issue 01/24
British Plastics and Rubber
Jan/Feb
in association with interplasinsights.com
bp&r
THE PUSH FOR PLASTICS
Titelseite_BP&R_185x235_EN.indd 2
Philip Law on the BPF’s start to 2024
The pioneer of mouldmaking for 100 years.
MATERIAL DRYING
Drying thermoplastics correctly by Richard Brown
PRICE KNOW-HOW
Mike Boswell’s review and 2024 outlook
13.02.2024 12:02:24
OUR SHOWROOM: YOUR RESOURCE OUR fully equipped BOY & Hi-Class Machinery showroom is available NOW – with a comprehensive range of BOY machines and ancillary products. Book your slot for: • Mould & material trials • Product range training • Basic machine maintenance courses • Tailormade training programs for new and existing machine users – with certification Tel: 01933 354460 Email sales@boy.ltd.uk
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COMMENT
British Plastics and Rubber www.interplasinsights.com Head of sales: Mandy O’Brien T: +44 (0) 01244 952 519 E: mandy.obrien@rapidnews.com Portfolio sales manager: Gareth Jones T: +44 (0) 1244 952 370 E: gareth.jones@rapidnews.com Portfolio sales manager: Kelley Jo Beattie T: +44 (0) 1244 952 375 E: kelleyjo.beattie@rapidnews.com Head of studio: Sam Hamlyn T: +44 (0) 1244 680 222 E: sam.hamlyn@rapidnews.com Subscriptions: T: +44 (0) 1244 680 222 E: subscriptions@rapidnews.com Publisher: Duncan Wood 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
© 2024 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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NEW YEAR, NEW FOCUS W
elcome to 2024, now the interminable month of January has come to an end, we can focus on getting through the rest of the year and all the challenges that will undoubtedly arise in the plastics industry. You will notice that we have changed the cover focus this year to machinery and processes, last year’s cover design with industry leaders was hugely enjoyable, however, new year, new focus.
“Our aim is getting through the rest of the year and all the challenges that will undoubtedly arise in the plastics industry.”
Hasco is our cover star this month as the company is celebrating its 100-year anniversary, quite a feat in any industry. To celebrate the success of its centurylong company history, Hasco will hold events worldwide throughout the entire anniversary year. CEO Christoph Ehrlich said: “As a pioneer in the field of mouldmaking, our aim is to carry on setting innovative milestones for the industry over the next 100 years too!” Read more about their rich history and future plans on pages 12 and 13. Team BP&R has been on several road trips already this year and has visited Billion (read the Q&A with their UK MD on page 10), Boy Ltd and In Touch Monitoring to discuss their plans for the year and highlight how we can help them market to the wider plastics audience. We were also invited to spend a very enjoyable afternoon with industry peers at Sepro’s picturesque UK office to celebrate their 50th anniversary year with a hog roast, make sure to check out the photographs on our LinkedIn page and website, connect with me if you would like a visit from us too.
New year thoughts do of course turn to trade shows. June 5-6th will see Rapid News events taking place at NEC in Birmingham. Make sure you have registered to attend our shows Med-Tech Innovation Expo and TCT 3Sixty for free. There is plenty of crossover with the plastics industry and an ideal opportunity to network with clients and industry colleagues - which leads me seamlessly into an Interplas 2026 promotion! Now just over 2 years away, we are in 3 halls for June 2026 and are over 50% booked already. Get in touch to see the current floorplan or secure your space in this unmissable UK plastics show.
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HEAD OF SALES, PLASTICS
DYNACON CUSTOM CONVEYORS Modular design allows design changes at any time • Save Money with Long Lifetime, Low Energy Cost & Easy Maintenance • The light weight design makes it easy to assemble, install, and move • Available in a wide array of angles and widths • Easily integrated with additional equipment
Please visit dynaconeurope.com for more information or give us a call! Labotek GB +44 (0)1564 822172 • sales@labotek.co.uk • dynaconeurope.com
CONTENTS 18
3
24
COMMENT
Industrial Strength Resilience
The pioneer of mouldmaking for 100 years.
12
14
34 Titelseite_BP&R_185x235_EN.indd 2
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6
14
Challenging conventional standards of biodegradable polymers
Trexel expands into the blow moulding space for sustainability
BIODEGRADABLE PLASTICS
BLOW MOULDING
8
18
Benefits of drying thermoplastics properly to maximise efficiency
Mike Boswell’s price know-how review and outlook
DRYERS
POLYMERMAN
10
24
BP&R’s conversation with Billion UK’s managing director
Why plastics manufacturers should consider laser technology
Q&A WITH BILLION
LASERS IN PLASTICS
12
28
Hasco’s 100-year journey in mouldmaking excellence
The case for robotic integration in injection moulding
ON THE COVER
ROBOTICS
REGULARS
34 Column: Philip Law, BPF
4
www.interplasinsights.com
6
8
YOU AND
WORKING TOGETHER FOR BETTER MOULDING SOLUTIONS
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BIODEGRADABLE PLASTICS
CHANGING COURSE:
Applications and Standards of Biodegradable Polymers
B
iodegradable polymers are finding evermore applications within society, from carrier and food bags, food packaging, singleuse cutlery and beverage cup lids, to agricultural applications such as mulching film. Whilst there has been, and continues to be, significant development in biodegradable polymers, with new grades of PHA, PBS & PLA for instance, entering the market, the same cannot be said of the associated standards which are referenced as suitable for the applications or anticipated disposal routes. These standards have typically been developed to reflect what the material can do rather than what it needs to do, and by and large do not reflect actual conditions, as evidenced by consideration of the most commonly recognised biodegradable polymers; those marketed as “compostable”. These are usually only suitable for industrial composting disposal routes as per EN13432 [Packaging. Requirements for packaging recoverable through composting and biodegradation] or ASTM D6400-21 [Standard Specification for Labelling of Plastics Designed to be Aerobically Composted in Municipal or Industrial Facilities]. These polymers add no value to the compost, rather, a minimum of 90% of the organic carbon with the polymer needs to be converted to CO2 within 6 months at 58°C in a standardised test compost. However, industrial composting facilities generally
6
Dr. Gary Ogden FIMMM, CSci, technical manager at Wells Plastics Ltd. operate at lower temperatures, with much shorter periods of time and the mix of compost ingredients being highly variable. This unsatisfactory situation with “compostable” polymers is further complicated with the development of “home compostable” test methods which attempt to reflect the varied conditions and management of home compost heaps, which are more akin to natural environments. How to standardise the natural environment for laboratory testing to produce a definitive result applicable to all natural environments? The issues of assessing the polymer biodegradation in a natural environment such as soil, is illustrated by consideration of the test criteria in ISO17556 [Ultimate Aerobic Biodegradability of Polymers in Soil. Degradation of Polymers and Plastics in Soil]. Test material may be micronised to powder, increasing the surface area of the polymer to the test inoculum, mixed and tamped to increase surface contact with a highly prescribed standard soil composition and tested at (typically) 25-28°C for up to 2 years. A minimum of 90% of the organic carbon of the polymer is required to be converted to CO2 within two years for the polymer to be classed as soil biodegradable. How reflective of real, natural soil environments are these highly prescribed test conditions? Especially when ISO17566 is used within EN17033 [Plastics - Biodegradable mulch films for use in agriculture and horticulture - Requirements and test methods] to determine whether a material may be classed as a biodegradable mulching film, and thus allow the polymeric film to be ploughed into the arable ground at the end of the growing season. www.interplasinsights.com
ASTM D6954-24 [Standard Guide for Exposing and Testing Plastics that Degrade in the Environment by a Combination of Oxidation and Biodegradation] recognises the issues of the relevancy of standardised test conditions to a variety of natural environments with regards to biodegradability of polymers by prescribing a tiered approach and a requirement for a highly prescribed reporting of test results caveated with test conditions. This brings its own issues, with no simple message proffered compared to compostability and soil biodegradation testing. It is therefore necessary for standards bodies to develop more appropriate standards which better define material performance to realistic conditions, thus safeguarding the public and environment from those materials which do not perform as advertised.
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be the first DRYERS
Richard Brown, chair of judges of Design Innovation in Plastics Awards, discusses the benefits of properly drying thermoplastics to maximise efficiency and eliminate processing issues.
