sales manager Wolfgang Eglseer. In addition, FLF technology meets the current requirements of the automotive industry in terms of automation and footprint reduction.

ALTTEXT
ALTTEXT

More News

This might be interesting for you as well

08 Oct 2019

Brueckner Group USA Participates in Career Fair at University of Massachusetts-Lowell

Read more
24 Jun 2019

Basic RF Welding Training

Kiefel Service US – Portsmouth, NH
Read more
One of the latest successful cooperations: 2nd BOPP line for El Salvador
04 Jul 2018

Oben Holding Group increases BOPP film capacity

South America’s first 10.4m high speed line for Colombia
Read more
PACKAGING DIALOGUE - Kiefel Kuhne Cup Day USA
28 Jun 2018

Kiefel Packaging Dialogue at Kuhne/US Extruders in Rhode Island, USA - From extrusion to the packaged product.

It was a successful PACKAGING DIALOGUE on June 21, 2018 at the premises of US Extruders in Rhode Island.
Read more
11 May 2018

NPE 2018 – An excellent show for Kiefel

Kiefel’s solutions for the automotive-, appliance-, medical- and packaging industries attracted the experts. The largest plastics and rubber trade fair for the United States, has been again also a perfect informative platform for visitors from...
Read more
Kiefel Packaging Dialogue. Kiefel-Kuhne Cup Days Europe 2018
09 Apr 2018

Kiefel Packaging Dialogue – View back to successful Kiefel-Kuhne Cup Days

Unique barrier material. Multifunctional 91 cavity PP-tool. Fully integrated downstream-automation.
Read more
Markus Gschwandtner (left) and Tobias Fuchs
19 Dec 2017

Management changes within Brückner Servtec

Read more
Super cooperation - tremendous line start
08 Dec 2017

Oben Holding on their way to being Latin America’s BOPET No. 1

Second polyester biax line successfully on stream in Lima
Read more
06 Dec 2017

Colostomy bags: Reliable production ensures quality of life

In 2012 the worldwide market for incontinence and stoma products amounted to 11.5 billion US dollars. This figure was published by the American market research firm Grandview Research in May 2016. And an end to the growth is certainly not in sight....
Read more
28 Nov 2017

Kiefel Automotive: Cost saving potential in the production of interior trim parts.

It was a successful Technology Day Automotive on 09. November 2017 in Livonia, MI – USA. The event focused on potential for saving material and costs in the production of interior components, such as door panels, instrument panels and centre...
Read more