WE GET PLASTIC IN SHAPE
www.ibv.hu
OUR MISSION
n CUSTOMER FOCUS The customer is the focus of all our activities. Our goal is to meet our customers’ requirements at the highest level of quality. We primarily consider those risks and opportunities that can affect the conformity of products and services and can influence customer satisfaction. n ENVIRONMENT In addition to the quality of the product, our company also places special emphasis on the protection of the environment and the development of an environmentally conscious way of thinking. n CONTINUOUS IMPROVEMENT We identify our weak points and improvement areas by analyzing and evaluating our activities and processes. Our goal is to prevent occurance of errors, ensure the stability of our processes, the quality of our service activities as well the continuous improvement of our environmental performance. n COMMITMENT We are committed to the professional development of our employees and to the training of their quality and environmental awareness, enabling us to work at an ever-improving quality efficiently, economical and on an environmentally conscious way.
ABOUT US
IBV Hungaria Lighting and Plastic processing company was founded in 1993 in Kiskunfélegyháza (120 km south from Budapest) as a subsidiary of the German IBV Holding GMBH. Our 2 main activities are the production of our own developed industrial luminaries with high IP-rating for fluorescent tubes or equipped with LED modules, as well as the manufacturing of GRP-based (glass fibre reinforced polyester) products designed in cooperation with our partners from different industry areas. More than 95% of our production volume is sold on international markets in more than 60 countries of 5 continents. Feedback from our customers continuously acknowledges the excellent price-performance ratio of our products, proving the high level of competency of our staff. During the last years several multinational companies transferred their plastic processing acitivity to our site. We satisfy the high expectations from our clients both in thermoplastic and thermoset technology.
450
t
4500 T
30 Mio €
35.000 m 2
n MILESTONES
Foundation of IBV Hungaria Lighting and Plastic Processing Company as a subsidiary of IBV Holding
Machine capacity increase in thermoplastic production
Silicon sealing technology launch
BMC (Bulk Moulded Compound) technology naturalization
1993
1997–2000
2004
2005
2010–2013
2014
2018
2020
Investments: • 9000m 2 plant extention 2000t press machine CNC controlled PUR sealing equipment
P.I.M.C technology launch
6.600 m 2 plant extention
Further investments in machinery
Machine capacity increase in thermoset production
Large workspace plastic milling machine Injection machine Profile co-extruder machine
Thermoplastic technology start
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3
COMPLEX SERVICES
FROM IMAGINATION TO REALITY
IDEA
LOGISTICS
1
7
Deliveries to 60 countries in 5 continents 5600m 2 warehouse
Thinking together Feasibility study
IDEA
LOGISTICS
PRODUCT DEVELOPMENT
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PRODUCTION
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Compression moulding with 37 machines up to 2000t clamping force P.I.M.C (Powder InMould Coating) technology Injection moulding up to 1300t clamping force Extrusion Sealing with silicon and PUR foam solution Milling Assembly 6
2
2D/3D documentation 3D printing Plasticisation Test production
PRODUCTION
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PRODUCT DEVELOPMENT
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TOOL DESIGN
3
CAD / CAM
SAMPLING
SAMPLING
TOOL MANUFACTURING
5
TOOL DESIGN
5
Sampling Process capability study Machine capability Documentation
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3
TOOL MANUFACTURING
CNC milling Laser welding EDM Finishing
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COMPRESSION TECHNOLOGY
n THERMOSETS A thermoset composite compound is based on unsaturated polyester or vinyl ester resins, fillers and fibre reinforcement. Catalysts, stabilizers, mould release agents, thickeners, pigments and other functional additives are utilised to enhance the properties of the thermoset material, designed to offer superior mechanical properties, excellent electrical and fire protecting characteristics, as well as “Class A” surface appearance and low density characteristics. Its colour can be adjusted to customer needs nevertheless to achieve perfect aesthetic look P.I.M.C technology to be applied.
n COMPRESSION TECHNOLOGY Compression moulding is the transformation technique which is most commonly used for SMC and BMC moulding. This technology is an ideal choice also when large-scale products need to be manufactured. The press tool is a two-sided, hardened or chrome-plated manufacturing tool. Heating of the mould can be provided by steam, oil or electricity. Special shapes and undercuts are formed by hydraulically moved inserts (sliders). At IBV Hungária Kft. we use hydraulically operated press machines with a vertical structure (down: fixed machine table; top: moving side), capable of exerting a compressive force from 200 to 2000 tons
At IBV Hungaria Kft the most common appearances of thermoset material are SMC (Sheet Moulding Compound) and BMC (Bulk Moulding Compound)
n SMC APPEARANCE
A ready to mould glass-fibre reinforced polyester material primarily used in compression moulding.
The material is available in rolls or paper boxes. Both sides are protected with foil (film) that prevents from evaporation of styrene, which is first removed by using a customized cutting machine and then cut to proper size.