I
n plastics, processing plants material dryers are a standard piece of equipment as not correctly drying thermoplastics can cause aesthetic and mechanical defects triggered by the presence of water. Moisture can originate from within the plastic pellet of hygroscopic resins or condense on the surface of non-hygroscopic resins. If material is not dried correctly, this can cause potential issues during processing and in the component post-processing. When cosmetic defects occur in non-hydroscopic resins, e.g. polyethylene or polypropylene, these can often be traced back to excess surface moisture deposited due to rapid changes in the temperature and humidity. This can be resolved by allowing the raw material to come to equilibrium within the surrounding atmosphere where it is processed so that the surface moisture can evaporate, or it can be conventionally dried using a hot air dryer to remove the surface moisture. This preheating is particularly useful in circumstances where material has been stored outside in the cold and is brought into more warm and humid conditions for processing.
cosmetic problems and even chemical reactions, such as hydrolysis, where water molecules break chemical bonds within the polymer that can have an impact on the mechanical properties of the material. It is also important to be aware that some nonhygroscopic materials may still require drying due to the presence of additives. For instance, impact-modified acetal (POM) usually does not require drying, but if an impact modifier is added, then pre-drying becomes necessary. It also needs to be remembered that over-drying material for too long or at too high temperatures can also cause potential problems. Over-drying and too long residence time in the drying process can cause colour changes and the subsequent scrapping of components.
MATERIAL DRYING:
mythology OR
METHODOLOGY?
Drying Technology It was in the late 1950s that the desiccant dryer first emerged, when the first generative dryer using silica gel as the desiccant was developed. Further advancements were made with microprocessor controls being added and the dryer units becoming more compact. The compressed air dryer offers a moisture removal membrane that is not a desiccant but a filter that blocks the water molecules, this type of dryer needs no regeneration, unlike desiccant dryers. There is also a challenge to desiccant drying with the vacuum-type dryers that are available. There are several drying options that are available to plastics processors to ensure that their raw material is in the optimum condition for processing, these are: • Hot Air Dryers - designed to remove surface moisture from no-hygroscopic material and to pre-heat material before processing. • Twin Tower Central Desiccant Driers - contain two towers that are equally filled with hygroscopic materials. During operation, one tower is used to actively eliminate moisture from the compressed air routed through it, while the other tower undergoes a reverse
It is essential then that proper drying techniques are implemented, to prevent
BP&R's editorial advisory board Richard Brown, Chair of Judges Design Innovation in Plastics Awards
8
Dr Sally Beken Knowledge Transfer Manager – Polymers Innovate UK KTN www.interplasinsights.com
Robin Kent Managing Director Tangram Technology
Dr Carmen Torres-Sanchez Reader in Multifunctional Materials Manufacturing Loughborough University
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be the first
DRYERS process where moisture is removed to revitalise the desiccant material. • Rotor Wheel Dryer designed to address energy issues presented by other types of drying. Rotor Dryers have a constant dew point. • Vacuum Drying – designed to accelerate the plastic material drying process by using a vacuum to lower the boiling point of water from 100 °C to 56 °C drying materials in 20% less time than that required by a desiccant dryer. • Compressed Air Dryers - generally a method of drying employed for smaller throughput machines, the dryer is equipped with twin desiccant beds like that of a dehumidifying dryer. • Silo Dehumidification Units – are designed for bulk storage systems where a silo dehumidifier is used to remove moisture from the air inside the resin silo. The dehumidifier works by using a desiccant material to absorb moisture from the air.
expensive conversely, large throughputs through desiccant dryers bring the cost per tonne to dry material down significantly. However, the cost of leaving a desiccant dryer on tick-over is an expensive practice.
The Drying Process Proficiency is key in the drying process, and it involves four key elements: heat, airflow, dew point and drying time. All play a critical role in achieving effective drying of material to maintain production efficiency and quality. The first drying parameter is heat, it is necessary to heat the pellet to release the moisture. The second is the dew point, this being the temperature at which the air condenses, and moisture molecules can release from the exterior of the pellet. Thirdly, the drying parameters need to be known as it takes time to dry a plastic pellet to enable the water molecules to break away from the pellet surface. Finally, the fourth parameter is airflow around the pellet which conveys low dew point heat or dry heated air to the pellets in the dryer. The volume of this air must be enough to maintain the desired temperature in the dryer for the throughput of the material.
The drying process can also now be intelligent in the era of digitalisation with the addition of load cells and advanced control systems allowing the operator to monitor and manage the drying parameters at their fingertips. Previously, these drying parameters would need to be manually checked and monitored.
Technology When selecting a dryer, it is important to understand what the current cost per tonne is to dry your material with current equipment. Understand your requirements and what the best system for your facility would be around your manufacturing methodology. Small batches through desiccant dryers are
Moretto, through its R&D, has challenged the design of the conventional dryer construction and developed a more efficient method of drying polymers. Their breakthrough was to redesign the material flow through the dryer hopper by adding a hollow ‘rocket-like projectile’ at the core of the dryer which enabled layering of the material, allowing a more consistent flow of material compared to a conventional desiccant dryer and reduced residency time.
Professor Edward Kosior CEO and Founder Nextek
Dr Thomas Bennett Research Fellow University of Manchester
Correct drying procedures reduce potential manufacturing delays that are the result of moisture-related defects. Liaising with the equipment supplier when selecting equipment can streamline processes and sustain efficient production. Material consistency is paramount for producing quality products and correct drying ensures the material properties remain consistent during the process. Moisture-related challenges need to be fully addressed at the outset to prevent issues during manufacture.
Dr Michael Junior Hopkins Managing Director Ross Polymer Services
The cost of a conventional desiccant dryer versus adopting vacuum drying technology needs to be explored as generally the use of a vacuum provides several revenue benefits e.g. faster drying, and reduced maintenance. It is perceived as a modern and efficient process and there are several generations of these now being actively used in the industry.
Pravin S Mistry Global CEO PREA Ltd.
www.interplasinsights.com
9
Q&A LEADING WITH INNOVATION: A CONVERSATION WITH SIMON JOHNSON, MANAGING DIRECTOR AT BILLION UK LTD BP&R: What makes Billion UK stand out from the competition? SJ: What sets us apart from our competitors is our unparalleled commitment to rapid response times and exceptional support quality. Centralised operations in the UK enable us to guarantee an average 24hour response window for engineering breakdowns, ensuring minimal operational downtime for our clients. This swift responsiveness is complemented by our dedication to innovation and build quality, aligning us with the leading trends in machine manufacturing. Our approach extends beyond just providing top-notch machinery; it encompasses a comprehensive support system designed to meet our clients’ needs promptly and efficiently. Moreover, our competitive edge is further sharpened by our advantageous pricing and the strong relationships we foster with our customers. Despite offering high-quality services and maintaining quick response times, our charges are significantly lower than many competitors, thanks to our lean operational model with minimal overheads. This
10
In January 2024, BP&R Magazine visited Billion UK Ltd’s managing director, Simon Johnson (SJ), in Milton Keynes. Leading since 2021 and with the company since 2018, he has guided Billion UK, a key subsidiary of Billion SAS, in providing a wide range of injection moulding machines from 40 tonnes to 1100 tonnes. Alongside these, Billion UK supplies Cartesian robots and additional injection units, all complemented by the user-friendly Dixit 4 control system.
pricing strategy, coupled with our flexibility and understanding of customer priorities, allows us to offer tailor-made solutions that ensure customer satisfaction while keeping costs manageable. As we consider expansion, our focus remains on sustaining this balance to continue providing exceptional value without compromising service quality. BP&R: What are some of the main market challenges that you face? SJ: The current market is primarily challenged by consumer spending hesitancy due to recent economic shifts, notably fluctuating interest rates and energy market volatility. These factors have made consumers wary, affecting their willingness to invest in significant assets. Additionally, businesses face strategic dilemmas in prioritising investments
due to space constraints and the need to balance multiple projects without disrupting ongoing operations. Regulatory uncertainties, such as the new packaging tax, further complicate decisionmaking, particularly in sectors where such costs could significantly impact operational expenses. These challenges underscore the complex environment businesses
must navigate, balancing growth opportunities against a backdrop of economic and regulatory changes. BP&R: What are the current market trends you’re seeing at Billion? SJ: Current market trends are steering towards enhanced machine efficiency, with a notable rise in demand for twin-shot machines, reflecting a preference for more sophisticated outputs straight from the moulding process. Our collaboration with Sepro for robotics underscores a broader industry trend towards automation, despite some manufacturers opting to produce their own robotics. The shift from hydraulic to electric machines is also prominent, driven by their energy efficiency and operational cost savings, although there’s some resistance from those less familiar with electric machinery’s benefits. Nonetheless, electric machines, particularly in the 200 to 400-tonne range, are gaining popularity due to their ability to balance performance with sustainability, aligning with market priorities for advanced, efficient production solutions.
