BP&R April 2022 by BP&R Magazine

British Plastics

and Rubber

bp&r APRIL 2022

AUTOMOTIVE SOLUTIONS

FROM PLASTICS. TO THE FUTURE. THE ROAD TO CHANGE. PAVED WITH QUALITY - SEE PAGE 12. TAXES, TAXES Plastics packaging tax – who’s ready?

POLYMERMAN Uncertainty in Europe impacting resin

EXTRUSION Rob Coker at Coveris

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www.interplasinsights.com head of content: dave gray

T: +44 (0) 1244 680 222 E: david.gray@rapidnews.com editor: rob coker

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T: +44 (0) 1244 680 222 E: duncan.wood@rapidnews.com PRINT SUBSCRIPTION Qualifying Criteria UK – Free Europe – £249 ROW – £249 FREE digital issues available to view and download online British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2022 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age. PEFC Certified This product is from sustainably managed forests and controlled sources PEFC/16-33-254

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Head of Content

Dave Gray

st April is usually a bit of a laugh – then again, in an age where we’re all on high alert for fake news, you’ve got to be pretty good to catch people out. Hats off to the guys at Broadway Colours for their announcement of a new launch – hand-cut masterbatch – that made me grin. Those poor people must be there all day pelletising by hand! Still, nothing like a hard day’s work. But the first day of the month ushered in something else – and it’s less funny, at least for some. The Plastics Packaging Tax officially kicked in, meaning that from now on, plastic packaging with less than at least 30% recycled content is subject to a levy. The industry broadly welcomes measures which incentivise sustainability. After all, it’s likely to be an effective way to accelerate words into action. That said, there are significant hurdles. Food contact packaging, for example, remains a huge problem. Current regulations make it difficult to incorporate recycled plastics into some types of food packaging. Given the already rising costs of food cupboard staples, there are concerns that food suppliers who may find themselves paying more as a result of the tax will end up passing those costs onto consumers – worsening the cost-ofliving crisis in the UK. The implementation of the tax has been short sighted in other ways, too. As Adam Bolsover at St. John’s

Packaging told the audience at a recent BPF event on this topic, the market for recyclate for use in flexible food packaging is just not yet fully established – which will likely leave some producers with no option other than to pay the tax. Until the supply meets the demand, that is not a sustainable market. Yes, there is an argument that this is why the tax is needed – to force a change in market conditions – but what price will industry and consumers have to pay as a result? Many manufacturers though may count themselves ‘ready to go’ in terms of preparedness – such as HLP Klearfold. They contacted me with some guidance specifically for buyers/users of plastic packaging, to help them understand if/how they are likely to be impacted. Senior account manager Amanda Stokes explains all in our regular Sustainability feature further on in this issue. Despite this additional challenge to business conditions for some parts of the plastics industry, the outlook remains positive in general. I’ve been travelling the country, meeting with key figures in the industry over the last few weeks, and they’re all reporting encouraging signs of growth, in spite of (and in many cases, resulting from) Brexit and COVID. Significant CapEx investments are being made – and many are plumping for smart/ digital systems in hopes of reaping efficiency gains. It’s the sign of an industry moving forward, embracing change and seeking growth. Finishing this note, I’m making final arrangements for my travel to Lyon, and the FIP expo, to see how our colleagues across the water have fared through the last two years. Au revoir!

On the Cover

21 REGULAR

IM and PUR finishing in one process for high-end auto interiors – See page 12

Carla Eslava, Recofloor, on collection schemes for vinyl flooring

Automotive solutions

Women in Plastics

3 COMMENT

22 INTERVIEW

8 FEATURE

A recycler’s-eye view of the plastic packaging tax

Rob Coker goes back to his roots

24 FEATURE

Evolution of Extrusion

11 FEATURE Fasten up

EVs fuel market demand for plastic components

Plastics, policy, potential

Taxes, taxes, taxes

Amanda Stokes, HLP Klearfold, on helping customers navigate the new tax

31 FEATURE Made Smarter

Meet the UK converters benefitting from digital manufacturing support

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Regulars and Features 19 TEMPARATURE CONTROL NEWS 21 WOMEN IN PLASTICS 27 POLYMERMAN 28 MACHINERY NEWS 35 BUYERS’ GUIDE 38 DIRECT FROM THE DIRECTOR

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interplas

celebrates 75 years in 2023 After a hugely successful 2021 show, Interplas will return to the NEC in September 2023 for an unmissable three day event.

elebrating 75 years of Interplas, the 2023 edition will see almost 400 exhibitors present solutions, products, machines and ideas from across the plastics sector, as well as materials, automation, contract manufacturing and supporting technologies including software, testing, inspection, surface treatments and much more. From 26-28 September 2023, high-profile exhibitors including Arburg, Engel, Negri Bossi, Billion, Summit Systems, Borche, Sepro Robotique, Piovan, Haitian, Snetor, Albis, Biesterfeld, TH Plastics, Bole, CMS, BMB, Simoldes and hundreds more will meet with over 12,000 attendees at the NEC, Birmingham to demonstrate the machinery, materials and services available to solve the current and future challenges of the plastics industry. Duncan Wood, CEO of Rapid News Group said, “On the back of a highly successful 2021, despite the challenges of a pandemic and a fuel strike, we are looking forward to celebrating the 75th birthday of Interplas with the whole of the UK plastics industry. The enthusiasm for 2023 in the months after the show has demonstrated that the market is still 100% behind Interplas. We have planned a host of new enhancements and investments for the next edition, to ensure the show is relevant for the next 75 years. We will create an experience that is both a celebration of the UK plastics sector and still the primary place to do business.” The latest figures show the UK plastics market has a turnover of £27bn, with over 6,000 companies and 182,000 people directly employed by the industry; Interplas is the showcase for these numbers, and they come alive on the show floor. After the incredible success of Interplas 2021, Interplas 2023 has seen a record rebook rate already, with many previous exhibitors eager to return and emulate the triumphs of previous years.

Terry O’Reilly, Sales Director at Borche said: «We were delighted with the result from the Interplas show last year, and thus we had no hesitation in booking our stand for the next one.” Borche UK had their best ever Interplas result in 2021, with over £588,000 worth of secured orders on the day and extremely high enquiry levels. Colin Tirel, Managing Director at Arburg Ltd was equally positive, “Interplas 2021 was a complete success for Arburg, we didn’t falter from our commitment to the show despite the challenges we all faced beforehand. We saw over 170 customers and potential customers across the three days. It was really nice to be able to see people again and enjoy the personal engagement, something of course we took for granted before. We look forward to being at Interplas 2023!” “All days the visitor numbers were good on stand, new enquiries and new customers coming to see us each day, but Wednesday was by far the best. It was like a conveyor carrying customers on stand from 10am until 4pm, we didn’t even get chance to go for a break. The visitors were focused, time spent with them was purposeful and it was great to see everyone after the last 18 months or so of the pandemic.” Glen Eves, General Manager at Sepro UK. Interplas is also endorsed by leading industry associations, trade bodies and media. It continues to be the UK’s definitive and leading industry event, presenting the constantly developing plastics industry to the UK and wider markets. “Interplas is the national showcase for the UK plastics industry. If you’re serious about doing plastics in the UK, you’ve got to be here.” Philip Law, Director General at British Plastics Federation. For more information visit

www.interplasuk.com

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www.cjpsales.co.uk | Specialists in technical polymers

FEATURE

R ROB COKER VISITED COVERIS UK’S MANUFACTURING SITE IN WINSFORD, CHESHIRE, WHERE HE SPOKE WITH TECHNICAL DIRECTOR MIKE RICHARDSON AND SALES DIRECTOR SUJOY BOSE.

ack in the late 90s I took a temporary job as a janitor at Britton TACO’s film extrusion site for packaging applications on Winsford Industrial Estate. The factory floor was dark, dusty and littered with thousands of lost little pellets that I was tasked with sweeping up and sieving into a bulk bag ready to be shipped off to I have no memory of where. I believe this was possibly best practice post-industrial recycling at the time, please correct me if I’m wrong. It was noisy, and the shifts were long and lonely. The only social space I recall was a box room with makeshift wooden benches around the perimeter, where dozens of overall-clad lads sat eating sandwiches and smoking during breaks. Almost a quarter of a century later I returned to the site, now operated by Coveris UK, in the capacity of a plastics industry journalist. Now a much more illuminated place to work than I remember, the factory floor is cleaner by far, and I saw approximately zero bulk bags containing a compound of pellets reclaimed from the floor and dust and general industrial detritus. There were no janitors. It even seemed quieter, most likely due to improvements in the extrusion machinery and relevant process control technology. A stylish canteen has been established where employees can sit in comfort whilst watching the news. And, of course, there is no smoking. The only familiar thing to me was the warm smell of the great vibrating bubbles as they stretched upward toward the roof. There I met Technical Director Mike Richardson, who has worked his way up – starting as a trainee operator – since 1985. “Since I started here the site has changed beyond recognition, turning a tired old Metal Box canning site into the largest extrusion-only site in the UK. “Our net waste is now less than two per cent, and this is offset to almost zero by using postconsumer recycled raw materials, predominantly from the supermarket waste stream. Our products range from high-spec technical barrier films to the lowest carbon footprint tertiary wrap film available.

