British Plastics
and Rubber
bp&r
1963 -
Distrupol was established
JUL/aug 2022
1969 -
A Nylon flag was put on the moon
1979 -
The first portable phone was released
1988 -
R olling back the years
Green triangle for recycling plastic was introduced
1996 -
Salad-in-a-bag packaging introduced
2013 -
App-controlled prosthetic limbs launched
2020 -
Global plastic production reaches nearly
2022 and beyond - ?
DISTRUPOL REFLECTS ON SIX DECADES IN PLASTICS - AND WHAT LIES AHEAD — SEE PAGE 22 K 2022 Who's next to launch into AM?
RESHORING Moulders say 'welcome home'
A SOLAR POWERED IMM Yep, a solar powered IMM
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THE GOOD, THE BAD... AND THE K SHOW
was impressed to read that the UK plastics industry has slashed lead times by more than 50% for ’21’22, vs the same period in ’20-’21. It’s an encouraging sign of resilience and agility. Having travelled through multiple international airports recently, I can confirm that not all sectors are recovering their efficiencies in quite the same way. In fact, according to the Product Lead Time Index, which is produced by software company Unleashed, plastics and rubber in the UK was the secondfastest sub-sector to recover lead times, after tea and coffee (and let’s face it, nobody’s willing to wait too long for a brew). What’s even more impressive about this stat is that the shortening of lead times has come in spite of significant levels of re-shoring (resulting from the very same challenges that caused delays for manufacturers in the first place). With brand owners still scrabbling to bring back production from the East and elsewhere before the next major disruption hits supply chains, moulders in this country have been reporting the need to run all hours, often at max capacity. It’s welcome news, and it makes that shortening of lead times even more impressive. BEC Group, for example, told me they’ve seen a 30% increase in enquiries for new projects in the last 12 months. Just-in-time supply chain models are no more – now, the major concern has to be ‘just-in-case’. Speed and competitive pricing, at the expense of quality, is a model that limped on for a long time, albeit beset by problems and doomed expectations. Now though, manufacturers and brand owners have started to see the light – and it only took a global pandemic and one massive stranded container ship to get there. Read more from BEC Group’s experience with reshoring on p.17. While the mood in the industry right now is cautiously optimistic, UK manufacturers are facing a serious challenge ahead, with further rises to energy prices set to bite again in
October. It’s not fun to talk about, but it’s something that can’t go unacknowledged. I met with Carl Reeve at Premier Moulding Machinery recently. On his desk he keeps a copy of Dr Robin Kent’s book, Sustainability Management in Plastics Processing. Carl pointed out to me that when he speaks to manufacturers, the number one thing he hears on the topic of sustainability is, ‘we’ve upgraded the lighting’. As Robin Kent points out – that’s really not the game-changer when you’re running something as energy-intensive as a moulding operation. And putting energy prices aside for one moment, it’s certainly not going to make much of a dent if we’re going to get the industry to net zero. Carl elucidated his thoughts on what the plastics sector can do mitigate the risk of rising energy prices in a recent column, which you can find on InterplasInsights.com. Spoiler alert – it involves accelerated capital investment. He’s put together some eye-popping statistics, so I really recommend giving it a read. Now is the time to acknowledge there is a – manageable – challenge coming around the corner. That said, new machinery investments may not be the solution/necessary for all moulders and processors – but nevertheless, the impact of ramping prices may turn out to be more than it appears right now - plan ahead. Finally, we’ve started our coverage of K early this year. I had a feeling there was going to be a lot of ground to cover, and so far, I’ve been proven right. In this issue we focus on some big news from KraussMaffei, plus a look at solutions for the automotive industry, and finally, a whistle-stop tour of the materials launches that have been announced so far. Enjoy! Head of Content
Dave Gray
21
contents
POLYMERMAN
Mike Boswell on the new world order for polymer supply
3
COMMENT
Dave Gray
34
OPINION
Christina King on data, digital and diversity
29
RECYCLING Edward Kosior on juggling the industry’s sustainability problems
22
ON THE COVER
Distrupol rolls back the years
6
50
K 2022
KraussMaffei goes additive
FROM THE BPF
Philip Law responds to the ‘Big Plastics Count’
11
WORD FROM HIRD
K 2022
PMMDA chairman Richard Hird shares the outlook from the community
17
Regulars
Materials driving automotive change
RESHORING
BEC Group on the post-pandemic surge
42 INDUSTRY NEWS
32
44 MACHINERY NEWS
GAME-CHANGER
46 MATERIALS NEWS
RWC on its game-changing employee initiatives
38
FLOWER POWER
Bloom-in-Box powers IMM directly via solar panels
4
43
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The world’s largest injection moulding machinery manufacturer Energy is typically 7% of a moulder’s turnover. Industrial Electricity costs today stand, on average, at £0.14 kWh. Renewal costs on average stand at £0.42 kWh. A 300% increase. There is technology that can cut your energy use by 60-80%. Servo hydraulic and electric machines from Haitian.