“Current market trends are steering towards enhanced machine efficiency, with a notable rise in demand for twin-shot machines."
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The pioneer of mouldmaking for 100 years. HASCO has carved a remarkable journey over the past century, establishing itself as a pioneer in the mouldmaking industry. From its humble beginnings in 1924, the company has thrived on innovation and an unwavering commitment to excellence. This story delves into HASCO’s evolution, highlighting its role as an early adopter and innovator, shaping not just its own destiny but also setting benchmarks for the industry at large. The inception of HASCO under Hugo Hasenclever’s vision in 1924 marked the beginning of a revolutionary journey in mouldmaking. Starting as a small craft operation, the company’s early foray into innovation was spearheaded by Hugo’s son, Rolf Hasenclever, who recognised the potential for transformative change. This period was characterised by pioneering efforts that laid the groundwork for the company’s future, with a focus on quality, efficiency, and the nascent idea of standardisation that would later define HASCO’s contributions to the industry.
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09.02.2024 06:45:52
ON THE COVER
100-YEAR JOURNEY
IN MOULDMAKING EXCELLENCE MAJOR MILESTONES: 1924 - 2024
1924
1937: Initiation of a bespoke apprentice workshop by Hugo Hasenclever, emphasising training and skill development 1937
1924: Hugo Hasenclever establishes the craft enterprise, marking the beginning of HASCO
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1957
1960
1957: Rolf Hasenclever, a trained toolmaker and mechanical engineer, assumes leadership following his father’s passing
1969
1976: Wordwide expansion and increase of production and storage capaitieds leads to opening of sales branches and warehouses in Singapore, England and France
1970: Patent application for conical heating cartridges
1960: The revolutionary modular standard mould system is patented, facilitating international standardisation
1970
1969: Hasenclever & Co.
changes its name to the globally protected and recognised HASCO
1973
1976
1973: Worldwide expansion - Increase in production and storage capacities ensures rapid delivery to customers
1980
1982
1980: New central warehouse at the headquarters in Lüdenscheid - Capacities increased from 30,000 to 60,000 standard mould units
It may not have been until 1957 that Rolf took over the family business, but he was always something of a protégé. As a youngster Rolf, would creep into his father’s workshop at night to help; to finish projects, projects like a roly-poly toy - a notoriously difficult engineering project, in the mid 20th century, it had to be perfectly engineered so it would wobble but not fall down. This kind of ingenuity meant his father had full faith in Rolf’s ability to propel HASCO.
In a press conference to celebrate the centenary, Christoph Ehrlich pointed to the fact that the company’s approach is that necessity is the mother of invention. “Everything we innovate is about making things easier. There are always consultants who coin terms like 'digitalisation' but in the end, it’s companies like HASCO that must design and implement the processes. That’s what we do and always have done throughout our history.”
The year 1960 was a watershed moment for HASCO, with the patenting of the modular standard mould system, a game-changer that significantly reduced production times and costs, heralding a new era in mouldmaking. This innovation was followed by a series of advancements, including the adoption of cutting-edge machinery and the development of unique technologies that further solidified HASCO’s leadership in the industry. These breakthroughs not only enhanced HASCO’s product offerings but also redefined industry standards, showcasing the company’s commitment to pioneering new solutions.
HASCO’s 100-year narrative is a testament to its pioneering spirit, with a consistent focus on innovation, customer satisfaction, and a forward-thinking approach. The company’s readiness to lead the mouldmaking industry into the future is evident in its historical achievements and ongoing commitment to excellence and innovation.
In 2007, HASCO underwent a significant leadership transition, setting the stage for a new chapter in its storied history. This period saw the company doubling down on modernisation efforts, including infrastructure upgrades and the introduction of innovative tools like HASCO SET. The new management’s strategic vision was clear: to maintain HASCO’s tradition of innovation while steering the company towards a future filled with possibilities, ready to adapt and lead in an ever-changing industry landscape.
HASCO’s journey through the latter half of the 20th century and into the 21st was marked by significant expansion and modernisation. The company’s international footprint grew, with a strategic focus on global markets that necessitated a modern approach to production and operations. Advancements in CAD technology were swiftly adopted, enabling HASCO to enhance design precision and efficiency. These steps were part of a broader strategy to not only meet the growing demand for high-quality moulds but also to stay ahead in a rapidly evolving industry.
1982: Thomas Hasenclever marks third generation to take over leading positions in the company 1983
1984: Start of plate manufacture in California, USA
1984
1983: Launch of the HASCO CAD standard mould unit module - a milestone in the history of CAD development
1997
“An incredible journey of 100 years lies behind us,” stated Ehrlich. “Even a world war and several economic crises could not stop. This journey will continue, and we will always have our innovative strength as a constant companion.”
HASCO’s journey into the digital era, guided by CEO Christoph Ehrlich’s foresight, reflects a proactive embrace of digital processes and tools to streamline operations and enhance customer experiences. This digital transformation, rooted in HASCO’s foundational principles of innovation, global outreach, customer focus, and teamwork, underscores the company’s resilience and adaptability.
1999: Large-scale construction project: New administration building and production facility with opening of the present-day company headquarters 1999
1997: First HASCO 3D standard mould unit module for Uni Graphics
2007
2014: Brand relaunch and presentation of the new HASCO portal with innovative tools
2014
2007: Berndorf AG acquires a majority shareholding, with Christoph Ehrlich appointed CEO
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2015
2019: Launches HASCO SET – The offline Standard Engineering Tool for designers and mouldmakers 2019
2015: Fully automatic sales processes Industry 4.0
2024
2024: HASCO - The pioneer of mouldmaking celebrates its centenary
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BLOW MOULDING
Trexel Brings its MuCell Technology Beyond Automotive Applications
T
he use of recycled plastic materials is a critical factor in the move towards a fully closedloop economy in the plastic industry. Between 2009 and 2020, the total mass of packaging waste generated in the EU rose by 20%. The packaging and packaging waste division (PPWDDirective 94/62/EC) lays out
Sam Dix, R&D director at Trexel Inc., dissects Trexel’s expansion into the foamed blow molding space for consumer packaging in response to challenging new sustainability targets. measures to prevent such waste to encourage the reuse of such packaging. The proposals are designed to reduce the disposal of packaging waste and promote a fully circular economy. In October 2023, the European Parliament Committee on the environment, public health and food safety (ENVI), adopted a proposal stating
that general packaging should contain at least 35% content recovered from postconsumer sources, rising to 65% by the same date in 2040. This report proposal was voted in favour by a majority of 68% by the EU Parliament in November 2023. The governing EU council then adopted the ENVI's negotiating position in December 2023. The
“General packaging should contain at least 35% content recovered from post-consumer sources, rising to 65% by the same date in 2040." (Article 7. EU 2022/3096COD) 14
consensus is that this will become not just a directive, but a full legislation. This is part of a wider initiative to reduce waste per capita by 10% by 2030 and 20% by 2040. Some of the wider objectives include changes to the recycling and reuse of wood, metals and glass, as well as providing initiatives in plastics to not only recycle but to also refill items like beverage containers at the point of sale. It is not just PET bottles that are being targeted. These targets are set to follow over the Atlantic and beyond in coming years with some states already in the USA following suit. With such aggressive targets and time-sensitive goals in the headwinds, producers are concerned
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BLOW MOULDING about implementation and costs associated with such developments. Not only will supply and demand of raw materials be a major issue borne on the resin suppliers, but also the availability of appropriate technology to ensure processes and products are cost-competitive and do not contribute to costs passed on to the consumer in times of high inflation. These measures have been long in the making and Trexel has been preparing an array of technology options using its MuCell trademarked technology. Trexel has built a reputation as a main physical foaming solution in injection moulding and has had great success to date in automotive and industrial foamed goods to reduce product weight, clamp tonnage (wear on the mould) as well as improving dimensional stability by eliminating sink marks and warp. Additionally, because the technology allows thin to thick foaming along the flow path, moulds can be redesigned to remove even more weight. These physical foaming systems can be purchased as options for most injection moulding OEMS in the market around the globe. Trexel also
sells a patented chemical foaming solution that boasts a superior surface appearance, but is used for lower weight reductions where the focus is to purely eliminate sink and warp. In direct response to the new legislation proposals, Trexel has leveraged its technology to provide foaming of beverage containers for reusable cups. These can be foamed down to a density of 200kg/m3 and provide the correct insulation for hot beverages whilst having enough integrity to be reused and refilled at the point of sale. This is something outlined in the directive, such that 20% of beverages filled at the point of sale available in reusable packaging will be 20% by 1st Jan 2030 and 80% by 1st Jan 2040. This technology was on display at Trexel’s booth at the K-Show in 2022 a collaboration with Arburg and Bockatech, which it called EcoCore. Trexel has also entered the foamed blow moulding space for consumer packaging in addition to its portfolio of solutions for low-density automotive ducts. The consumer packaging blow moulding solution can be used to foam a 2 or morelayer bottle to reduce the overall weight of the part by up to 25% for a similar thickness as solid bottles with corresponding similar; top load, impact strength and ESCR properties. This is a game changer when incorporating 35% PCR content as per the proposed legislation because the foaming
can reduce the overall package price. For example, a bottle foamed 15% with the same wall thickness containing 35% PCR at 1.5 times the cost of the solid can be produced at the same cost as the virgin solid, thus providing a very cost-effective and sustainable option that abides by the new legislation. Preferentially, the foaming also creates an opacity that enables off-white PCR grades to look white again without adding more tiO2 masterbatch. The technology does require a multiple layer machine, but the gas pumping system can be directly retrofitted by
simply drilling a hole into the barrel. The solution can be applied to shuttle or wheel machines. There is no need to change other equipment. The technology revolves around a pump investment only and there are no license fees. Typical applications are; household goods, cosmetics and industrial containers. Trexel is working with W. Muller in Germany and USA to provide a turnkey solution. W. Muller is a specialist in multilayer head technology for the processing of PCR, and the synergy of the two technologies lends itself well to creating the best possible foaming solution.