OF EXT “Coveris Winsford houses the only nine-layer barrier line in the UK. Supported by 39 silos, the site is the biggest of its kind in the country, and one of the largest in Europe. Operations have changed considerably since I started.” In 2022, the Winsford site is expected to produce over 47,000 tonnes of extruded blown film plastics, equating to around 130 tonnes per day. In January 2022, the site produced 420 tonnes of process waste, yet even 400 tonnes of this was recycled and re-introduced into various products via the on-site recycling centre. Here, Sales Director Sujoy Bose, confirmed how Coveris’ sustainability vision of ‘NO WASTE’ and the UK Plastics Packaging Tax, which states that all packaging products should include at least 30 per cent recycled material, had “already done its job”. “Our mass-balance approach,” Bose said, “brings raw materials in to create valuable products. For example, 100 tonnes of raw material creates 100 tonnes of product. We currently have a 98 per cent mass-balance efficiency rate. Our products are present in a broad range of applications in the packaging, medical and construction industries, with the damp-proof membrane helping to increase efficiency by giving a function – a second life – to waste that is difficult to manage.” In the packaging sector, Coveris is focusing on recyclability, food science and shelf-life extension. Many of these products have gone from being unrecyclable mixed laminates through conversion into monomaterial, singular laminate structures, and the company remains committed to further innovations through its onsite Film Science Lab in Winsford, where the UK Packaging Award-winning Duralite R range of shrink film was developed. The ‘R’ represents recycled content and comes in a range of 30 per cent, 50 per cent, and an R-MAX variety.

www.interplasinsights.com

Specialists in technical polymers | www.cjpsales.co.uk The capacity increase Bose mentioned has already improved by 20 per cent in what was already the UK’s largest blown film extrusion facility. But a greater number of extrusion lines must logically produce a larger amount of waste, I asked.

TRUSION

“Coveris operates a ‘NO WASTE’ vision,” Richardson added, “in which all employees – from the machine operatives to the executive team – can get involved and take equal responsibility for the initiatives. In 2021, Coveris introduced a No Waste Champion Award, an internal competition for all employees to contribute ideas on how we can reduce waste, use our resources better and become more sustainable. Nadia Mazzei, Inventory Manager at Coveris Winsford and a founding Green Team member, was our first ever NO WASTE Champion with her idea to cut pallet labelling of finished goods in half, which equates to a 1.8 tonne reduction of CO2 per year at the site. “Furthermore, the Green Team initiative aims to reduce Kw/h per tonne, fossil fuel dependency, and waste using a mass-balance approach. We take responsibility for own waste right here by investing in the right machinery from the right industry partners, and empowering our employees to get involved in the operation.”

In 2020, we set out on a journey to expand our sustainable films operation and to position ourselves as a world leader in innovation for our stretch, agri, industrial, food and recycled product markets. This was when Richardson led me through to the in-house recycling facility, where I could see the strategic partnerships in action through machinery supplied by Europe-based giants EREMA and NGR, as well as materials handling solutions from Summit Systems. I’m no expert in polymer science, but I could see that the colour and the quality of the pellets showering into the bulk bag was as near to virgin as I could imagine. “This bag stock of recycled pellets, when full, will be tested and returned to the shop floor and fed straight into one of our blown-film extruders,” Richardson concluded.

Bose added: “In 2020, we set out on a journey to expand our sustainable films operation and to position ourselves as a world leader in innovation for our stretch, agri, industrial and recycled product markets. To do this we needed to invest in nextgeneration co-extrusion capacity and capability. In less than a year we built a brand-new 825 square metre stretch film manufacturing hall to house four state-of-theart lines.”

It almost seemed like a concession that the infrastructure to perform such an operation in society is not yet there, but the old saying reminds us, constantly, that if you want something done – do it yourself. In the extrusion manufacturing sector, and certainly at Coveris, as I have witnessed, recycling, circularity and sustainability are now interwoven into the fabric of each business in ways that were just not possible 25 years ago.

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Your Automotive Polymer Partner from Design to Production

FEATURE

A ANDREW FLETCHER, DIRECTOR OF PLASTICS & RUBBER (COMMERCIAL & TECHNICAL), TR FASTENINGS LTD., EXPLAINS WHY NOTHING COMPARES TO PLASTIC WHEN IT COMES TO GREENER CONSUMER CHOICES SUCH AS ELECTRIC VEHICLES.

FASTEN UP

How electric vehicles are fuelling market demand for plastic components

s the global momentum of EV production continues at pace, automotive manufacturers are increasingly turning to alternative component materials to help improve the overall efficiency of electric vehicles. With government regulations on vehicle emissions, a key driver for EV growth, most automotive manufacturers are now looking at using plastics as base materials to build automotive parts. Plastics and composites have been used in vehicles for decades, mainly due to their lightweight properties which can be 30% to 50% less compared to metal. Today, lightweight plastics can make up 50% of a vehicle’s volume, but only 10% of its weight. Therefore, it is a natural development that plastic components are being incorporated into electric and hybrid vehicles. THE PERFECT MATERIAL FOR DESIGN TEAMS There are further benefits with plastic components including their exceptional electrical and thermal insulation qualities, and its resistance to corrosion. For those in the design field, plastic remains an extremely flexible material, one that can be incorporated into even the most complex components with relative ease and freedom. And for high volume production, an important factor as EV production continues to increase, it’s possible to remain pleasingly cost-effective. In addition, it’s worth noting that the more common plastic components can not only be produced in high quantities, they can also be manufactured more cost effectively, benefit from shorter lead times and are less wasteful. Metal components, which have been widely used in car manufacture, are generally unable to offer such benefits. This leads to them becoming more marginalised in the automotive industry in general, and the EV sector in particular. The advantages of plastic components will of course inevitably be accompanied by challenges, but these are becoming more inconsequential. For example, plastic is limited in its torsional stiffness, as well as its impact and punch resistance. There are heat resistance and flammability issues that also need to be considered. A hurdle the industry is acutely aware of is achieving the necessary levels of trust in the

materials in order to change design practices towards using non-metallic materials. Overall, however, concerns around using plastic are outweighed by the various advantages that it can clearly offer. APPLICATION VERSATILITY Currently, the most common plastic applications in EVs include instrument panels, module housings, breakers and switches, battery trays, trim fasteners, cooling system components and crash protection systems. Given the flexibility of plastic as a manufacturing material, and of course its lightness, it’s understandable that designers are incorporating plastic even more frequently now. In certain applications, metal components can be incorporated into plastic mouldings to help achieve the required structural performance. Compression limiters are a good example of this. They are used extensively in composites and plastic mouldings as through holes to help reduce the stress generated by conventional fasteners. Traditional threaded fasteners can generate a great deal of compressive stress during their everyday use, but metal compression limiters can protect against damage without compromising on the integrity of the materials involved. Demand for compression limiters has mainly been driven by the automotive sector. THE DRIVE TOWARDS ENERGY EFFICIENCY Going forwards, it’s easy to imagine plastic components, their mountings and their housings all taking on an even more crucial role in the design of electric vehicles. Battery ranges between charges are already important, of course, and they will need to continue to improve. Keeping vehicles on the lighter side, perhaps with increased usage of reinforcing materials such as glass and carbon fibre, will inevitably lead to further gains in the drive towards energy efficiency levels that were previously thought unachievable. One of the challenges facing our design team has been the need for components that are capable of maintaining maximum performance under stress. The integrity of bends and joints under the most intense pressure is a must in EVs, and that remains a high priority for product developers and designers.