Initial position
Final position
n CHARACTERISTICS
Material
Steel
Al Mg
Thermoplastics
SMC&BMC
Customizing
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Corrosion resistance Low weight design
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Fire resistance
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Stiffness
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Water absorption
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Paintability
--
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Temperature resistance
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Mass colouration Recyclability E-Permeability Eco efficiency
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n POWDER COATING P.I.M.C. technology can be used if we want to produce a high quality product in one step (without post-painting, varnishing) or the goal is to achieve “CLASS A” surface quality (body elements, sanitary ware, furniture elements, stadium / train public transport vehicle seats). It is based on the P.I.M.C. powder that is sprayed onto the surface of the tool heated up to 140-150 °C prior to the pressing process. The aesthetic surface made by the P.I.M.C process is better than those ones made with coloured SMC / BMC. Further advantage is that contrary to other post coating processes it is scratch- and chemical-resistant.
n COMPRESSION MOLDING As one of the largest users of glass fiber reinforced polyester (SMC) in Europe, our company processes more than 3,200 tons of raw materials per year. With our fleet of 37 presses (with a closing force of 200 to 2,000 tons), we are capable to manufacture the desired product in a wide range of sizes.
SMC is used in areas where light weight but high strength and resistant components are also required.
Thermoset - Compression moulding
Clamping force
Machine table size
Quantity
Powder coating application Insert SMC into press
Press in
(tons)
(mm)
(pcs)
200 250 400 400 500 500 550 630
2400 x 1100 1610 x 800 2350 x 1000 1900 x 1500 2400 x 1000 2500 x 1500 2200 x 2000 2100 x 1250 2600 x 1800 2300 x 1800 3000 x 1800
2 5 4 4
1 1 1
14
1000 1250 2000
2
1
2
10
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APPLICATION FIELDS
MASS TRANSPORT
ELECTRICAL SEGMENT
APPLICATIONS: - Lighting canopies - Cabinets and meter boxes - Fuses & switchgears - Low- and medium voltage devices
APPLICATIONS: - Seats - Interior fittings, fixtures and cladding - In tunnel seating and furniture - Electrical insulators
PERFORMANCE: - Dimensional accuracy over a wide range of temperatures - Excellent electrical insulating properties - Flame retardant and low smoke system - Self coloured and fully pigmentable to a wide range of colours - Corrosion resistance - Halogen free formulation - Maintenance free
PERFORMANCE: - Permeability of electric waves
- Retention of dimensional properties - Excellent sound dampening properties - Corrosion and abrasion resistance - Flame retardant and low smoke system - Mass-colorization
AUTOMOTIVE
ENERGY SECTOR
APPLICATIONS: - Inverter cabinets - Electric charger houses - Battery lids - Electric car charging station (inner and outer application, vandal proof design) PERFORMANCE: - Dimensional accuracy over a wide range of temperatures - Excellent electrical insulating properties - Self coloured and fully pigmentable to a wide range of colours - Corrosion resistance - Halogen free formulation - Maintenance free
APPLICATIONS: - Body panels - Visible panels - Headlamp reflectors - Engine under covers, Technical front ends,
Under the hood parts - Semi structural parts - Filter housings
PERFORMANCE: - Permeability of electric waves
- Retention of dimensional properties - Excellent sound dampening properties - Corrosion resistance - High heat and chemical resistance
- Class A surface - Speed to market - Weight savings
SANITARY
COMMERCIAL VEHICLES
APPLICATIONS: - Sink - Bath tubs - Shower trays - Toilet seats
PERFORMANCE: - Corrosion and abrasion resistance - Thermal resistance - Resistance to chemical agents
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INJECTION TECHNOLOGY
n BMC (BULK MOULDING COMPOUND) BMC is a ready to mould glass-fibre reinforced thermoset polymer material primarily used in injection moulding. Based on mixing strands of chopped fibers, styrene and initiator and filler mixed with unsaturated thermoset resin. It is produced in bulk or in logs.
At IBV Hungária Kft, we provide to our customers excellent quality and mecha- nical properties on a 200-ton Krauss Maffei injection molding machine. With this machine, we can produce a number of products made by thermosetting injection moulding, which we intend to provide for different industry fields.
Heating
n BMC TECHNOLOGY Due to the shorter fibre length, BMC is well suited to injection moulding where it flows freely into the smallest cavities, making it suitable for the most intricate parts. The higher inorganic filler load guarantees very high temperature resistance and an extremely good surface appearance, which is why BMC is commonly used for headlamp reflectors and appliances requiring good aesthetic and high heat performance.
