Setting up the FZP42 at Schütz
Ecobulk
Since 1958, Schütz has focused on the processing of metal and plastic materials. The company headquarters in Selters, Germany, not only makes new products, but also develops and builds various machines and production lines in-house, employing 7,000 people across 55 production and service locations worldwide. Recognized as a leading international producer of industrial packaging for liquid filling products, the Schütz portfolio includes Intermediate Bulk Containers (IBCs), canisters and drums.
"Almost everyone knows the IBC," explained Eduard Tom, Machining Specialist at Schütz. "With the invention of the IBC, our company founder revolutionized liquid packaging and the transport sector. Today, there are many variants of IBCs, and we are the world leader in their production."
A typical Schütz IBC consists of a multilayer inner container and a robust steel cage with a pallet base, now used worldwide in the chemical and food industries. The inner container is made from High-Density Polyethylene (HDPE).
"The container is produced by blow molding," said Tom. "For that process, we manufacture all our molds and tools in-house. Even the smallest deviations can lead to material defects later. We are working in the thousandth-dimension range."
The previously used machines were increasingly reaching their limits: failures, quality deviations, and extensive reworking processes had led to significant delays. Looking for a solution, Schütz connected with Zimmermann, a portal milling machine builder, at a trade show.
After extensive testing, the company finally selected two machines: an FZP42 for rough machining and an FZP37 for precision finishing. Both offer motion ranges of 4,000 mm x 3,500 mm x 1,500 mm. The FZP42 is equipped with the powerful dual-axis fork head VH60 and a 63-kW spindle, while the FZP37 features a slim VH30 head and a 70-kW spindle, enabling optimum accessibility when machining fine structures. The result? Increased dynamics, shorter machining times, and outstanding surface quality.
The special construction concept, a thermo-symmetrical box-in-box design, offers maximum stability. "This construction minimizes thermal influences and the machine geometry remains constant," explained Rüdiger Hellwig, Sales Manager at Zimmermann. "This keeps the tool precisely positioned at all times, which is reflected in long-term accuracy and stability."
In addition to this unique construction, the machine's dynamics were also compelling for Schütz. Due to a lower moving mass, it can operate faster and with greater precision, according to Hellwig.
With the 5-axis technology, cooling channels can be drilled flexibly and with greater contour accuracy into the molds. This enhances tool cooling, reduces cycle times and boosts long-term process reliability.
This technology was on display when Schütz used the FZP42 to rough one half of the mold from a 2.2-ton aluminum block, while the FZP37 performed the finishing and drilling operations. This opens up new possibilities in tool manufacturing as cooling channels can now be positioned more flexibly and closer to the contour. The system is no longer limited to fixed angles, enabling bores with an inclination of 0.6° over 1.4 m. Consequently, part quality is improved and cycle times are noticeably reduced.
As Tom noted, "With the new Zimmermann machines, we now have entirely new options for adapting the cooling channels in the tool, so we are significantly more flexible now."
The configuration features a combined cooling and lubrication system, high-pressure pumps for deep-hole drilling, minimum-quantity lubrication, chip conveyor, and air cooling, as well as a 121-position tool changer. The machines operate almost around the clock, said Tom. Due to significantly reduced rework, processing times and overall effort in tool manufacturing have dropped substantially, he noted.
To simplify service, each Zimmermann machine is equipped with a QR code. Scanning the code automatically generates a service email with all relevant machine data, enabling the Zimmermann support hotline to respond quickly and efficiently.
For more information contact:
Zimmermann Inc.
30587 Century Drive
Wixom, MI 48393
248-956-8511
sales@zimmermann-inc.com
www.zimmermann-inc.com