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the big story

BENEATH THE SURFACE

T Trends in the aesthetics and functions of in-car control panels are always changing. For most car makers, this means multifunctional, elegant and high quality – and ideally, sustainable. Techniplas, a major global plastic component supplier to the automotive industry, uses ColorForm technology from KraussMaﬀei to achieve this finelytuned balance.

HOW INJECTION MOULDING AND PUR SURFACE FINISHING IS BEING COMBINED FOR HIGH-END AUTO INTERIORS WHAT IS ‘COLORFORM’? ColorForm is KraussMaffei’s combination of injection moulding technology and surface finishing with polyurethane in a single step. The technology is designed to make large-scale production of high-quality components more economical and sustainable. “ColorForm technology offers great potential for a lower CO₂ footprint in the production of components with a noble, multifunctional surface,” said Michael Fuchs, global application owner surface and lightweight at KraussMaffei. By consolidating the process down into one step, the user saves time and resource on intermediate storage, painting, and reworking of components. By using a transparent polyurethane surface treatment, Techniplas can also achieve ‘depth effects’ on the final component. The company uses the MXW 1000 ColorForm system at its Treuen, Saxony site. IN-MOULD COATING The ColorForm process effectively works by combining injection moulding and polyurethane processing. The multi-component injection moulding procedure is the foundation of this process. After injection moulding of the thermoplastic mould base body, the body is flow-coated with polyurethane (PUR) or polyurea (PUA) as the surface material in a second cycle. The RimStar Flex ColorForm reaction process machine, which was designed specifically for this process, and the mixing head, feed the surface material (PUR/PUA) directly into the cavity. “RimStar systems take up very little space and meter even small amounts precisely and at a high cycle frequency,” said Philipp Strasser, global application owner, RPM and automotive at KraussMaffei.

Schematic of the PUR/PUA ﬂow-coating in the mould. RimStar Flex for PUR metering, we fully meet these requirements,” added Toni Luckner, process developer at Techniplas in Treuen. “Our ColorForm system is used to produce parts using the injection compression moulding process, which are given a high-quality, transparent PUR surface for a special depth effect. Another line for the project is currently being commissioned,” said Luckner. “We produce under cleanroom conditions in the process. Thus, when the mould is open, no grain of dust can get between the coating and the substrate surface. We thus achieve very low reject rates,” Luckner said. SAVINGS POTENTIAL Using ColorForm tech means Techniplas doesn’t need to transport and paint components, or invest in a painting plant. The finished components are also ready for installation when they’re discharged from the automated production cell, saving on buffer storage and drying.

“Our customers, major OEMs from the automotive industry, place the highest demands on quality. There must be no defects larger than 0.2mm on the entire transparent component. With the MXW 1000 in combination with the (Right) KraussMaﬀei supplied both the MXW 1000 injection moulding machine and the RimStar Flex mixing and metering machine.

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(Left to right) - Peter Giessmann (KraussMaffei), Eric Jan Frijters (Techniplas), Philipp Strasser (KraussMaffei), Michael Fuchs (KraussMaffei), Rene Rudolf (Techniplas), Sarah Seidel (Techniplas)

RimStar systems take up very little space and meter even small amounts precisely and at a high cycle frequency. LONG-TERM COOPERATION Techniplas has used the ColorForm process for several years – although the manufacturer refers to it as “ColorFuse” technology. There are four ColorForm systems in Treuen and one in Rüti, Switzerland. An in-house technical center in Treuen also uses two further systems. SHORTENING THE SUPPLY CHAIN DURING THE COVID PANDEMIC A new system has recently been put into operation, for which Techniplas used an existing MXW 1000 injection moulding machine from KraussMaffei as the basis. Techniplas had the MXW retrofitted at its manufacturer’s main factory in Munich’s Allach neighborhood. “There, all necessary equipment is available on-site, and commissioning at the TechCenter was also completed on schedule – both for the injection moulding machine and for the PUR technology, that is, for the RimStar Flex with two MK 5-2K CCM mixing heads for simultaneous production of two components. This cannot be taken for granted under the current basic conditions determined by the pandemic,” says Luckner. Techniplas also uses two MK5-2K CCM mixing heads alongside the ColorForm system.

The swivel plate for the thermoplastic substrate. NEW CONTROL SYSTEM AND ORCA COOLING The MXW 1000 was not just retrofitted for ColorForm technology. Its control system was also completely upgraded to KraussMaffei’s MC6 control system, and a new ORCA cooling system was installed. “The system performs a contactfree temperature measurement, which minimises maintenance. The technology allows us to control the twenty cooling circuits of the MXW precisely and thus makes a critical contribution to the high, uniform quality of the components,” explained Luckner. The ColorForm technology is available in the UK market via KraussMaffei UK.

26-28 SEPTEMBER 2023

Exhibitt w Exhibi with ith it hu uss Interplas is back in 2023, bringing with it the opportunity for you to experience the UK’s largest plastics industry exhibition showcasing the full spectrum of plastics processing machinery, materials, software, services and ancillaries in one place. It’s also the only plastics event in the UK where visitors can see working machinery LIVE on the show floor and where they’ll come to compare, contrast and buy. With an expected 12,000+ attendees across the three-day event, as well as new features and an expanded floorplan, now is the time to position yourself as a company that can offer solutions, showcase innovation and offer expertise to an audience known for its quality and purchasing power.

@InterplasUK #InterplasUK www.interplasuk.com +44 (0) 1244 952 519

Your Automotive Polymer Partner from Design to Production

FEATURE

A COLLABORATION BETWEEN SWITZERLANDBASED LIGHTWEIGHTING COMPANY BCOMP AND AUSTRIABASED KTM TECHNOLOGIES HAS RESULTED IN A SUSTAINABLE MOTORCYCLE BRAKE COVER AND A PLACE AMONG THE FINALISTS IN THE JEC COMPOSITES INNOVATION AWARDS 2022.

mong the environmental credentials of this innovative new part is its achievement of an 82 per cent reduction in thermosetrelated carbon emissions, the use of ampliTex – a sustainable flax fibre composite material – and, at the end of the part’s life, the components can be separated and recycled or reused. What is more, the natural fibre composite can be used to generate electricity via thermal energy recovery. As well as the flax fibre composite, the part uses an over-moulded PA6 thermoplastic using a KTM CONEXUS coupling layer, which protects the fibre component from debris and damage with bond reinforcement ribs and fasteners. Compared to a traditionally injection moulded part, the Bcomp and KTM Technologies brake cover saves weight, has increased stiffness and reduced vibrations, and significantly reduces the part’s overall carbon footprint. The achievement has already inspired KTM Technologies to begin development of a completely bio-based brake cover. Hans Lochner, Team Leader, Material and Application at KTM Technologies, said: “With this demonstrator component, we have succeeded in proving the series production capability of this technology. This is an important milestone for our efforts in the field of sustainable engineering and the use of bio-based composites. This is a testament that with biobased plastics and fibres, it is possible to produce performance components in series.”

two-wheeled machines? Electrically powered lightweight alternatives are already becoming prevalent in everyday transport, yet – and according to Lochner – this particular area of the automotive industry has something to prove in terms of applicability since numerous components could also make use of this technology. Christian Fischer, CEO and Co-Founder at Bcomp, agreed: “The idea of sustainable bodywork with valid and beneficial end-of-life options is revolutionary with far-reaching implications. KTM Technologies’s CONEXUS has been a critical enabler of our ampliTex-based composites in new applications, allowing us to add local reinforcements, attachment points and edge protection using thermoplastic parts while still gaining the advantages of our flax fibre composite technologies.” The recognition received from the JEC Composites Innovation Awards is testament to the progress made by the two companies. Nominated in the Sports, Leisure and Recreation Category, Bcomp will face stiff competition from Japan-based Toray Carbon Magic’s CFRP wheelchair designed for use by disabled badminton players, and UK-based Hypetex, which has designed and manufactured a carbon composite hockey stick for international sports company adidas. The JEC Innovation Awards 2022 will be presented at JEC World 2022, which will take place in the ParisNord Villepinte exhibition centre, from 3-5 May.