WWW.HASCO.COM
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ENABLING WITH SYSTEM
k preview: big launches
Parents visiting K 2022 hoping to bring something fun home for the kids will be pleased to know that the precisionMolding machine on display will be producing a soft tennis ball racket (from 100 percent sustainable raw materials – a popular trend in the toy industry).
I
INJECTION MOULDING MACHINERY GIANT KRAUSSMAFFEI HAS DROPPED HINTS RECENTLY ABOUT A LAUNCH INTO THE ADDITIVE MANUFACTURING SPACE. DAVE GRAY LOOKS AT WHAT MIGHT HAVE MOTIVATED SUCH A MOVE, PLUS WHAT THE GROUP WILL BRING FOR TRADITIONAL INJECTION MOULDING.
Is KraussMaffei about to launch an
INDUSTRIAL 3D PRINTER AT K?
S
peaking at a pre-K press event in Düsseldorf, where the K Show will take place in October this year, Michael Ruf, CEO at the Munich machine maker said the group would “have something to ‘add’” at K this year, adding that it would be a world premier. And the firm has now published a page on its website dedicated to additive manufacturing, and although no specific machinery is mentioned, a statement reads: “Production without material waste and infinite design possibilities - we bring these advantages of additive manufacturing from prototyping to the industrial series production of plastic components.” The last major plastics machinery firm to venture into additive manufacturing was Arburg, which, in 2013, teased its K Show appearance using the advertising slogan ‘Freedom has to be experienced’ – a reference to the freeform additive manufacturing technique. 3D printing has similarities with injection moulding – in that plastic is melted and extruded – and while the technologies have historically been seen as complementary, KraussMaffei could soon be the next major IMM player to enter the fray. The market for industrial additive manufacturing is reported to be seeing a resurgence, not least due to supply chain issues caused by the pandemic, and other recent challenges (e.g. the Suez canal blockage).
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Kathy Bui, product lead, engineering business at 3D printer manufacturer Formlabs, said of the present-day state of the AM market: “In 2022, we will continue to see AM play a role in the supply chain with 3D printers becoming a manufacturer’s Swiss army knife, an adaptable tool that can keep production lines running. With in-house industrial grade 3D printers, manufacturers can fortify their business against supply chain challenges and mitigate risk rather than replacing traditional manufacturing processes. 3D printers will be used as a risk mitigation tool rather than replacing traditional manufacturing processes.” Arburg has historically touted the technology as its route into high value, low production markets, with complex medical parts often being demonstrated on the Freeformer at trade events and in-house displays. It remains to be seen which markets KraussMaffei will target. Precision and speed of production are both likely to feature as highlights of the innovation, however. The group’s new AM-focussed webpage also states: “In plastics processing, the variety of options has never been more in demand. Additive manufacturing systems enable geometric diversity without impacting price or production time. Experience with us the fast product changeover on a machine and the simultaneous production of different products on an industrial level.” A video on the page teases the launch, with the slogan “we have something to ‘add’” following on from a list of the the firm’s existing offering
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ENABLING WITH SYSTEM
of injection moulding, extrusion and reaction process machinery. The official announcement of the launch will be made on the first day of K 2022, October 19, at 4.40 p.m at the group’s stand in hall 15, stand C24 / D24 New IMM launches The group is also planning to launch two new injection moulding machine ranges at this year’s K, dubbed ‘precisionMolding’ and ‘powerMolding’ respectively. Available for US and European customers, the new range will be debuted running applications for the toy and automotive industries. Both have previously been launched into the Asian market. The precisionMolding machines are based on the all-electric PX series from KraussMaffei, but feature a reduced number of optional extras, making them suited to high volume, standard part production. Similarly, powerMolding is a stripped-down version of KraussMaffei’s hydraulic GX series
The powerMolding machine will process 100% recycled polypropylene to produce door modules for the automotive sector
“In the basic machine concept, we offer our customers outstanding fast reaction times and thus short delivery times to enhance their efficiency and competitiveness even more. At the same time, of course, this opens up entirely new applications and groups of customers for us we have not been able to serve before,” said Xiaojun Cui, executive vice-president, new machines business, at KraussMaffei.