“With such aggressive targets in the headwinds, producers are concerned about associated costs."
PENWELD A
PRECISE PLASTIC WELDING
LEFT: Figure 1 - Trexel hot drink container foamed to a density of 250kg/m³.
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17
POLYMERMAN
Price Know-how Review & Outlook 2023 REVIEW
FIG 2 Feedstock GBP per Tonne
FIG 1
Brent Crude Oil Price per tonne 900.00 850.00 800.00 750.00 700.00 650.00 600.00 USD per tonne
GBP per tonne
550.00 500.00 450.00
Ja n22 Fe b22 M ar -2 2 Ap r-2 2 M ay -2 2 Ju n22 Ju l-2 2 Au g22 Se p22 Oc t-2 2 No v22 De c22 Ja n23 Fe b23 M ar -2 3 Ap r-2 3 M ay -2 3 Ju n23 Ju l-2 3 Au g23 Se p23 Oc t-2 3 No v23 De c23
400.00
Crude Oil Brent Crude traded in a relatively tight range of 75 90 USD per barrel. Prices fell until mid-2023 before a short rally over the summer months, and then fell sharply back to levels that were below those at the start of the year. The reaction of crude oil prices to the issues in the Red Sea area at the end of the year was quite muted, with a view that domestic inventories and increased supply from Saudi Arabia would be sufficient to smooth any disruption. 18
£2,500.00 Brent Crude Naphtha Spot
£2,000.00
Ethylene (C2) Spot Ethylene (C2) Contract
£1,500.00
Propylene (C3) Spot Propylene (C3) Contract
£1,000.00
Benzene Spot Benzene Contract
£500.00
Styrene (SM) Spot Styrene (SM) Contract
£0.00
02 2 r2 02 ay 2 20 22 Ju n 20 2 Ju 2 l2 02 Au 2 g2 0 Se 22 p 20 O c 22 t2 0 N o 22 v2 0 D e 22 c2 02 2 Ja n 20 23 Fe b2 M 3 ar 20 Ap 23 r2 02 M 3 ay 20 23 Ju n 20 2 Ju 3 l2 0 Au 23 g2 0 Se 23 p 20 O c 23 t2 02 3 No vD e 23 c2 02 3 Ap
Paraxylene (PX) Spot
M
22 20
20 b
ar 2
Fe
Ja n
22
Paraxylene (PX) Contract
M
Executive Summary The economy in 2023 was dominated by the effects of the global economic slowdown. Relatively high levels of price inflation present in the first half of the year started to moderate towards the end of the year. In addition to the continuing conflict between Russia and Ukraine, the terrorist attack by Hamas on Israel and the subsequent conflict in Gaza raised geopolitical tensions in the Middle East, and at the very end of the year Houthi terrorist action against commercial shipping in the Red Sea, raised concerns about supply chain security and shipping costs. Energy prices moderated from the hiatus in 2023. In the polymer markets, the price trend continued lower. All sectors witnessed supply exceeding demand, a situation which for many materials was exacerbated by producer capacity increases. A small price upswing, for volume polymers, in the Autumn was not sustained as producers fought hard to win available volumes. Prices have now fallen to the extent that polymer producers termed the situation as ‘bottom of cycle economics’ resulting in idling and closure of plants where the financial performance is no longer viable. This effect was more pronounced in Western Europe, due to the higher cost of operating polymer plants in this region, which will inevitably result in a greater dependence on imports. In the energy sector, the risk of global recession continued to outweigh geopolitical concerns that could affect the supply of oil and gas. Even the disruptions caused to shipping routes by the actions of the Houthi rebels at the very end of the year had negligible impact on pricing, as markets took the view that domestic inventories were sufficient to cover any delays in shipments. Despite the challenges of 2023, the UK plastics sector has once again demonstrated resilience in the face of significant challenges.
Feedstock The volatility of aromatic feedstock continued in 2023, with both Benzene and Styrene monomer recording significant swings, which were often independent of Brent Crude and Naphtha. The olefin situation was dominated by over-supply, with spot prices trading at a significant discount to the contract values. In the case of C2 high import penetration of competitively priced PE, suppressed demand, and although C3 is typically a coproduct of Naphtha cracking from C2 production, the reduction was insufficient to avoid a glut of C3 and hence the large discounts for spot purchases.
FIG 3
C2 Jan 2022 Feb 2022 Mar 2022 Apr 2022 May 2022 Jun 2022 Jul 2022 Aug 2022 Sep 2022 Oct 2022 Nov 2022 Dec 2022 Jan 2023 Feb 2023 Mar 2023 Apr 2023 May 2023 Jun 2023 Jul 2023 Aug 2023 Sep 2023 Oct 2023 Nov 2023 Dec 2023 Cumlative 2022 Cumlative 2023 Sum
C3 0.00 67.50 95.00 230.00 (70.00) 0.00 (100.00) (70.00) (120.00) (45.00) 35.00 (25.00) (95.00) 85.00 30.00 (40.00) (10.00) (80.00) (40.00) 0.00 75.00 60.00 (45.00) (30.00) (2.50) (90.00) (92.50)
SM 0.00 67.00 95.00 225.00 (65.00) (10.00) (120.00) (85.00) (165.00) (50.00) 20.00 (30.00) (95.00) 80.00 30.00 (40.00) (15.00) (80.00) (50.00) 0.00 60.00 60.00 (40.00) (30.00) (118.00) (120.00) (238.00)
Benzene 119.00 209.00 (51.00) (85.00) 93.00 20.00 360.00 48.00 84.00 45.00 16.00 297.00 155.00 386.00 (509.00) (663.00) (287.00) (318.00) 9.00 22.00 4.00 42.00 (132.00) (196.00) 115.00 145.00 10.00 108.00 (113.00) (1.00) 19.00 (1.00) 55.00 89.00 (127.00) (110.00) (87.00) (79.00) 108.00 (18.00) 170.00 41.00 60.00 232.00 (149.00) (148.00) (116.00) (196.00) (139.00) (193.00) (55.00) 62.00 (194.00) (131.00)
Such was the state of demand for polymer raw materials, that producers were typically forced to pass through monomer discounts in full, with polymer converters typically resisting full monomer increases and often able to achieve discounts greater than monomer as competition for available volumes was intense. The following graph (Fig 4) clearly confirms the oversupply of both C2 and C3 with spot volumes selling at significant discounts versus Naphtha. Even contract monomer margins were dragged down by spot pricing; this is especially evident for C3 in the late summer period.