MOTORCYCLE FRIENDLINESS Does this mean, then, that lightweight, sustainable materials use combined with a reduction in carbon footprints in the production of motorcycles – whether for high-octane competitive sports or commercial use – will extend the use of, and thereby increase the appeal of, fossil fuel powered

This is an important milestone for our efforts in the field of sustainable engineering and the use of bio-based composites.

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FEATURE

P PLASTIC COMPOUNDING IS EMERGING AS AN IMPORTANT ENGINEERING PROCESS AMID RISING INDUSTRIAL RELIANCE ON POLYMERS. GLOBAL MARKET INSIGHTS (GMI) ANALYST SALONI WALIMBE EXPLAINS WHY.

Versatility for

he versatility of plastics is derived partly from the ability of the materials to be combined with different types of substances or additives, which can enhance known properties as well as establish new ones. These can range from foaming, flame retardancy and flexibility, to impact resistance, thermal and electrical conductivity, and recycling potential. The compounding process is essential to creating plastic materials that are highly adaptable and suited to a multitude of consumer needs. Research from Global Market Insights, Inc. has shown that the global plastic compounding market is expected to exceed $63.2bn (~£48.2bn) by 2028. Compounding alters the existing properties in engineered thermoplastics, from aesthetics to thermal components, by melting down a blend of plastics and additives to create a new product. The process of compounding can involve various materials, with PP, PE, ABS, PVC, and other polymers among the most common. INCREASING FOCUS ON AUTOMOTIVE LIGHTWEIGHTING Historically, metal has been the material of choice for the automotive industry, especially for engines and bodywork. With evolving consumer habits and regulatory mandates promoting the shift towards weight reduction and fuel efficiency in vehicles, however, the role of compounded plastics in the design and production of automotive components has become increasingly prominent. As per Nexant, over a third of the 30,000 parts used in modern vehicles are made from plastic, with PVC, PA, PU, and PP accounting for almost 70 per cent of the plastics used in these applications. Compounded plastics give automotive manufacturers the ability to design exterior and interior components with strong characteristics including abrasion and vibration resistance, haptic properties, and durability. A major boost to the adoption of plastics in automotive production is the intensifying focus on lightweighting. Prominent nations have established mandates targeted towards weight reduction in cars, contributing largely to plastic compounding industry growth from the automotive segment, which registered a more than $15bn valuation in 2021, as per GMI projections. In addition, fuel efficiency has also become a major pain point for automotive producers, owing to the ever-increasing pressure from environmental regulators as well as rapid escalations in fuel prices. Compounding is of great benefit in this scenario, by producing lightweight and durable materials

designed to optimise vehicular performance whilst reducing overall weight. This is mainly due to the lower density of plastic than metals such as steel, which enables them to deliver better durability and mechanical strength despite being lighter in weight, which can in turn improve the vehicle’s fuel efficiency. Estimates from the American Consumer Council corroborate this by claiming that cars in the US using plastics can travel over 1.5km more per litre of petrol than they would without the material. Major component manufacturers and plastic producers have taken this burgeoning trend into account and are thus engaging in targeted activities to maximise the use of compounded plastics in automotive applications. For instance, in March 2022, Covestro added two new polycarbonate compounding production lines at its New Delhi facility. The objective behind this was to accommodate the growing demand for compounded plastics from automotive industries. Plastic Omnium also made similar moves by setting up a new 2,700 tonne dual-compound press at its exterior component R&D centre Σ-Sigmatech in Lyon, France. Using the new equipment, the company was aiming to work with automotive producers on proposing, designing and authorising innovative exterior components with strong aesthetics and integrated functionalities. Plastics are among the most ubiquitous and versatile man-made materials in the modern industrial world. According to estimates from Plastics Europe, plastic production increased from 2,000,000 to 368,000,000 tonnes between 1950 and 2019. From its use in everyday applications such as packaging, to more complex uses such as the fabrication of various industrial and engineering components, the versatility of plastic remains unmatched.

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TEMPERATURE CONTROL | NEWS Linkam updates humidity control range Linkam Scientific Instruments has launched the latest update to its range of humidity control systems. With upgraded internal electronics and colour touchscreen, the RHGen enables the user to precisely control the humidity around a sample, without the need for an external dry air supply. Magnetic connectors for the bottle enables easy water changing and refilling for users and when used in combination with a Linkam stage or other sealed chamber device, and the RHGen can offer humidity control between three and 95 per ent RH, at temperatures from ambient to 85°C. Accurate humidity control is ensured through the placement of the feedback sensor close to the sample block, and the device can be used in conjunction with light microscopy, Raman, FT-IR and X-ray to offer further sample characterisation. The precise humidity control also enables users from a variety of sectors to understand the impact of humidity

Digital temperature controls enable variable settings from air-only up to 110 degrees Celsius in one degree increments.

Vastex introduces low-temperature cabinet oven

on their samples. Examples include: the study of water ingress on internal electrical components in electronic devices including solar cells; examining the effects of humidity, or dry air, on food storage conditions; and understanding the behaviour and breakdown of pharmaceutical compounds to inform packaging decisions, amongst other applications. Duncan Stacey, Director of Sales and Marketing, said: “Humidity is often overlooked as a testing parameter,

The precise humidity control also enables users from a variety of sectors to understand the impact of humidity on their samples.

as in the past it has been notoriously difficult to control. This device brings essential upgrades to our previous humidity control system, the RH95, which is already widely used by customers who are incorporating environmental control in their research, and the RHGen will provide customers with further accurate and reliable humidity management.” There are RHGen compatible versions of a number of Linkam stages, including the THMS600, LTS420, and Modular Force Stage (MFS), providing an ideal solution for investigating the effects of changing humidity as well as temperature. The device can also be combined with the Inert Gas Regulator (IGR), which acts as a regulated pressure interface between the RHGen and an external gas supply to allow inert gases into the chamber, to replicate unique environmental conditions.

A Dri-Vault 253610 lowtemperature infrared cabinet oven for heating, drying, curing and conditioning of bonded or coated parts has been introduced by Vastex Industrial. Intended for smallscale production and laboratory applications, it features a doublewalled enclosure with positive-pressure filtered air flow to prevent particulates from entering the chamber, and a 10cm exhaust duct to remove moisture and fumes. Latched doors with gaskets maintain total darkness during operation. The five CMM blower draws filtered air over an industrial stainless

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steel-finned heater at 1,250 watts (120V) or 1,550 watts (240V). Digital temperature controls enable variable settings from air-only up to 110°C in one degree increments. Non-corrosive, coated steel racks measuring 63.5cm wide x 91.4cm deep are vertically adjustable to fit items up to 61cm tall. The unit measures 100cm deep by 88cm wide, with a height of 81cm (74cm without castors). Vastex Industrial manufactures two larger models of cabinet ovens and 11 models of hightemperature tunnel ovens for pilot testing up to high-capacity production.

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FEATURE

SPOTLIGHT circular vinyl

C CARLA ESLAVA IS THE COLLECTION SCHEMES MANAGER FOR RECOFLOOR, A COLLECTION SCHEME FOR COMMERCIAL WASTE VINYL FLOORING THAT CAN BE RECYCLED INTO NEW PRODUCTS. HERE SHE DISCUSSES THE SCHEME’S CONTRIBUTION TO THE CIRCULAR ECONOMY IN CONSTRUCTION.

