FAKUMA 2026 | SHOW PREVIEW
system automatically selects the desired colour while the other materials continue to circulate in the loop. The colour change takes place directly within the process, quickly, reliably, and without mechanical retooling. The second change – made with its develop-
ment partner Siegfried Hofmann – is the ability to apply a much thinner coating, cutting material use by 80%. They have succeeded in coating thermoplastic components directly in the injection mould with a 0.1mm polyurethane layer. ColorForm previously produced surfaces with layer thicknesses of up to 0.5mm, the new develop- ment is more resource- efficient. “By reducing the PU layer thickness from 0.5 to 0.1mm, we are achieving a major technological leap,” said Andreas Bierbaumer, technology manager at KraussMaffei. “The material savings of up to 80% reduce the material costs for each component.” The reduction of the PU layer thickness was made possible by optimising the component fixation, sealing system, preform and mixing head. It shows that ultra-thin PU layers can be produced directly in the injection mould with reliable processing and high quality, says the partners. “We are using the development mould to demonstrate that layer thicknesses of this kind can be achieved reliably,” said Stefan Hofmann, manag- ing director of Siegfried Hofmann. “The design and dimensions of the tool are based on current exterior automotive components such as trim panels or diffuser lenses.” �
www.kraussmaffei.com
Maag will show its Extrex 6 EC gear pump at Fakuma – which it says is designed for continuous conveyance of rigid PVC, overcoming the mate- rial’s high thermal sensitivity and tendency to degrade.
Maag developed the Extrex 6 EC to overcome the
limitations of conventional gear pumps – especially material remaining in dead spaces for too long. Its gap-free design prevents polymers from accumulat- ing inside the pump. This reduces the thermal stress on PVC and cuts the risk of degradation. Other highlights include: increased extruder
efficiency, as uniform, pressure-stable conveying reduces the load on the extruder; and a reduction
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in process temperature of up to 10°C, which can eliminate the need for stabilisers. After testing at Rehau’s technical centre, a final
prototype was tested with a production profile in early 2025. By optimising the pump’s thermal balance, Maag ensured that the increase through the pump did not exceed 6°C – even with a melt temperature that was already 10°C lower. In addition, it will present its Purity Concept V
offline testing system from Sikora. The system is used for random sampling and analysing pellets, flakes, and test plates. Using an optical camera, it detects contamination such as black or coloured specks and discoloration from a size of 50 microns. Analysis takes less than a minute and directly delivers a test certificate and an HSV colour map of the detected colour deviations, contributing to the assur- ance of product quality. �
www.maag.com
Moretto will showcase several materials handling innovations at
Fakuma – including a conveyor, deduster and dryer. It says its Loadmatik is a “revolution” in plastics conveying, as it automatically recognises and applies conveying parameters. Once the source and destination are specified, the system independently calculates the parameters, regardless of the distance or quantity. It consists of three technologies: the smart server One Wire 6 Plus monitors and manages conveying parameters; the X-Loader is a receiver that provides active support for the automatic detection of load values; and KruiseKontrol is a dynamic granule speed control system that manages operating pressures, adapting the material’s convey- ing speed to actual operational needs. Self-learning algorithms continuously analyse
operating data such as granule speed, operating pressures, pipe emptying time and receiver loading level to manage the entire path of the granules. At Fakuma, visitors will see a full-scale conveying system in action. At the same time, Moretto has developed the new Deduster dust separator, which uses a combination of the Vortex effect, mechanical separation and centrifugal force to separate dust from granules before moulding. It is engineered to ensure material only contacts stainless steel components, eliminating the risk of contamination. An integrated ioniser is also available, ensuring results that comply with the severe regulations of the medical and optical sectors.
Left: Maag’s Extrex 6 EC gear pump is designed for continuous conveyance of rigid PVC
� September/October 2026 | INJECTION WORLD 33
IMAGE: MAAG
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