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FIG 4
FIG 5 Aromatics Premium over Brent Crude
Olefins Premium over Brent Crude 100%
20% 80%
0%
60%
Ja n 2 Fe 022 b 2 M 02 ar 2 20 Ap 22 r M 202 ay Ju 202 n 20 Ju 22 l2 Au 022 g2 Se 022 p 2 O c 022 t2 N o 022 v2 De 022 c2 Ja 022 n 2 Fe 023 b 2 M 02 ar 3 2 Ap 023 r M 202 ay 3 2 Ju 023 n 20 Ju 23 l2 Au 023 g2 Se 023 p 2 O c 023 t2 N o 023 v2 De 023 c2 02 3
10%
40%
-10% -20%
20%
-30% -40%
Ja n 2 Fe 022 b 2 M 022 ar 20 Ap 22 r2 M 02 ay Ju 202 n 20 Ju 22 l2 Au 022 g2 Se 022 p 2 O c 022 t2 N o 022 v2 De 022 c2 Ja 022 n 2 Fe 023 b 2 M 023 ar 2 Ap 023 r2 M 02 ay 3 2 Ju 023 n 20 Ju 23 l2 Au 023 g2 Se 023 p 2 O c 023 t2 N o 023 v2 De 023 c2 02 3
0%
-50%
-20%
-60% -40%
-70% -80%
-60%
Naphtha Spot
Ethylene (C2) Spot
Propylene (C3) Spot
Propylene (C3) Contract
Ethylene (C2) Contract
Naphtha Spot
Benzene Spot
Styrene (SM) Spot
Styrene (SM) Contract
Benzene Contract
The graph above right (Fig 5) clearly illustrates the relative volatility of aromatic feedstocks, with periods of discount and significant premium. The past year has been more stable, with SM peaking in August on the back of supply restrictions. Polyolefins Min
Max
Average
Range
GBP Volatilty
Euro Volatilty
2011
£1,083.86
£1,254.28
£1,254.28
£170.42
14%
18%
2012
£996.99
£1,296.36
£1,190.35
£299.38
25%
24%
2013
£1,178.07
£1,312.98
£1,252.85
£134.91
11%
10%
2014
£1,075.70
£1,251.19
£1,182.12
£175.50
15%
11%
2015
£879.41
£1,247.39
£1,088.53
£367.98
34%
37%
2016
£1,071.30
£1,239.74
£1,157.95
£168.44
15%
7%
2017
£1,174.96
£1,289.37
£1,247.21
£114.41
9%
9%
2018
£1,231.36
£1,303.88
£1,266.78
£72.51
6%
7%
2019
£1,083.50
£1,266.89
£1,174.44
£183.39
16%
10%
2020
£978.78
£1,144.82
£1,072.74
£166.04
15%
16%
£1,128.83
£1,868.60
£1,628.61
£739.78
45%
53%
£1,545.91
£2,074.12
£1,765.68
£528.21
30%
33%
2023
£1,305.14
£1,563.53
£1,446.00
£258.39
18%
15%
Overall
£879.41
£2,074.12 £1,273.46
£1,194.71
45%
53%
FIG 6
FIG 7
2021 2022
PE Basket Spreads £1,800.00 £1,600.00
Polyolefins
£1,400.00 £1,200.00
£2,100.00
PE Basket
£1,000.00
PE Basket Over Crude
£800.00
£1,900.00
PE Basket Over Naphtha
£600.00
PE Basket Over C2 Spot
£400.00
£1,700.00
PE Basket Over C2 Contract
£200.00
Naphtha Spot Ethylene (C2) Contract
£900.00
Propylene (C3) Spot Propylene (C3) Contract Polyolefin Basket
£500.00
De c23
Oc t-2 3
No v23
Se p23
Ju l-2 3
Au g23
Ju n23
Ap r-2 3 M ay -2 3
M ar -2 3
£2,500.00 £2,000.00 £1,500.00 £1,000.00
£300.00
£500.00 £0.00 Ja n2 M 2 ar -2 M 2 ay -2 2 Ju l-2 2 Se p2 No 2 v22 Ja n23 M ar -2 M 3 ay -2 3 Ju l-2 3 Se p2 No 3 v23
Ju l-2 3 Se p23 No v23
Ju l-2 2 Se p22 No v22 Ja n23 M ar -2 3 M ay -2 3
£100.00 Ja n22 M ar -2 2 M ay -2 2
PP Basket Spreads
Ethylene (C2) Spot
£1,100.00
£700.00
20
Ja n23
De c22
Brent Crude
£1,300.00
FIG 8
£ per tonne
£1,500.00
Fe b23
£0.00
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PP Basket PP Basket Over Crude PP Basket Over Naphtha PP Basket Over C3 Spot PP Basket Over C 3 Contract
FIG 9
With the exception of a couple small upward blips in April and November, the price trend was fundamentally downward for the polyolefins basket. Polymer converters were able to exploit the strong competition among suppliers to their advantage. Polypropylene and polyethylene pricing coincided by the end of Q1 2023, and this is due to a number of factors including:
Relative PP/PE Pricing £ per tonne £2,300.00 £2,100.00 £1,900.00 £1,700.00 £1,500.00 £1,300.00
1. A relative reduction in the C3 price compared to the C2 price
£1,100.00
2. PP producers taking advantage of the low C3 spot pricing
Dec-23
Oct-23
Nov-23
Sep-23
Jul-23
Aug-23
Jun-23
Apr-23
May-23
Mar-23
Jan-23
Feb-23
Dec-22
Oct-22
Nov-22
Sep-22
Jul-22
Aug-22
Jun-22
Apr-22
Styrenics £2,600.00
£2,100.00
Brent Crude
£1,600.00
Benzene Spot Benzene Contract Styrene (SM) Spot
£1,100.00
Styrene (SM) Contract Styrene Basket
£600.00
Dec-23
Oct-23
Nov-23
Sep-23
Jul-23
Aug-23
Jun-23
May-23
Apr-23
Mar-23
Feb-23
Jan-23
Dec-22
Nov-22
Oct-22
Sep-22
Aug-22
Jul-22
Jun-22
Apr-22
May-22
Mar-22
£100.00 Jan-22
>
PE Basket
FIG 10
Feb-22
Styrenics A relatively stable year in terms of styrenic polymer pricing. The late summer increase in crude oil pricing passed through to selling prices, with prices then falling away towards the end of the year.
PP Basket
£ per Tonne
The supply of PE from the USA that resumed in 2022 became a dominant factor in 2023, with a strong flow of materials for film extrusion and blow moulding arriving at competitive prices. UK converters have become accustomed to the longer lead times and consequent need to often make forward price commitments in order to secure supply.
May-22
3. Lower production and/or demand for consumer durables such as cars and white goods for which PP is a much more significant market segment than it is for PE.
Mar-22
Jan-22
Feb-22
£900.00
Min
Max
Average
Range
GBP Volatilty
Euro Volatilty
2011
£1,455.41
£1,738.32
£1,622.02
£282.91
17%
11%
2012
£1,452.41
£1,642.55
£1,578.63
£190.15
12%
10%
2013
£1,671.73
£1,797.07
£1,735.75
£125.34
7%
7%
2014
£1,476.79
£1,676.77
£1,606.53
£199.99
12%
8%
2015
£1,225.39
£1,499.12
£1,362.43
£273.73
20%
23%
2016
£1,337.20
£1,637.95
£1,508.17
£300.75
20%
11%
2017
£1,688.91
£2,024.70
£1,821.47
£335.79
18%
17%
2018
£1,674.44
£1,947.98
£1,845.19
£273.53
15%
17%
2019
£1,470.71
£1,689.42
£1,613.05
£218.71
14%
13%
2020
£1,330.68
£1,654.70
£1,466.38
£324.02
22%
20%
2021
£1,760.01
£2,420.25
£2,100.55
£660.24
31%
34%
2022
£2,073.08
£2,731.88
£2,392.41
£658.80
28%
30%
2023
£1,858.61
£2,165.15
£2,016.37
£306.54
15%
12%
Overall
£1,225.39
£2,731.88
£1,743.77
£1,506.49
31%
34%
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21
FIG 11
Styrenics Basket Spread £1,800.00 £1,600.00 Styrenics Basket Over Crude
£1,400.00 £1,200.00 £1,000.00
Styrenics Basket over Benzene Spot
£800.00
Styrenics Basket over Benzene Contract
2024 OUTLOOK
Styrenics Basket Over Spot Styrene
£600.00
FIG 12
Dec-23
Oct-23
Nov-23
Sep-23
Jul-23
Aug-23
Jun-23
Apr-23
May-23
Mar-23
Jan-23
Feb-23
£400.00
Engineering Polymers £5,000.00 £4,500.00 £4,000.00
£ per tonne
£3,500.00 £3,000.00
Brent Crude
£2,500.00
Benzene Spot (EUR/t) Benzene Contract (EUR/t)
£2,000.00
Naphtha Spot (EUR/t)
£1,500.00
£500.00 Dec-23
Oct-23
Nov-23
Sep-23
Jul-23
Aug-23
Jun-23
Apr-23
May-23
Mar-23
Jan-23
Feb-23
Dec-22
Oct-22
Nov-22
Sep-22
Jul-22
Aug-22
Jun-22
Apr-22
May-22
Mar-22
Jan-22
Feb-22
£0.00
FIG 13
Engineering Polymer Basket Spreads £4,000.00 £3,500.00
Engineering Polymers Basket
£3,000.00 £2,500.00
Engineering Polymers Over Crude
£2,000.00
Engineering Polymers Over Spot Benzene
2011
22
Dec-23
Nov-23
Oct-23
Sep-23
Aug-23
Jul-23
Jun-23
May-23
Apr-23
Mar-23
Feb-23
Jan-23
£1,500.00
UK Economic Outlook The UK General Election, which is likely to be held in the second half of the year will be a significant factor affecting the UK economy, prior to which a budget in March may offer some economic stimulus through lower rates of taxation at either a personal or corporate level. Forecasts from the UK manufacturing sector are robust, with growth anticipated. Some recovery in the consumption of consumer durables is likely as consumer behaviour returns to a more normal pattern. The UK Government continues to review the UK REACH legislation and has already extended the registration deadlines. Consultation that took place in 2023 may result in further changes and it is anticipated that registration fees are set to be lowered.