The market for industrial additive manufacturing is reported to be seeing a resurgence, not least due to supply chain issues caused by the pandemic, and other recent challenges (e.g. the Suez canal blockage).
With shorter supply chains now in high demand, and reshoring taking place in response to the COVID pandemic and other global challenges, the introduction of readily-available, no-frills machines for bringing back high volume, efficient processing to home territories may well prove to be well-timed for many moulders. Add to that the soaring cost of energy, and newer, less expensive but more efficient machines seem an attractive investment. Options that are available with the new machines include a variety of mould installation heights as well as the integration of automation solutions. The precisionMolding machines are based on the all-electric PX series from KraussMaffei, but feature a reduced number of optional extras, making them suited to high volume, standard part production.
According to its maker, depending on the application, the powerMolding machines can offer a boost in throughput of up to 15 percent over comparable standard injection molding machines on the market, brought about by short dry cycle times, shot weight consistency and low scrap rates. “The bottom line is that the investment pays off very quickly for our customers, precisely when compared to other standard machines on the market,” said Cui. Parents visiting K 2022 hoping to bring something fun home for the kids will be pleased to know that the precisionMolding machine on display will be producing a soft tennis ball racket (from 100 percent sustainable raw materials – a popular trend in the toy industry). Based on cane sugar, the biopolyethylene from FKUR ‘binds CO2 during production’ and ‘can be recycled up to 100 percent after use’, according to KraussMaffei. The firm’s APC plus function comes with the machine, and is designed to compensate for the process fluctuations – especially useful for running biomaterials and recyclates. Meanwhile the powerMolding machine will process 100% recycled polypropylene to produce door modules for the automotive sector – and again, will use the APC Plus functions to stabilise material fluctuations. The material itself will come from caps for insulin pens, produced on a KraussMaffei PX 200-1400. The material will be shredded and then prepared on a ZE 28 BluePower twin-screw extruder with different additives such as bonding agents and liquid dye.
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Matching Colour. No one gets closer.
k preview: automotive
W WITH E-MOBILITY AN EVER-LOOMING REALITY, IT’S NO SURPRISE THAT AUTOMOTIVE IS SET TO PLAY A MASSIVE ROLE AT K 2022. DAVE GRAY, HEAD OF CONTENT AT INTERPLASINSIGHTS. COM AND BRITISH PLASTICS & RUBBER, LOOKS AHEAD AT SOME OF THE DRIVERS OF INNOVATION TO EXPECT AT THIS YEAR’S K SHOW.
RIGHT: The back of an inner tailgate trim part that is foam injection molded with Sabic’s PPc F9005 grade.