HOW DOES RECOFLOOR EXTEND THE VALUE CHAIN FOR USED PVC/VINYLS? Recycling vinyl flooring installation offcuts ensures they get a second life. Clean vinyl can go back into new flooring, while unsuitable material can be used in traffic management products, such as traffic cones. This means used vinyl is given at least another 10 years’ life in durable products that can ultimately be recycled again. The use of recycled PVC in those types of products has revolutionised that industry. As most manufacturers can shred end-oflife products, the PVC can be recovered and reused again – potentially for decades. It’s a great example of the circular economy in the construction sector. With difficulties in virgin and raw material supply, being able to recycle is really important. There is rising demand for recycled polymer in general. For Recofloor, the best-case scenario is to recycle it back into flooring because it means that flooring manufacturers are using less virgin material. There’s a huge and growing demand for traffic management products wherein manufacturers rely on recycled polymer. If it can be collected, there is a use for it. WHICH MATERIALS ARE ACCEPTABLE, AND WHICH CANNOT CURRENTLY BE RECYCLED? Acceptable materials are installation offcuts and uplifted smooth and loose lay vinyl, as well as Luxury Vinyl Tiles (LVTs) and safety offcuts and rollends. Cushion vinyl cannot currently be recycled. Safety flooring, with its gritty texture, is more challenging to process. Uplifted material is the most challenging due to the adhesive or screed, but also because of potential legacy additives. Waste management and collection of uplifted material is an area of future focus for the industry. HOW FAR IS THE INDUSTRY FROM IMPROVING THE RECYCLING RATES OF THESE? It’s quite far. That’s why we’ve put a lot of effort into recycling the offcuts. The flooring manufacturers have done a great job in reducing

I’m seeing women playing a greater role in taking action to drive a sustainable circular economy and address climate change.

waste when flooring is manufactured, and all the production scrap is recycled. Recycling the cleaner offcuts is the next stage and this is going well through Recofloor because it’s clean material and easier to recycle. If more people participated in the scheme, and if there’s more buy-in from the construction industry, we could get more material. However, tackling the uplifted flooring is always going to be challenging given that there is no dedicated sorting and recycling infrastructure. Recofloor relies on the flooring network and the efforts of its 500+ members to collect the material, which is then backhauled to the manufacturers for on-site sorting. Recycling waste vinyl flooring is done either by the manufacturers or those making the traffic management products. They are relying on the existing infrastructure, which is actually there, albeit for different reasons. HOW MUCH PVC FLOORING HAS RECOFLOOR HELPED TO DIVERT FROM LANDFILL/ INCINERATION TO DATE? HOW MUCH EVADES YOUR EFFORTS? Just over 6,000 tonnes since September 2009 when the scheme was launched by flooring manufacturers Altro and Polyflor. Of the estimated 7,500 tonnes of offcuts generated annually, we collect about 600 tonnes per year. Just under 7,000 tonnes are disposed of by other methods. There is an economic incentive for contractors to use the Recofloor scheme as collecting offcuts through Recofloor is more costeffective, saving on disposal costs. There are around 29,000 floor layers in the UK, offering great potential to spread the message, attract new Recofloor members, and collect more material for recycling. HOW WELL DOES THE RECYCLING INDUSTRY PERFORM IN TERMS OF GENDER EQUALITY COMPARED TO OTHERS? While gender equality across the industry is still a work in progress, I’m seeing women playing a greater role in taking action to drive a sustainable circular economy and address climate change. Throughout my 10-year career I have learned so much from the many women working in waste management and recycling and continue to be inspired by them. I feel fortunate to work in materials recovery and towards a more inclusive, circular economy. I’m sure that the industry will continue to see and hear more female voices at the forefront of climate and waste issues.

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WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

interview

PACKAGING TAX: Plastics, policy, potential

S SENIOR POLICY ADVISOR FOR MURA TECHNOLOGY DR GEOFF BRIGHTY OFFERS THE RECYCLER’S EYEVIEW OF THE NOW IN EFFECT UK PLASTICS PACKAGING TAX.

PLASTICS INDUSTRY PLAYERS, PARTICULARLY THOSE IN PACKAGING MARKETS, HAVE STRESSED THE IMPORTANCE OF A HEAD START IN WORKING WITH THIS NEW PACKAGING TAX. IS THAT A STRATEGY YOU AGREE WITH?

Importantly, it could be critical to secure recycled plastic feedstock as this tax should see an increase in demand for high-quality recyclates, which might affect both availability and price. Engaging the supply chain will be key so that the cost of compliance is minimised.

As with any new regulatory measure, it isn’t fully clear how the marketplace will respond, and ultimately what impact will be achieved. Moreover, we don’t know how significant recycled packaging is as a differentiator in the mind of the consumer, but we can expect brand claims emerging soon as they adapt their packaging to be compliant with the tax threshold of 30 per cent recycled content. Companies placing packaging on the market should be looking into this now for two reasons: On financial grounds, to avoid the tax burden at £200 per tonne, which is a further cost to business that can be avoided legitimately through recycled content; and enhancing the sustainability of the packaging, and therefore the sustainability credentials of a manufacturer. Being engaged early gives companies the best chance of understanding the implications so they can respond quickly to emerging challenges and opportunities.

FINDING THINGS TO TAX SEEMS LIKE A DEFAULT SETTING FOR THE UK GOVERNMENT. AS AN ADVANCED RECYCLING COMPANY, WOULD YOU SAY THE TAX WAS FIT FOR PURPOSE?

WHAT MEASURES WOULD YOU NOW TAKE IN ADVISING ANY BUSINESSES CURRENTLY NOT IMPLEMENTING THE MINIMUM PCR CONTENT STIPULATION?

We understand from HMRC that the intention is to drive behavioural change to more sustainable packaging, and success is effectively ‘no tax revenue is collected’ because all packaging will have 30 per cent PCR content. It’s a useful principle to drive up recycled content in packaging. However, for the tax to be effective, it needs to address all plastic recycling and applications into packaging. This is currently not the case for chemical recycling, or its value chain. Although chemical recycling is identified in the primary legislation (Finance Act 2021) as being an appropriate process to generate recycled content, in practice, HMRC has yet to agree how this is accounted for in the petrochemical system.

HMRC has stated that it wants behaviour change through incorporation of recycled content into packaging, and thereby not to receive the tax. There is really no reason why a business shouldn’t engage organisations like the BPF, who have been leading on this for some time. We would recommend consulting their guidance now, at least to see how to comply.

What we don’t want to see is the tax avoidance driving divergence into other packaging materials that are not subject to tax, but are worse from an environmental sustainability perspective, such as from plastic to glass.

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WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

Currently, plastic produced from our hydrocarbon will not count towards the 30 per cent content. This is part of an ongoing discussion with HMRC, and how mass-balance accounting can solve this challenge. In practice, as chemically recycled content would not be accounted for, this is a challenge for foodcontact packaging which cannot use recyclates generated by the mechanical recycling industry. Therefore, there will be winners (those that use mechanically recycled plastic for content in packaging) and losers (those that need to meet other technical regulatory requirements in packaging). As a consequence, these will only be able to use fossil material and pay the tax. IN WHAT WAYS IS MURA BEST PLACED TO GUARANTEE AN ONGOING SERVICE FOR THE PLASTICS PACKAGING SECTOR? We know the plastics sector is looking for highly versatile, recycled hydrocarbon that can be applied to a range of packaging and other applications and, similarly, recycling processes that can then take the packaging post-use and take it back to recycled hydrocarbon. Chemical recycling delivers both outcomes for the plastics packaging sector, addressing the recyclability of plastic packaging (which relates to Extended Producer Responsibility market regulation) and generating recycled content for new packaging, as incentivised by the Plastic Packaging Tax. Mura’s strategy is therefore set on a sustainable, circular plastic economy, and on technology which can be deployed at scale. To do that we are focusing on recycling post-consumer household waste plastic, and especially the hard to recycle packaging such as flexible, multilayered packaging – most of which is sent for incineration. Mura’s technology generates recycled hydrocarbon ( which has the widest possible set of applications for the plastic packaging sector) for the consumer market. IN WHAT WAYS DOES THE TAX HELP MAINTAIN THE ESTABLISHED PACKAGING QUALITY THAT CONSUMERS EXPECT? Whilst this is still very early in the life of the tax, we think there will be changes in the way companies will look at their packaging; this will lead to new innovations and even diverting away from plastic. This will include issues such as function and ‘form’. For example, recycled plastic tends to be darker through the blending of different coloured plastics. We have already seen testing of recycled plastics in packaging that delivers functionality but diverts from corporate branding. What we don’t want to see is the tax avoidance driving divergence into other packaging materials that are not subject to tax, but are worse from an