Engineering Basket
£1,000.00
£4,500.00
Engineering Polymers The engineering polymers market very much reflected the broader global economic situation with prices sliding throughout the period. The high level of competition for available volumes eroded producer margins.
Global Geopolitical Issues The Israel conflict with Gaza added to the pre-existing Russian invasion of Ukraine. As 2024 gets underway, there is the further issue of Houthi rebels from Yemen causing disruption to global shipping routes. These conflicts raise concerns of a wider conflict between East and West. Logistics The increase in shipping time resulting from not using the Red Sea and Suez Canal routes is effectively reducing shipping and container capacity and this has caused a
Min
Max
Average
Range
GBP Volatilty
Euro Volatility
£2,797.47
£3,125.71
£2,992.91
£328.24
11%
8%
2012
£2,709.19
£2,821.57
£2,759.92
£112.38
4%
3%
2013
£2,806.99
£2,911.74
£2,864.60
£104.74
4%
2%
2014
£2,653.57
£2,798.40
£2,798.40
£144.83
5%
3%
2015
£2,336.07
£2,549.00
£2,406.03
£212.93
9%
2%
2016
£2,474.80
£2,886.83
£2,653.97
£412.03
16%
2%
2017
£2,803.68
£3,223.95
£3,054.98
£420.27
14%
19%
2018
£3,235.48
£3,409.01
£3,328.41
£173.53
5%
5%
2019
£2,942.34
£3,276.32
£3,153.67
£333.98
11%
8%
2020
£2,908.67
£3,098.01
£3,027.08
£189.34
6%
4%
2021
£3,104.82
£3,760.12
£3,533.57
£655.30
19%
18%
2022
£3,697.17
£4,403.93
£3,984.32
£706.76
18%
21%
2023
£3,662.96
£4,351.57
£3,984.32
£688.62
17%
13%
Overall
£2,336.07
£4,403.93
£3,133.14
£2,067.85
19%
21%
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significant spike in spot container shipping rates. Whilst the effect on pricing is not likely to be as severe as it was in 2022, some polymer converters are facing shortfalls in supply at the start of 2024. If the situation in the Red Sea is resolved, then there will be a consequent reduction in shipping times, and with that the risk of a supply glut. On the domestic front, the issue with a shortage of HGV drivers appears to have eased, and even in the final quarter of 2023 when seasonal demand is high, there were no significant issues. Logistics cost inflation appears to be easing due to a reduction in demand for physical storage as the inventory glut that resulted from the end of the Covid-19 era continues to diminish. The high cost of finance is also causing inventory levels to be reduced on the grounds of affordability. Exchange Rates US and UK elections are likely to have a significant influence on exchange rates. The outcome of the UK general election is more predictable, and any uncertainty will relate to the changes in economic policy that a new government may choose to make, or how manifesto pledges are delivered. Crude Oil The likely scenario is that Brent Crude will continue to trade in the 70 – 90 USD per barrel range, with energy companies trying hard to manage supply in an economic environment that will tend towards falling prices. It is notable that many traditional energy companies that have been heavily reliant on Crude Oil sales, have increasingly diversified their sources of revenue, with many now turning more to renewables for sustainability both for the planet and their business models. Feedstock C2 (Ethylene) Ethylene pricing is likely to be heavily influenced by the level of PE imports from the USA, which are expected to increase further in 2024 and keep C2 pricing at relatively low levels. C3 (Propylene) C3 has a double reliance on crude oil refining in which C3 is a significant co-output of Naphtha cracking for ethylene and also a by-product of the FCC (Fluidised Catalytic Cracking) process used to upgrade the petroleum fraction of crude oil distillate to the required environmental standards. Whilst the ratio of C2 to C3 in the Naphtha cracking process can be adjusted, this is within a relatively narrow window and therefore low C2 demand along with refinery output rates will impact C3 availability. Demand for petroleum is likely to be reduced through the increased use of EVs. Recovery
in C3 demand to make polypropylene required for consumer durables, could tip supply/demand back in the favour of the producers. In turn, this could lead to some cross-subsidy of C2, which is derived from Naphtha cracking. Benzene This is an important aromatic hydrocarbon compound which is the basis for the following intermediates including: Ethylbenzene Cumene Cyclohexane Nitrobenzene Linear Alkylbenzene Maleic Anhydride Others Of which Ethylbenzene, Cumene and Cyclohexane are precursors to key monomers including SM (Styrene based polymers), Bisphenol A (PC) and HMXDA (PA66) Price volatility is expected to continue, particularly as petrochemical producers seek to improve the economics of this important aromatic petrochemical compound. Styrene Monomer (SM) The fortunes of SM are closely related to Ethylbenzene and in turn Benzene. An important characteristic of SM and the Benzene family is the relative ease with which these products can be shipped around the world in tanker vessels, and this tends to increase volatility as the material is either distressed in the case of surplus and exported or imported in the case of shortage.
Engineering Polymers 2024 starts much the same as 2023 finished with downward pressure on prices and plentiful supply from producers across the board. It is expected that notations for most engineering polymers will continue to soften throughout the year, as competitive pressures continue. Taxes PPT and Corporation Tax The UK plastics packaging tax that came into effect in April 2022, at a rate of £200 per tonne for plastics packaging that contains less than 30% recycled content, was increased to £210.82 from April 2023 and is likely to be further adjusted by the rate of inflation in 2024. In the case of plastic raw materials, this typically costs about £1.00 per tonne due to the liability incurred on plastic valve sacks. The more significant impact relates to the supply of plastic packaging where the liability applies to each tonne of packaging produced, with the last entity undertaking a ‘significant transformation’ picking up this tax liability. The opportunity to use chemical recycling and adopt a mass balance approach is still under discussion with HM Treasury. Following the increase in the rate of UK Corporation Tax in April 2023 from 19% to 25%, it is possible that this rate may be eased at the forthcoming spring budget.