DRIVING ME K-RAZY RECYCLED GRADES ON RUBBER STREET Returning to its spot on ‘Rubber Street’ at K, Kraiburg will show its new post-industrial recycled (PIR) TPE grades for car interiors. The new grades contain up to 38% recycled material, derived from post-industrial waste acquired from third party businesses. Applications for the new grades include anti-slip mats, floor mats, soft components in cup holders, fixation elements, and other designs requiring a hardness range between 60 and 90 Shore A. Kraiburg is also bringing its universal postconsumer recycled (PCR) TPE, containing up to 41% recyclate. The firm says the compounds are available in “natural colours” as well as in the grey colour characteristic of recycled plastics (which can be dyed as needed). The firm says the mechanics of these recycled-content grades “are in no way inferior to that of standard solutions”. FOAM PARTY IN HALL 6 Sabic, meanwhile, will introduce its latest line of PP compounds for foam injection molding (FIM). The new mineral-reinforced Sabic PPc F9005, PPc F9007 and PPc F9015 grades are being marketed for use in automotive interiors with complex geometries, such as door panels and trim, seat and trunk cladding, A/B/C/D pillar covers and center consoles. The company says the compounds could help resolve aesthetic issues for foamed interior parts, removing streaking and swirling in low-gloss textured (grained) surfaces. Talc filler in these grades acts as a nucleator that promotes the generation of finer bubbles, which contribute to a consistent surface appearance, according to Sabic. Custom colouring is available. According to a cradle-to-grave life cycle assessment study (pending third-party review), the new materials can help OEMs lower carbon dioxide (CO2) emissions by as much as 15 percent. Different grades have been developed for various foam moulding techniques – and the choice of technique can have an impact on final part weight. Short-shot moulding, which uses the same tooling as an injection moulded part, can reduce weight by up to 10 percent, according to the Sabic. PPc 9007 is formulated for short-shot FIM and low-impact applications. Core-back moulding, which requires part redesign and new tooling, can lower weight by as much as 30 percent. Both Sabic PPc
9005 and PPc 9015 grades are formulated for coreback moulding and deliver medium stiffness and impact. LSR FOR THE CAR Momentive Performance Materials will bring new liquid silicone rubber (LSR) grades for under-thebonnet and other automotive applcations. NL6830FR and NL6850FR, both in dark gray, meet the UL94-V0 flammability requirements at 1 mm thickness. With Shore A hardnesses of 35 and 45, respectively, Momentive says they “combine balanced yet very good mechanical properties with low compression set”. Possible applications include seals in the intake area of combustion engines, collective seals and O-rings, for example for use in sensor technology and in the drive area of electric vehicles requiring flame resistance. Also new on the stand will be Silopren LSR 2725/40, which is a further iteration of the firm’s self-lubricating LSR grade. This one is designed for applications where engineering plastics are overmoulded – to add integrated sealing or damping, for example. The product works in three stages. During moulding, an initial adhesion to the substrate takes place. Full adhesion is then achieved during subsequent storage at room temperature. While this is happening, a migration process takes place, which gives the LSR surface its self-lubricating property, which benefits the onward assembly. HIGH STRENGTH AND BATTERY POWER Lanxess’ is another of the players with a focus on electromobility at K 2022. Joining the group’s Tepex brand of continuous fiber-reinforced composites, will be a new line based on recyclates or biobased raw materials. One grade in the new range is Tepex dynalite Scopeblue 813, which has just gone to market and is produced from flax fibers and polylactic acid. The group is also developing new products for the EV charging infrastructure where high temperature resistance and electrical insulation are needed. New to the Lanxess offer is a halogen-free flameretardant and hydrolysis-stabilized PBT (polybutylene terephthalate) compound for high-voltage connectors. SHOW ME THE LIGHT Rohm will showcase its polymethyl methacrylate (PMMA) brand Plexiglas, including its latest development, a molding compound called Plexiglas Optical HT, which has been design for high longterm service temperatures in lighting applications such as lenses for high-performance LEDs and long light guides. The firm will also demonstrate solutions for car taillights – increasingly a part of the brand identity for many automakers, as well as compounds for vehicle fronts.
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Matching Colour. No one gets closer.
k preview: masterbatch & additives
ACQUISITIONS AND PARTNERSHIPS
DRIVING ADDITIVE TRENDS AT K
AT PRE-K PRESS EVENTS, BOTH CLARIANT AND ASCEND PERFORMANCE MATERIALS ANNOUNCED CROSS-INDUSTRY COLLABORATIONS WHICH WILL FOCUS AT THIS YEAR’S K SHOW. ROB COKER WRITES.