DOMESTIC APPLIANCES
APPLICATIONS : - Iron heat shields - Coffee machine components - Microwave ware - White goods components
PERFORMANCE : - Thermal resistance: BMC material will not deform - Resistance of chemical agents - Mass colouring - Compliance to food contact requirements - Electrical insulation - Fire resistance - Glossy and smooth surface finish
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n INJECTION MOLDING Injection moulding is a continuously developing and expanding industry. The technology is widely used for plastic products manufacturing with the most precise process possible. The principle is that the polymer melt, which has been heated to a low viscosity liquid by heating above the melting point - is “injected” at high speed through a narrow inlet into a closed die - and in this closed die any shaped (3D) part, practically waste-free, with plastic shaping, high dimensional accuracy is formed.
n INJECTION MOULDING PLANT At IBV Hungaria Kft. we started injection process of various thermoplastics in 1997. Since then we have manufactured several hundred types of products from differ- ent raw materials. Our manufacturing output by now has reached the 1,5 million pcs of products per year. We have experimented suitable technical plastic mixture to the complete satisfaction of our customers several times. Over the years, we have expanded our machine park in accordance with demands, so that by now we have 8 injection molding machines and their service equipment at the disposal of our customers in the closing force range of 25 to 1,300 tons. Working together with several tool makers, we now produce injection pieces that meet all needs.
Cooling
SAN PA
n MATERIALS USED Injection molding is a high-precision and highly productive component manufac- turing. The size limits of the manufacturability are extremely wide. The weight of the manufactured product can be several kilograms on an injection molding ma- chine of the right size. It is mainly used for thermoplastic polymers, typically PE, PP, PS, PVC, PMMA, ABS, POM, PC, PA, SAN nevertheless the process developed for materials can also be used in the processing of non-thermoplastic polymers.
PMMA
PC
90% of our production are luminaire components and the rest are other industrial products. Our machinery can be used to produce up to 20 g - 2000 g product weight. As a benefit from the wider partnership that has developed over the years, we provide a complex service to our partners from design to implementation.
Manufacturer
Clamping force (t)
Fastening points
1300 1000 1000
2200x1990 1840x2070 1840x2070 1850x1810
Engel Husky Husky Engel Engel Engel Engel Engel
900
90 90 90 25
730x420 730x420 730x420 470x280
n EXTRUSION Extrusion is a widely used continuous plastic molding process in which the raw material can be mixed with plastic dyes, stabilizers and other additives and then added to a mold. In addition, it is possible to create profiles with extrusion. In case of direct forming, the forming tool is located immediately after the extruder. This process is called extrusion molding.
Many profile shapes can be produced by extrusion. Tubes, sheets, fibers, coated wires, and other shaped materials can be made by such a process.
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SANDWICH PANEL PRODUCTION
n GRP SANDWICH PANEL The fiberglass-reinforced plastic, hereinafter referred to as GRP is a multilayer prefabricated component consisting of a thermal insulation layer and / or load-carrier layers of different thicknesses and a GRP reinforcement around it.
n MANUFACTURING PROCESS At IBV Hungária Kft., we have been producing GRP sandwich panels since 2018. Colleagues with decades of GRP sandwich panel manufacturing experience are involved in the design and management of the technology and help our custom- ers find the most appropriate solutions. The process of sandwich panel production starts with cutting GRP sheets from rolls and sizing the core materials and integrated inserts. The prepared components are built on a 9 x 3 m vacuum table where a special 2-component PU adhesive is applied between the layers. Thereafter, a vacuum compresses the individual layers together until the adhesive has set, thus ensuring the flatness and uniform thickness of the sandwich panel.
n GRP ARMAMENT CAN BE
High-gloss or mat in different colours
Surface structure can be smooth, squared fabric structure or anti-slip grinsor even carbon fiber
CORE MATERIAL PUR / PIR
Very high tensile strength With special coatings: UV resistant, extra abrasion resistant or even antibacterial
XPS PET
PP Honeycomb Plywood birch Metal
n MACHINE PARK - Sheet cutting machine - Core and panel cutter - Vacuum table - 5-axis milling machine
n BENEFITS OF USING GRP SANDWICH PANEL The advantage of the GRP armored panel over the traditional metal armored sand- wich panel is the corrosion resistance and the increased load-bearing capacity char- acterized by different types of core materials. The structure of the sandwich panel can be 100% customized according to the functionality and the application way. The tensile strength of the GRP armament is several times higher than of the steel in terms of self-weight, so that is highly resistant to various forms of stress, weather and abrasion.
APPLICATIONS :
Automotive industry - Caravans - Vehicles with box body Logistic applications - Suitcases - Boxes
The GRP sandwich panel can be sized in the same way as wood with simple hand tools.
One-component MS Polymer adhesives adhere extremely well to the GRP surface.
Building construction - Side walls
Prefabricated e.g. glued application of corner profiles not only ensures quick installa- tion and aesthetic appearance, but also has an extremely strong bond. Tightening screws can be easily applied with wood, metal or PET reinforcements integrated in the GRP sandwich panel.
- Design of walls and surfaces with high hygienic properties
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H-6100 Kiskunfélegyháza Csanyi út 71. HUNGARY Tel.: +36 76 562 100 +36 70 463 2175 Fax: +36 76 562 170 E-mail: sales@ibv.hu www.ibv.hu
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