environmental sustainability perspective, such as from plastic to glass. What is critically important is that trust remains in the system so that consumers can be confident that claims made by brands are verifiable. HOW DOES MURA CONTRIBUTE TO ASSISTING THE CONSUMER AND – MORE IMPORTANTLY – PROTECTING THE ENVIRONMENT? Broadly, Mura’s environmental sustainability approach is to be able to recycle hard to process plastics, particularly packaging, into beneficial hydrocarbon products that can be used for a wide range of applications. The consumer benefits by purchasing goods in sustainable packaging that can be recycled again. This is likely to become an important selling point for consumer-facing brands. The environmental benefits are that plastic is not otherwise lost to the system by being incinerated, landfilled or escaping into the environment, and avoids the significant carbon emissions associated with these processes. The recycling process avoids the need to extract and refine virgin fossil oil, thus conserving oil stocks and processing the hydrocarbon at a much lower carbon footprint. CAN YOU EXPLAIN A LITTLE ABOUT HOW YOU COLLECT THE WASTE PLASTIC AND THE SCIENTIFIC PROCESS USED IN CREATING THESE RECYCLED MATERIALS? The plastic that Mura processes predominately comes from post-consumer household waste left over after mechanical recycling operations. The HydroPRS (Hydrothermal Plastic Recycling Solution) process utilises the CAT-HTR technology, which uses supercritical water and heat to break down the long-chain hydrocarbons and donate hydrogen to produce shorter-chain, stable hydrocarbon products, converting plastics into valuable chemical and oils for sale into the petrochemical industry. This can then be used in the production of new plastics and other materials. FINALLY, WHAT ARE THE MAJOR CONTRIBUTIONS MURA CAN OFFER THE UK PLASTICS INDUSTRY? Mura’s first plant in the UK is already under construction in Teesside and is expected to be operational later this year. Capable of processing 80,000 tonnes of plastic waste per year, the site is a blueprint for the rapid global roll-out to meet our ambition of reaching one million tonnes of recycling capacity by 2025. The site will be capable of recycling all forms of plastic an infinite number of times, playing a key role in eliminating single use plastic waste and putting the UK at the forefront of the circular global plastics economy.

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feature

HOW TO HELP CUSTOMERS NAVIGATE THE PLASTICS PACKAGING TAX

s the new plastic packaging tax (PPT) comes into effect, we at HLP Klearfold are noticing an influx of customers coming to us with questions about how the tax will affect them.

The Plastic Packaging Tax applies to plastic packaging that has been manufactured or imported into the UK and does not contain at least 30% recycled plastic. It is a step forward in the battle for sustainable packaging and manufacturing, as IT’S CLEAR THAT research shows that plastic packaging currently accounts for almost 70% of plastic waste.

THE PLASTICS PACKAGING TAX WILL HAVE AN IMPACT ON THE PLASTICS INDUSTRY – BUT WHAT ABOUT ITS BUYERS? AMANDA STOKES, UK SENIOR ACCOUNT MANAGER AT CLEAR PACKAGING MANUFACTURER HLP KLEARFOLD, GIVES HER ACCOUNT.

Our customers are representative of the general confusion surrounding the tax, as seen by the 23% rise in online searches for ‘plastic packaging tax guidance’ over the last three months. WHERE THE CONFUSION IS LIKELY TO ARISE Confusion may arise from businesses trying to establish if the tax applies to them and to what extent. There are many exemptions within the tax and HLP Klearfold recognises that this is an overwhelming time for businesses trying to understand whether they’re subject to paying the levy or not. There could also be confusion over what the tax is going to achieve; the sole purpose is to promote recycled plastic to reduce the amount going to landfill. It is not intended to stop the production or use of plastic as a packaging solution as in many cases it is recognised that plastic is the only viable option; the fantastic properties of plastic were vital in helping to prevent the spread of Covid19, from face shields to screens HLP Klearfold’s aim is to not only produce material that exceeds the minimum requirement meaning the tax would not apply to our products but also provide guidance to our wider market, who may not currently be working with us. The tax is welcomed by HLP Klearfold, despite us being a plastic packaging manufacturer: we have been working on our 100% recycled content material for years to

This is an overwhelming time for businesses trying to understand whether they’re subject to paying the levy or not.

ensure we are able to accommodate customers’ ever growing desire to care for the planet now and in years to come. Any confusion over who the tax applies to and how it can be avoided can be discussed with our experts and our PPT guide has been designed to be a very simple point of reference. WHAT MIGHT BE SUBJECT TO CHANGE ABOUT THE TAX? The tax at present is applied at £200 per tonne on plastics containing less than 30% recycled content. There are no revisions to change this in the near future. However, this is likely to be reviewed annually to see how businesses are complying and how successful the tax is performing in its pursuit to promote the recycling of plastic. HLP KLEARFOLD’S PLASTIC PACKAGING GUIDE The introduction of the plastic packaging tax is a necessary step towards more sustainable packaging. As with any new tax or regulation, it takes time for businesses to understand what exactly is going to happen and how it will affect them. HLP Klearfold’s guide uses a bespoke traffic light system which details who will not have to pay the plastic packaging tax (green), who is exempt from paying the tax for a specific reason (amber) and who is eligible to pay the PPT (red) as it comes into effect. Red - Those who import or produce plastic that does not contain the minimum 30% recycled content, these are predominantly single use plastics, e.g. bottle tops, etc. Amber - These are businesses who are exempt for a specific reason. For example, licensed medicine or where the plastic is an integral part of the product such as an ink cartridge in a pen. Green - Those who are already using the required minimum content of 30%; HLP Klearfold’s standard material exceeds this and is 100% recyclable. Businesses who currently import less than 10 tonnes also fall into this category to ensure smaller businesses are not disproportionately hit. It’s hoped that this guide may also encourage those who are eligible to consider how they can improve their recycled plastic production, in order to avoid the tax and become more sustainable.

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GEOPOLITICAL TENSIONS AND FURTHER OUTBREAKS OF CORONAVIRUS RESULT IN PRICING TURBULENCE FOR THE ENTIRE POLYMER SUPPLY CHAIN

AS GLOBAL UNCERTAINTY CONTINUES TO AFFECT PRICING, MIKE BOSWELL GIVES HIS ANALYSIS.

arket expectations at the beginning of Q1 2022 were of a situation in which the high polymer prices experienced for the last 18-months and the difficulties impacting the global logistics industry would at least show some signs of easing. Whilst the Russian invasion of Ukraine is causing concern about the supply of crude oil and natural gas, recent outbreaks of COVID in China and the far east are dampening these expectations, with concerns about further lockdowns resulting in diminished energy demands. The graph below shows the reaction of the crude oil market, over the February and March periods, to these conflicting price drivers. Many suppliers of polyolefin and styrenic polymers reacted to the developing situation in Ukraine by implementing mid-month price increases, and shutting order books early. Given the crude oil price volatility, many plastic converters were understandably critical of the firm action that polymer producers have adopted.

A further potential issue could be the imposition of sanctions on the import or sale of Russian origin PE or PP. It appears that material from Russia has gained a significant share of the European market, typically taking up much of the void in PE from US origin supply resulting from high US domestic prices, strong demand, and the aftermath of the winter 2020/21 storms in the Gulf Coast region.

(Source S&P Global Insights)

Who is ‘Polymerman’?

Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution. co.uk | www.pieweb.com

As March began, the prices of key monomers were significantly hiked with C2 (ethylene) and C3 (propylene) hitting record highs. Due to the energy intensive nature of polymer production, many producers sought to apply energy surcharges in addition to passing through the increased cost of the respective monomer feedstocks. It looks as if, for many polymer converters, the very same energy cost increases along with input cost inflation may prove so severe that they will choke production output in order to stem their own financial losses, as margins could even become negative after variable costs are accounted for. Such restriction in demand could, in theory, result in surplus supply of polymer raw material from which the change in supply/demand balance could result in a muchwished-for reduction in polymer pricing. That said, polymer producers may well adapt output to ensure that market conditions remain in their favour.