C
lariant will take ‘For a greater between’ as its K show slogan to reflect the company’s position in the value chain and its agility in collaborative projects. At K, the masterbatch and additives specialist will announce further collaborations, as well as push its EcoCircle iniative to support the transformation to a circular economy by bringing business units together to look at the challenges in increasing circularity – although Clariant’s Chief Technology and Sustainability Officer Richard Haldimann conceded that “it’s not enough to provide technical solutions.” Additives can enable the recycling of various polymers, and Clariant is receiving increasing requests for advanced recycling solutions, where focusing on collaboration can make the difference, according to Haldimann: “Bringing sustainable solutions to market requires transparency and communication,” he said. But what are the sustainability qualities of a sustainable solution? “The transition towards sustainability is accelerating,” he added, as Clariant aims to provide the additives that enable recyclability. The ‘sweet spot’ lies somewhere between innovation and sustainability – and the innovation has to come through Clariant in order to become sustainable, according to Haldimann. The Clariant K Show slogan also implies a greater chemistry between people and planet with a focus on innovative chemistry and engaging with people – because the right partnerships require ‘chemistry’, to paraphrase a Hollywood romance, as well as the chemistry inherent in Clariant’s everyday processes. “Transparency and trust generate better relationships and better products,” Haldimann concluded. “Customers expect more environmentally friendly solutions … This is the starting point of a journey. Clariant is now in a position to provide greater insights regarding a product’s carbon footprint.” It seems Haldimann and Clariant are seeking to put an end to the term ‘value chain’ due to its linear connotations and in favour of a ‘value loop’. But are there enough loops currently in the industry to allow such a phrase into the canon? Similarly, Ascend will operate under the motto ‘Advancing Together’ at K 2022, where it will also focus on the power of collaboration. In Rotterdam, John Saunders, VP EMEA and India, reminded delegates about the 2019 decision to start looking at opportunities involving local strategies and local talent: “We
acquired a company called PoliBlend (Italy), a company founded about 20 years ago and, as its name indicates, they are masters in producing high-quality, consistent recycled grades (colours), so this was the perfect acquisition for us. We expect to take this technology and the knowledge base from our plant in Milan and expand to all other plants across the world.” With Poliblend came another, smaller acquisition of a sister company called Esseti Plast, a producer of colour masterbatch. Such acquisitions, according to Saunders, are key to the success of a global business such as Ascend. “Esseti Plast serves Ascend with a lot of the masterbatch that we require for our products globally,” he added, “but also we serve external customers, so we are also looking into multiplying this model in other regions.” In early 2020, Ascend acquired Eurostar Engineering Plastics (France), which has around 30 years of knowledge in flame-retardant products. With this acquisition, Ascend has gained additional knowledge and ability in colouring. To conclude, Saunders announced the recent completion of another acquisition, India-based compounder Formulated Polymers Limited (FPL), which it is expected will support customers in the region. Within the three-year period since 2019, Ascend has acquired six production sites, which is being recognised by its customers as a growing footprint regarding manufacturing, and additional knowledge and talent in areas where its customers expect it to be.
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pioneering plastics
k preview: machinery
ALPHA & OMEGA
THE PLASMAC TEAM AIMS FOR A PROMISING K SHOW, FROM THE FIRST TO THE LAST DAY
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lasmac is gearing up for another stellar K-Show. 2019 saw Plasmac take more than 30 per cent of the yearly order intake in the eight days of the show and are hoping for the same again in 2022. As part of both the Syncro Group and the EREMA Group, Plasmac will be present on the EREMA Group stand and will be showing two of its latest innovations: the ultra-compact and energy efficient Alpha XS machine with air cooled pelletiser; and the latest addition to its shredder extruder range, the Omega M vented unit with water cooled pelletiser. The Alpha XS has been designed from the ground up. With a footprint of less than 0.6m2, the XS can pelletise at outputs up to 50kg/h, and comes equipped with trim basket and rollfeed for inline trim recycling. It can simultaneously recycle scrap reels without issue. With a maximum installed load of 17kW and an approximate running load of just 9kW, this gives an approximate energy consumption of less than 0.2kWh/Kg, making it one of the most energy efficient machines on the market. Designer Creighton Varney said: “With energy prices continuing to rise, the brief I was given was to design a machine that would cost our customers the least to run, would need the least amount of valuable floor space, and be a simple plug and play design. We’ve achieved that and more with the Alpha XS.”