SM is also a derivative of Propylene Oxide synthesis which is an important component of polyurethane manufacture, for use in markets such as automotive and furniture. Polyolefins 2024 will continue to be challenging for Polyolefins as new capacity for all grades comes on stream and demand is not expected to match it. Highly commoditised grades such as PPHP, HDPE for blow moulding and LLDPE C4/C6 for film applications will be under the most pressure. Oversupply in these sectors will push producers to increase output of more specialised grades which will bring downward price pressure on these more premium products Styrenics The situation for 2024 starts with some uncertainty. In the case of ABS and speciality styrenic polymers, it appears that the increases in global shipping costs have already sparked calls for price increases. Polystyrene prices are likely to closely follow the volatility of SM (Styrene Monomer). www.interplasinsights.com
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 23
INDUSTRY NEWS
Time for Change: Lasers in the Plastic Industry Christopher Ogden, founder of Laser Partners UK Limited, based in Sheffield, explores the plastic industry’s hesitancy to introduce laser technology and why it could be something to consider. Growth in Industrial Laser Uptake The uptake of industrial laser processing since its inception into the mainstream industry in the 1970s has been nothing short of phenomenal, with $5.7BN worth of lasers sold in 2018 and a prediction that this will increase to $14.5BN by 2026. So, what can laser technology offer the plastics industry? In summary, quite a lot. Here’s a brief list of the laser process options available today: • • • • • •
Laser Marking Laser Plastic Welding Laser De-Gating Laser Cleaning Laser Stripping Surface Texturing
Laser Marking of Plastics Probably the most popular and widely used of these technologies is Laser Marking – where laser systems with different wavelengths can be used to mark almost all plastic materials. Fast marking times of just a few seconds are achieved for the most basic marking applications. Companies typically use laser marking systems to mark company logos, part numbers, and machine-readable codes such as 1D and 2D barcodes. "The wide range of plastic materials and their different colour additives and glass fibre content can make it difficult to mark some materials with a high contrast mark. But by using the right laser technology, almost all of these can be marked with a really good quality mark - whether the plastic is dark, light or colourless," stated Masahide Okano from laser system supplier, Datalogic.
CO2, Fibre and DPSS Laser Marking Systems 24
Laser Plastic Cutting and De-gating Most people are aware of laser cutting for steelbased applications, but using longer wavelength CO2 lasers also gives good results on thermoplastics. "With the right setup and laser parameters a cut edge with little or no discolouration can be achieved on most plastics, and on plastic material thicknesses of up to 25mm. With less dense materials thicker sections can also be cut," stated Lee Popplewell of Luxinar, a Hull-based CO2 laser technology company. CO2 laser technology creates a long wavelength of 10.6µm, by electrically charging gas contained within a sealed tube. Mirrors and lenses allow the system to build up sufficient power that can then be focused to perform different tasks. The longer CO2 laser wavelength means that it is readily absorbed by most polymers. Acrylic is one material where a neat, almost polished edge quality, is generally www.interplasinsights.com
achieved, and many other materials will also give excellent results. With laser de-gating, the simple application of laser cutting eliminates the need for mechanical cutting blades, that eventually wear and require scheduled maintenance. As with many laser processes, there is no mechanical load resulting from the laser beam, so parts do not need to be clamped in position for laser processing. Laser Mould Tool Repair Laser welding is used for the repair of steel injection mould tools, with many tool makers using laser welding with filler wires to repair worn edges, cracks and fractures on mould tools, to extend the life
of mould tools. These systems are surprisingly simple to use with filler wire options available for most steel grades, including wires that leave a hardened deposit. The use of pulsed laser technology, with a low flow rate shield gas, means that
INDUSTRY NEWS
thermal damage and discolouration of the repaired surface is minimised, with results vastly superior to conventional welding processes, although deposit rates with laser welding are typically quite low.
BEFORE
AFTER
Plastic Laser Welding A less well-known process is the use of lasers for ‘laser plastic welding’. Techniques are different to metal welding and this technology is not suited to all plastics and part designs, so careful consideration needs to be taken. A common approach is to use two different plastics (sandwiched together), one that’s absorbent to laser and one that is not. By focusing the laser beam through the nonabsorbent plastic, the underlying absorbent plastic will then melt forming a welded seal between the two plastics. This can be a fast and effective process if material selection and part geometry are carefully considered at the design stage. Laser Cleaning One technology with a huge future is laser cleaning, which allows parts to be cleaned without damaging the underlying material and without the need for chemicals or abrasive media. Fast, effective and consistent results are achieved by using pulsed lasers to break the bonds between the top surface layer and the substrate. Whilst not a new technology, laser cleaning is finding new applications for many industrial cleaning requirements including coatings, rust, and oxidation removal, as well as paint and contaminant removal. 26
Like all laser processes, care needs to be taken to use the laser safely, but UK manufacturer Woodrow Scientific has a big advantage with their patented eye-safe laser cleaning system, which can potentially be used without the need to fully enclose the processing area. These laser cleaning systems can be supplied and used as either a handheld system or integrated as part of an automated or robotic setup. The use of different laser powers, optics and scanning devices can allow the
laser to clean significant surface areas in a host of different applications with mould cleaning as a popular application. Lasers & Plastics - A Technology for the Future Changes to more technology-based solutions can seem a daunting task when compared with more conventional methodologies. Due to using a ‘light beam’ instead of mechanical parts, fixturing and work holding requirements are often quite simple, www.interplasinsights.com
“Whilst not a new technology, laser cleaning is finding new applications in many industries." with no mechanical load exerted on the parts from the process itself. However, safety needs to be carefully considered too, with some level of protection required for all laser processes to prevent harmful exposure. But surprisingly with lasers, their integration
can be quite simple. Power requirements are usually met by a standard 3-pin plug socket, which helps keep costs low. The need for consumables with laser processes is usually low, or non-existent too. Lasers might be worth a look!
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ROBOTICS
Nigel Smith, managing director of TM Robotics, the international distribution partner of Shibaura Machine and the UK and Ireland distributor of its injection mould machines, explores the changing landscape of plastic’s injection moulding sector and argues the case for investment in new technologies, both for better operational efficiency and improved sustainability. Injection moulding applications have long played a key part in the UK’s manufacturing industry, producing everything from medical components, automotive parts, food containers, packaging items and much more. Traditionally, our manufacturers have relied on hydraulic-powered injection moulding machines in their operations.
Investing in the UK’s injection moulding sector: The case for all-electric machines and robotic integration
However, the industry is now at a crossroads, faced with the imperative to embrace technological advancements for sustainability and costeffectiveness. The case for allelectric One notable observation is the prevalence of hydraulic legacy equipment that is still being used by UK manufacturers. The TM Robotics’ injection moulding servicing department has witnessed this first-hand and regularly visits manufacturing sites to service and maintain Shibaura Machine’s own hydraulic injection mould machines — some of which have been in action for up to three decades. On one hand, it is a testament to the resilience of these machines, but the industry must consider the environmental downsides of this ageing equipment. The injection moulding process is responsible for up to 90% of the Global Warming Potential (GWP) in the entire mould lifecycle.
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Recognising this, TM Robotics has championed investment in all-electric injection mould machines to replace older, more energy-intensive models. The flagship all-electric range from TM Robotics is the SXIII all-electric series from Shibaura Machine. Shibaura Machine is the new name for Toshiba Machine — the Japanese manufacturer of industrial robots and injection mould machines. The SXIII range boasts faster injection speeds, enhanced sustainability and a streamlined design when compared to its hydraulic predecessors. What’s more, despite the perception of higher costs for all-electric machines, this range can
improve cost efficiency by lowering the cost-per-part. This was demonstrated by TM Robotics’ customer Lotan, a manufacturer of plastic containers based in Leicestershire, UK. Lotan’s production facility exclusively uses all-electric injection mould machines from Shibaura Machine. The SXIII provides significantly faster injection speeds than traditional moulding equipment, providing 35% faster cycle times than conventional hydraulic servo IMMs. Robotic integration Another area of debate in the injection moulding world is robot integration. The UK seriously lags behind other
“The UK seriously lags behind other developed countries for its number of robot installations. That’s not just for the world of injection moulding, but in the UK manufacturing sphere more widely."
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developed countries for its number of robot installations. That’s not just for the world of injection moulding, but in the UK manufacturing sphere more widely. In fact, the International Federation of Robotics (IFR) reports that the UK has just 101 robots per 10,000 employees — rookie numbers compared to competitors in the US, China and Germany. Due to this lack of uptake, the UK industry is missing some of the potential benefits of industrial robots, including improved productivity, efficiency and throughput. As a primary distributor of Shibaura Machine robots in the UK, the TM Robotics team has spotted opportunities for the injection moulding sector to reap the rewards of robotic automation.
The most obvious application for robots in mould machine shops is for the loading and unloading of injection mould machines. However, many end users currently have relatively low robotic ability, having traditionally chosen Cartesian X-Y gantry style robots to unload injection moulding machines. There are over 5,800 companies operating in the UK plastics industry, contributing £25 billion to our economy each year. As a key player in Britain’s manufacturing sector, injection mould shops must embrace technological advancements in injection moulding machinery and accompanying automation for improved profit, productivity and sustainability.
BP&R Joins Sepro’s 50th Anniversary Celebrations
Cutting the celebratory cake is Bertrand Humel van der Lee, managing director EMEA (Europe, Middle East, Africa), Sepro Group.