The dynamics of trade sanctions on polymer imports are varied, depending upon whether the UK acts unilaterally, the UK and the EU27 act in unison and what, if any, countermeasures Russia imposes on the UK, the EU27 or both the UK and the EU27. There is of course adequate PO production to meet global demand, and whilst trade flows would equilibrate to meet demand, there could be considerable shortterm disruption if sanctions were imposed, most particularly for consumers of more specialist grades. Whilst at the time of writing there has been some easing in the tensions resulting from the hostile invasion of Ukraine by Russia, the conflict is far from resolved and further geopolitical tensions are likely to arise before the matter is settled. Furthermore, the impact of COVID-19 on the global economy is gradually becoming less severe as authorities and individuals increasingly accept the virus as endemic.

Given the crude oil price volatility, many plastic converters were understandably critical of the firm action that polymer producers have adopted. www.interplasinsights.com

www.kraussmaffei.com

pioneering plastics

MACHINERY | NEWS Engel UK team in Ukrainian refugee mission Project management within manufacturing throws a lot of situations at its practitioners daily. But when Engel UK’s Managing Director, Nigel Baker, met with team members Chris Stafford and Krzysztof Bruski to plan the company’s response to the humanitarian crisis on the Polish border with Ukraine, it would be fair to say they got more than they were expecting. Bruski speaks Polish, and has geographical knowledge of the area around the support centres. The team made swift plans for Stafford and Bruski to fly to Poland, hire a vehicle and provide instant access to funds to purchase urgently needed items for the centres in need of help. Engel UK kicked off the fund with a donation of £5,000. Following that initially donation, the team also set up a GoFundMe page, and using social media and business contacts to publicise the trip, donations from friends, colleagues and businesses within the plastics industry began to flood in. A few days later, the two Engel UK employees were en route to Poland. Arriving late at night, they kicked off their first day collecting a consignment of sleeping bags that they had already purchased online. Thirty sleeping bags that were so badly needed they had been allocated within 10 minutes, and later that day, they purchased another 50. Arriving at the border, they found tents erected

Editorial credit: Damian Pankowiec / Shutterstock.com on waste land and fields, set up by local residents and charities. Bruski’s knowledge of the language meant that he was able to make contacts who directed him to where help was most needed. They reported that much of the aid was being provided by local residents, who have grouped together to quickly organise to food, drink, warm clothing, and essential items for young children and babies. During their five days in Poland, they travelled back and forth between shops and warehouses. Staff at their hotel shared a wholesalers’ membership card with them, which proved useful for buying in bulk. With the donations, they were able to purchase nappies, drinks, fruit, and ingredients for emergency provisions for refugees. They learned

that support groups were struggling with fresh ingredients as they had no means of storing them, so refrigeration was also purchased as aid. During their visit, they made contact with an emergency orphanage in Krakow, for which they used donations to buy kettles, microwaves, and children’s treats. At a shelter for 70 mothers and children, refugees were washing up by hand. Stafford and Bruski were able to use some of the donated funds to buy an industrial dishwasher, with a steam function that kills 99.9% of viruses and bacteria, helping to reduce the spread of diseases at the shelter, and removing the reliance on single-use plastics and paper plates and cups. Baker said: “I am very proud that the whole Engel UK team were

Bruski's knowledge of the language meant he was able to make contacts who directed him to where help was most needed. behind this humanitarian campaign. We wanted to make a difference and make sure the right support and provisions were going exactly where they were needed. Our GoFundMe page is still running and if people would like to contribute, the additional funds are

www.interplasinsights.com

being spent remotely to continue to provide items to the contacts the chaps made.” At the time of writing, the total raised on the Go Fund Me page was £10,180, with an additional £5,000 donated by Engel UK before the page was opened.

www.kraussmaffei.com

pioneering plastics

A change in the guard at Billion UK After more than 37 years with french injection moulding machine manufacturer Billion, Peter Kirkham will retire at the end of May. Peter joined Billion back in 1984 as a service engineer, back when the brand was epresented in the UK by the Spaceminster Group. In 1985, Billion decided to set up its own subsidiary for the UK, with Peter being retained as one of three key staff moving to the new business, which lead to the formation of Billion UK Ltd in 1988. With business growing strongly, Peter soon progressed to the role of service manager, overseeing new engineers coming in and developing what has since evolved to be one of the most well reputed service support teams in the industry. In the early 90s Peter began to be more involved in the commercial side of the business, providing technical support for the sales team, leading to his appointment as technical director in the mid-90s. In 2001 Peter took on the role of managing director, replacing the then retiring Colin Swanton, a role which he has maintained to this day, helping Billion to develop and grow its UK market. Peter has also been active within the industry playing an active role within

the BPF and PMMDA industry committees for many years providing active support including participation in seminar events, not forgetting his strong involvement with the SPRA, especially through Napier University to encourage young professionals coming in to the industry. Billion has also been a staunch supporter of Interplas through Peter’s tenure, and has always been there to support and promote the industry showing new ideas and innovation. Commenting on his retirement, Peter said: “I feel extremely privileged and grateful to have spent the majority of my working life in this fantastic industry. I have nothing but thanks to Billion, my colleagues, my customers and actually everyone who has helped and supported me over the past 37 years. I am also very much looking forward to my retirement, to spend more time with my wife and family. I’m sure I don’t need to say that running a successful business is a 24/7 job, so it will be nice to be able to spend more time developing some of my hobbies, such as walking, motorcycling and cookery”. Simon Johnson was recruited in 2018 and has taken over the role of running Billion UK, since October 2021. Commenting on his successor, Peter stated “I have known Simon for quite some time. He is a great guy and I know that he will be able to continue to provide the high level of support our UK customers deserve, whilst developing the business with his own ideas. I wish him and all the Billion UK team every success for the future”.

COMMENT

The word from Hird

RICHARD HIRD, CHAIRMAN OF THE POLYMER MACHINERY MANUFACTURERS AND DISTRIBUTORS ASSOCIATION (PMMDA) ON HOW THE GROUP IS STAYING UP-TODATE WITH CURRENT TRENDS.

With an ever-changing industry we all need to ‘keep up with the times’. The PMMDA is no exception, with plans to modernise whilst still maintaining the basic principles established by our founder members back in 1966. Our modernisation process will focus on sustainability and ‘green’ credentials in the way that we operate and plan to promote this throughout our membership and the wider industry. With this in mind, we had an idea to add to our library of ‘Guide To’ documents a manual on Energy Efficiency; to offset

our carbon emissions from travel by tree planting; to have our new ‘Member’ boards made from recycled material and amongst other things to make PMMDA sustainability a regular feature on our social media posts and in our newsletters. This will all sit alongside our regular annual exercises and events that we’re busy planning for 2022 – especially now that restrictions are lifted, and we can be more flexible. We’re fortunate that PMMDA has a loyal and solid membership that continues to go from strength to strength, long may it continue…

The PMMDA is no exception, with plans to modernise whilst still maintaining the basic principles established by our founder members back in 1966.

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FEATURE digital transformation

T The plastics sector, like every industry, is experiencing a tectonic shift as digitalisation drives the automation of processes and products. Technology adoption is enabling businesses to overcome technical challenges, accelerate processes, improve productivity, and become more sustainable. But for SME manufacturers, barriers such as time and financial constraints, a lack of digital skills, and uncertainty of where to start often prevent them from keeping pace.

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Made Smarter: Plastics going digital

his became the foundation of the Made Smarter Adoption programme in the North West. Launched as a £20m governmentfunded industry-led pilot in 2019 following the Made Smarter nationwide review into UK manufacturing, it has since worked with hundreds of businesses, including many in the plastics sector, offering expert, impartial technology advice, digital transformation workshops, a leadership programme, digital technology internships, and funding for technology projects. Key to the adoption programme’s success has been helping manufacturers select the right approach, how much to invest and identifying which technologies will bring the greatest benefits. For this, Made Smarter developed a digital transformation workshop, an innovative, streamlined diagnostic of products, services, processes and people to find practical solutions to overcome everyday business challenges. The bespoke process is designed in a way that requires minimal time investment for manufacturers to turn the actions into results, and leave them with an easy-to-use digital roadmap with recommended first steps. Businesses such as Bloom-in-Box, a manufacturer of eco-friendly plastic products based in Burscough, and Norlin Compounding Services, a plastic compounder in Bolton, used the process as a platform to invest in the right technology.