The Omega M shredder extruder machine will feature a new look, compact footprint, and flexibility in layout due to a multi positional elevator and water cooled pelletiser. Based on Plasmac’s dual diameter short screw technology, the Omega M will have an installed load of 84kW and an approximate running load of just 46kW at 200Kg/h, it requires no chilled water or compressed air for the shredder and only needs 19kW of chilled water for the Hydrocool water pelletiser. The offline shredder design with integrated auger feeder into the extruder is also designed to accept a gravimetric feeder for additives or colour. The uniquely designed single-shaft, slow-speed shredder ensures no heat is generated and with minimal dust. The new stand-alone design makes it very stable and easy to split and ship. The new design of rotational elevator means the customer can position the elevator within an arc of 220 degrees of rotation and the latest design of Plasmac’s Hydrocool water pelletising system enables flexible orientation – it can be inline or orientated to either side, depending on the customer’s needs. A completely new Syncro Group “Infinity” control platform and HMI system allows the operator a host of new benefits. Designed with Industry 4.0 in mind, the control system can talk to Syncro Group’s TygerCloud portal, enabling the customer to remotely monitor the Omega from a PC, phone or tablet via Syncro’s new app-based viewer. All data is logged for simple trend analysis and output performance. It also comes with the PlasmacHub online portal for service and support, including line layout drawings, exploded sub assembly drawings for simple spare parts ordering, tutorial videos for operator and maintenance functions and for preventative maintenance. Plasmac will be able to call the customer and advise them to carry out maintenance, order consumables and even tell them when to change gearbox oil, for example. The system will also link to a camera installed in the shredder hood, so the operator can see how their material is behaving. Finally, the Omega will be linked up to Plasmac’s latest innovation, an inline machine throughput measurement and bulk density measurement system, giving the customer realtime output measurement, all viewable through the TygerCloud App, which is also available for the Alpha XS. LEFT: The Omega M Shredder Extruder; Alpha XS Extruder; Alpha S Extruder; and the Epsilon Shredder and Extruder.
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pioneering plastics
k preview: materials roundup
WHISTLE-ST
AS K 2022 LOOMS EVER NEARER, DAVE GRAY GIVES A WHISTLESTOP TOUR OF JUST SOME OF THE NEW MATERIALS AND ADDITIVES DESTINED FOR THE NEXT GENERATION OF PLASTIC PROCESSING.
IMAGES: Top to bottom: 1 – Momentive’s new LTC-LSR will be used to produce thick-walled, translucent tea light holders – the perfect romantic freebie for your significant other... 2 – Borealis and Uponor have teamed up on what they claim is a world-first: cross-linked polyethylene (PE-X) pipes based on renewable feedstocks 3 - Sterilisation via UV-C light has become more commonplace as a result of the COVID pandemic, but frequent exposure can cause polyolefin degradation, discoloration and microcrack formation. 4 - One fishery was able to benefit from the same properties as traditional Styropor, such as buckling stability and thermal insulation.
EVERYONE LOVES A FREEBIE Let's start with a look at LSR. Momentive will present the third generation of its LTC-LSR (Low Temperature Cure Liquid Silicone Rubber) at K 2022. This new liquid silicone rubber cures at even lower temperatures than the development grade presented at Fakuma 2021. Momentive will be demonstrating the processing of the new LTC-LSR at its stand on a Victory 100120 injection moulding machine from Engel. In this process, a fully automated mould with cold runner and valve gate system from ACH Solution will be used to produce thick-walled, translucent tea light holders as giveaways that resemble cut glass in appearance – the perfect romantic freebie for your significant other... RENEWABLES FOR CONSTRUCTION Borealis has announced that it’s planning to showcase a project with heating and plumbing supplier Uponor, whereby the groups have teamed up on what they claim is a world-first: cross-linked polyethylene (PEX) pipes based on renewable feedstocks. The resulting PEX Pipe Blue is also accredited by mass balance accounting under the International Sustainability & Carbon Certification Plus (ISCC PLUS) scheme. Using Borealis’ ‘Bornewables’ polyethylene derived from second-generation natural resources, such as waste from pulp production or residues from food processing oils, the new PEX Pipe Blue products reportedly offer a carbon footprint reduction of up to 90% when compared to conventional fossil-based PE-X pipes. SOLVAY’S SURFACE STABILIZERS Solvay will be showing off its latest launch – UV-C stabilizers – designed to protect surfaces against damage resulting