Monday 22nd January saw the official event to close off the 50th Anniversary celebrations for Sepro. Whilst the milestone was officially last year, the opportunity to gather OEM partners only arose in January.
Supporting communities worldwide with safe, reliable, efficient and sustainable polymer solutions from world-class producers.
As a truly independent global robot manufacturer, Glen Eves, general manager, was able to invite all of its UK OEM and integrator partners to join them for a hog roast lunch at their picturesque lakeside base in Milton Keynes.
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FTIR Plastic Analyser Method Package Including FTIR spectral library for plastics degraded by UV rays and heat
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NORDELL’S PATH TO SUSTAINABILITY:
Transforming Plastic Injection Moulding for a Greener Future Dan Grover, Nordell’s head of marketing & data analysis, sheds light on the various initiatives and innovations at Nordell that are driving its journey towards improved sustainability. The plastic injection moulding industry often faces scrutiny for its environmental impact, a challenge that Nordell takes seriously. We recognise the importance of advancing toward more sustainable practices as this commitment to environmental stewardship is deeply ingrained in our company ethos. From embracing renewable energy sources to developing bioplastics, we believe our efforts exemplify a dedicated approach to reducing our ecological footprint while maintaining our high production standards.
older, less efficient hydraulic moulding machines with cutting-edge electric models to enhance energy efficiency. This transition not only aligns with our environmental goals but also positions us at the forefront of technology in our industry. By adopting these energyefficient machines, we can minimise energy consumption while maintaining the highquality production standards that Nordell is known for. These steps are not just environmentally responsible; they also align with the UK’s goal of achieving net zero by 2050.
Investing in Green Energy
Pioneering with BioPlastics: Leading the Way in Sustainable Material Solutions
One of our primary strategies for reducing our environmental impact has been to focus on energy efficiency. Our facility in West Sussex is now home to a 270kw solar panel system. We are delighted that they have saved an impressive 51 tonnes of CO2 emissions so far, which is equivalent to the positive impact of planting 3,093 trees. With West Sussex recognised as one of the sunniest counties in the UK, we can benefit from the sun’s power (most) of the yearround. Meanwhile, a few years ago, we replaced our factory and office lighting with more energy-efficient LED lights. Not only do they help brighten our workspace, but paired with PIR (Passive Infrared) systems, they only activate when needed (in some non-critical locations), further maximising efficiency. Moreover, we have replaced
Our commitment to innovative material solutions is driven by an understanding of the environmental challenges posed by conventional plastics. By embracing bioplastics, we are not only responding to the growing demand for environmentally friendly products but also leading the way in sustainable manufacturing. Our collaboration with leading manufacturers in developing “Green” Bio-plastic alternatives showcases our dedication to this cause. A prime example of our efforts is our work with Trifilon Switch, a plant fibre-reinforced biocomposite. This material stands out for its eco-friendly composition and the ability to perform comparably to traditional plastics in various applications. www.interplasinsights.com
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INDUSTRY NEWS Trifilon Switch is made from renewable resources like sugarcane and beetroot, offering a responsible choice for eco-minded designers and engineers seeking to integrate sustainable materials into their products. Advanced Mould Tooling In our quest to overcome the challenges associated with integrating sustainable materials into existing applications, Archie, our talented trainee production engineer, spearheaded a transformative initiative. He conceptualised a novel approach to facilitate the adoption of bioplastics by our customers across various market sectors. His innovative idea involved the creation of a test product specifically designed to evaluate the properties and capabilities of new biomaterials under real-world conditions. This test piece featured an array of design elements, including bosses, ribs, varying wall sections, multiple surface finishes, flexible clips, and diverse draft angles. The goal was to simulate various scenarios that products might encounter, providing a comprehensive understanding of how these biomaterials perform. We invested in advanced mould tooling to support this endeavour, utilising our efficient modular insert system. This system streamlines the tooling process and significantly reduces both time and costs, making it an ideal choice for experimenting with various product designs. Recognising the potential of this project, Archie reached out to our material supply partners with the biotest plaque concept. The overwhelmingly positive response reflected our partners’ shared commitment to sustainable solutions. As a result, plans are now in place to produce injection
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moulded parts using this innovative modular tooling, showcasing a range of sustainable biomaterials provided by our partners. Embracing Lean Manufacturing and Continuous Improvement We have implemented LEAN methodology throughout Nordell, focusing on waste reduction and continuous improvement. This approach is more than just minimising waste; it enhances efficiency and maximises our resources. Our efforts are supported by our ISO14001 accreditation, which underscores our commitment to effective environmental management. Community Engagement: Beyond Business At Nordell, we firmly believe that our responsibility as a manufacturer in the plastic injection moulding industry goes hand-in-hand with our role as an active community member. This philosophy is exemplified by our involvement in initiatives like the ‘Annual Beach Clean’ in Worthing, a project that resonates with our environmental stewardship and community engagement ethos. The Annual Beach Clean is not just an event; it’s a symbol of our dedication to making a tangible, positive impact on the environment and the community we are a part of. Each year, our team at Nordell, equipped with rubbish pickers, gloves, and bags, sets out to clean up our local beach. This effort helps protect the marine ecosystem and preserves
“From renewable energy sources to bioplastics, we believe our efforts exemplify a dedicated approach to reducing our ecological footprint while maintaining our high production standards."
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the natural beauty of our coastline. But more than that, it’s a day where we strengthen our bond with the community, working side by side with other local businesses, volunteers, and organisations who share our commitment to the environment. In summary, Nordell’s journey towards sustainability showcases a practical and forward-thinking approach in the plastics industry. By investing in renewable energy, exploring bioplastics, and engaging with the community, Nordell demonstrates that integrating sustainable practices is feasible and beneficial for modern manufacturing. This trend indicates a broader shift in the industry towards environmental awareness. As more companies follow suit, the future of plastics looks set to balance industrial needs with ecological responsibility, a promising direction for both the industry and the planet.
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Philip Law BPF’s director-general Philip Law explains BPF’s productive start to 2024 after an insightful roundtable with the shadow minister for Business and Decarbonisation, Sarah Jones.
The Push for Plastics' Priorities The BPF hit the ground running at the opening of 2024. The highlight of January was a meeting with Sarah Jones MP, the shadow minister for Business and Decarbonisation. A small and representative group of BPF members, plus myself, met her for a discussion - a breakfast roundtable - on Wednesday, January 17th. Coming in the wake of the Government’s Advanced Manufacturing Plan it was interesting to discuss the Labour Party’s approach through its own Industrial Strategy. BPF is, of course, politically neutral and judges the policies of political parties solely on their internal merits. It has no interest in ideology or personality. Sarah Jones is the MP for Croydon Central and has a background in the civil service. She has only been in the role for six months, having succeeded Bill Esterson whom we had also met. He is now shadow minister for Roads. Sarah Jones’s role is interesting as it links up two related activities and this is very much a hallmark of Keir Starmer’s approach, wanting to create a much more ‘joined up’ government.
the third largest manufacturing industry in the UK. She was equally impressed by the range of products which were key to national security in terms of defence and the infrastructures for energy supply, transport, food and water distribution, healthcare and electronic communications. We told her that the City of London would not be able to function without plastics. Our members did us proud by articulating the BPF’s six current requests of the government. Bruce Margetts of Bericap spoke on the need for legislation on packaging to consider the benefits it brings such as reductions in food waste. BPF staffer, Mo Elkhalifa, pressed for recognition of mass balance techniques to measure the presence of chemical recyclate in products. BPF president, Nigel Flowers of Sumitomo Demag, put the case for more government support for upskilling and a more joined-up approach to training throughout government and educational institutions. He also called for
Given her short period of tenure, she was very much in listening mode and certainly had an open mind. As I related the plastics industry’s key dimensions, she confessed that she was ‘blown away’ by the fact that we employ 155,000 people, making us
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more government grants to be available to help the industry deploy more energy-efficient equipment in an attempt to decarbonise the industry. Martin Hitchin of Rehau urged for the revenues of the Plastic Packaging Tax to be deployed in developing the plastics recycling infrastructure. Mike Boswell of Plastribution called for a minimisation of trade barriers and greater alignment of legislation with the EU. Sarah Jones concluded that “plastics is a cross-cutting foundational industry that we need to make sure we have a plan for.’’ Within a week of the meeting, two Parliamentary Questions on chemical recycling were posed to the government by her colleagues. Immediately after she left the meeting, she participated in a Radio 5 Live programme in which she quickly rebuffed a call for a ban on plastics with data she had been given by us only minutes before. She might become an important figure in our future.
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