Made Smarter has accelerated our ambitions by years. Its support has really driven forward our plans to design and manufacture plastic products with more than just one life.

Hannah Reardon, Bloom-in-Box, a firm which made use of support from Made Smarter For Bloom-in-Box, which makes floristry packaging, security spike systems, laundry pegs, and scoops and measures, it invested in an electrical injection moulding machine which increases production speed and quality, enabling the business to increase production capacity by between 25-40%. David Reardon, Director, said: “We believe that investing in the next generation of moulding machines will develop a more digitalised manufacturing environment aimed at improving efficiency, expanding production capacity, and generating more revenue. This will allow us to expand and invest in new ideas, create jobs and develop more environmental products. “Made Smarter has accelerated our ambitions by years. Its support has really driven forward our plans to design and manufacture plastic products with more than just one life.” For Norlin, the workshop helped identify technology which would automate and control a vital blending process, while giving it real-time visibility of the key data. The outcome has been an increase in

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capacity and productivity, better real-time control of manufacturing processes, and improved its quality assurance. Jonathan Holland, Commercial Director, said: “Working with Made Smarter has been a great experience. The team were extremely knowledgeable and helped us get to where we needed to be, a lot quicker.” Others that have adopted new technology with Made Smarter support include Stirling Moulded Composites, a plastics manufacturer in Burnley, and Plastic Card Services (PCS), a plastic card manufacturer based in Macclesfield. PCS secured a £1.5M identity card contract after financial backing from Made Smarter enabled it to invest in game-changing digital printing technology. Adam Unsworth, Managing Director, said: “Quite simply, without funding through Made Smarter for the new equipment, PCS would not have been able to win the contract. The increase in turnover is huge for us. It’s a game-changer for our company.” Made Smarter is also supporting manufacturers to ensure they have the right skill sets to capitalise on these game-changing technologies. The Made Smarter Leadership Programme was designed to equip SME managers and directors with the strategic view and skills needed to pursue smarter manufacturing, using a hybrid model of classroom learning and site visits.

BELOW: Going digital at Norlin Compounding

Quite simply, without funding through Made Smarter for the new equipment, PCS would not have been able to win the contract [...] It's a game changer for our company.

ABOVE: Jayce McEvoy at Plastic Card Services Optimold, a manufacturer of precision plastic injection moulded components and assemblies based in Warrington, is one of 60 businesses to benefit. Joel Weightman Production Manager, said: “The leadership programme has been brilliant in teaching me new methods and ensuring that our business is focussed on all the dividends and not just the financial one. The dividends are now being seen across the company.” Made Smarter also offers specialist advice about organisational and workforce development, and Fully-funded Digital Technology Internships that enable university students and graduates the chance to work with businesses on their digital transformation. Such has the been the success of the North West programme, it has been rolled-out to the North East, Yorkshire and the Humber, and the West Midlands regions, meaning more manufacturers can access support to adopt digital tools which will increase their growth, productivity, efficiency and create high value, well paid jobs of the future. For more information visit www.madesmarter.uk

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Telsonic UK Ltd

Unit 3 Vitrage Technical Park 27 Witney Road , Nuffield Industrial Estate, Poole, Dorset BH17 0GL T: 01202 697340 E: info.uk@telsonic.com W: www.telsonic.com Blog: telsoniccuk.wordpress.com

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RJG TECHNOLOGIES LTD Moulding Technology

Affordable and flexible MES system for the plastics/rubber industry. Easy to use systems from a €600m company with over 30 years experience. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag and drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts.

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Zero Defect Moulding – What’s your target? Cycle time reduction Reduced scrap rates Improved process capability Higher yield and OEE

PRO-OP™ software provides a step-bystep procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection.The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.

158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu

Kistler Instruments Ltd

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T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.

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T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.

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Rubber Manufacturing Company

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As part of our ongoing strategy we are looking to aquire an additional business ideally with a current turnover of between £1-3m PA

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Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.co.uk

Goldcrest Engineering Technologies Ltd Unit 15 St Johns Way, St Johns Business Estate, Downham Market, Norfolk, PE38 0QQ

Unique group of engineering companies specialising in the development, design & manufacture of Granular Polymer Dehumidifying Dryers under the “Drymaster” Brand

Tel: 01366 383398 E: goldcrestengtech@gmail.com www.goldcrestengtech.co.uk

FILTRATION ALUMINIUM MATERIAL STORAGE BINS Off the shelf or made to order with very competitive pricing! Standard sizes available: 80l, 200l, 420l, 830l.

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BPR18

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SECONDHAND AND RECONDITIONED Cooper Plastics Machinery

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DTL Machinery UK

- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com

TransXL International Ltd

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comment

from the director

AS THE PLASTICS PACKAGING TAX COMES INTO FORCE, PHILIP LAW, DIRECTORGENERAL OF THE BPF, TELLS BP&R WHERE THE CONFUSION STILL LIES. PLUS, HE LOOKS AT THE ONGOING WAR IN UKRAINE, AND HOW IT IS AFFECTING UK RESIN SUPPLIES.

he Plastics Packaging Tax comes into force on April 1st. Whilst it has generated much administrative confusion for many companies, let’s hope that in time it will ultimately acts as a platform for greater levels of recycling and innovation, and in doing so takes some of the heat out of the public debate on packaging. The proceeds on the tax will be considerable and BPF will continue to press government to invest it in improvements to the plastics recycling infrastructure. To help members gain a deeper understanding of the tax and its implications, BPF has teamed up with consultancy EY to publish an explanatory guide available to BPF members. An offshoot of this is an online tool – a decision tree – to provide a quick and simple way for companies to ascertain whether or not their products are in scope to the tax. This tool is freely available on www. bpf.co.uk/PackagingTaxTool The motivation for this came from survey we carried out which indicated that less than a third of companies feel that they fully understand the upcoming tax. Even as I write this in late March, the government’s guidance on the tax is still not complete and BPF is continuing to press government hard to accept the adoption of mass balance methods to measure the quantities of chemical recyclate in products. Not surprisingly members are inundating the BPF with calls seeking clarification on vexed points. Areas of uncertainty include the evidence companies are required to submit to the authorities and at what point companies are eligible for tax credits. Uncertainty also exists around calculating the amount of tax liable (if any), how VAT is to be applied and on

the information required on invoices for taxeligible products. Meanwhile we are considering the impact of the Russian-Ukrainian War on the UK plastics industry. It is likely to vary from country to country. The direct effect might not be as small as was initially thought. Government statistics indicate that imports from and export to Russia were less than 1% of UK trade in plastics materials and products. However some are now pointing out that exports of polymer from Russia were increasing when raw material shortages were biting hard. Additionally, as substantial volumes of polymer enter the UK from Rotterdam this disguises the original provenance of the material. The UK, although it has a lower dependence on gas from Russia than some other European countries, will not escape the inflationary effects of rising prices of gas and oil generally. The effects on the availability of steel and other commodity metals will have an impact on the supply of equipment and on some customer sectors. Post Brexit, transport difficulties were given a high profile and the news that a disproportionately high number of lorry drivers are of Ukrainian provenance and that many have returned home, will certainly not help. On related themes, BPF maintains a strong seminar and webinar programme. On April 27th we are hosting a seminar on ‘Sustainability and Plastics’ and followed by a gathering on ‘Productivity’ at the British Motor Museum in Warwick on 28thApril. May 5th sees us exploring ‘Know Your Carbon Footprint, The Route to Net Zero’. If you have an interest in attending please contact my colleague Paul Baxter on pbaxter@bpf.co.uk

Not surprisingly members are inundating the BPF with calls seeking clarification on vexed points.

www.interplasinsights.com

Recognising and rewarding excellence in the Plastics Industry for 21 years

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BP&R April 2022

Articles inside

FEATURE