from sterilisation via UV-C light. Sterilisation via UV-C light has become more commonplace as a result of the COVID pandemic, but frequent exposure can cause polyolefin degradation, discoloration and micro-crack formation. The stabilizers can be used in polyolefin applications, including medical equipment in operation and patient rooms, aircraft and shared vehicle interiors, and sporting venues. PLASTICS FOR (AND FROM) RECYCLINGx Covestro will be promoting its new collaboration with Zurich-based bag company Freitag, which the firms hope will lead to “unlimited recycling of truck tarps”, using thermoplastic polyurethanes (TPUs) from Covestro. At the end of their useful life, the tarps are to be chemically recycled and used for new tarps or other products. Freitag expects it to be a few years before bags made from the tarps are mass-produced, but plans to put a first prototype on
P TOUR
a truck as early as this year. In terms of mechanical recycling, visitors to Covestro’s stand can expect to see an increased focus on monomaterial solutions for simplified material separation – part of the wider ‘design for recycling’ trend being seen across the industry. BASF will also touch on the subject of mechanical recycling. One of the new innovations on display at its stand will be IrgaCycle, a new range of additives that are targeted at recyclers and compounders making resins that incorporate recycled content. The difficulties associated with post-consumer and post-industrial content range from processability to thermal- and weatherresistance. The new additives are designed to resolve these issues. This new line of problemsolvers includes PS 030 G long-term thermal stability in rigid applications, (e.g. recycled HDPE); PS 031 G for processing and long-term thermal stability of recycled LDPE and LLDPE, for incorporation into films and related flexible packaging applications; PS 032 G for processing stability and long-term thermal protection for recycled PP and polyolefin blends containing impurities; UV 033 DD for weathering stability for reclaimed HDPE and PP blends for re-use in outdoor goods; and XT 034 DD, to neutralize impurities from the previous use of the plastic. There will also be a range of plastics made with recycled feedstock obtained via the company’s own ‘ChemCycling’ chemical recycling process. Launched in 2018, the process has since seen BASF work with brand owners on various new solutions, including a project for salmon farming group Bremnes Seashore. Using Styropor ‘Ccycled’ EPS made using chemicallyrecycled pyrolysis oil instead of fossil fuels, the fishery was able to benefit from the same properties as traditional Styropor, such as buckling stability and thermal insulation. Like BASF, Brüggemann is bringing its own range of additives to improve quality and processability for recyclers and compounders. At K 2019, the firm brought additives for mechanically recycling of polyamides. In 2022, the group is back, this time with a new line for recycling polyolefins. The firm’s technology “repairs defects in the molecular chains” which arise during the processing and use of polyolefins and degrade quality. One new grade in this line is TP-R2090, which which it is possible to recycle polypropylene from postindustrial and post-consumer waste – in particular, from battery cases. For recycling polyethylene, Brüggemann has developed Bruggolen TP-R2162 which again includes the new “repair technology” and is particularly suitable for recycled LLDPE for use in film extrusion. All additives in the line are supplied in the form of compact, dust-free blends.
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reshoring
HOW GLOBAL EVENTS HAVE REINVIGORATED RESHORING
R RECENT GLOBAL EVENTS ARE ACCELERATING RESHORING IN UNEXPECTED WAYS. KATIE REED, MARKETING MANAGER AT INJECTION MOULDER BEC GROUP EXPLORES THE IMPACT ON THE UK PLASTICS INDUSTRY.
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eshoring in large numbers started in the mid 2010’s when UK manufacturers began to seek out shorter lead times, better service, and greater control over goods being produced elsewhere across the globe. Britain’s exit from the EU in 2020 increased costs and bureaucracy from European imports into the UK and fueled the return of the “Made in Britain” image. Large multinationals such as Clarks, McLaren and Cadbury brought large parts of their production back to the UK and invested heavily. The global spread of the COVID-19 pandemic in 2020 showed the huge cracks that existed in lengthy global supply chains, highlighting their vulnerability and the lack of UK-based manufacturing for even basic goods such as masks and medical supplies. Whilst Brexit and the pandemic greatly fractured fragile supply chains the world over, geopolitical conflicts, the rising costs of fuels and shutdowns in China have contributed to this further- hundreds of container ships have been stuck outside Chinese ports, unable to unload and offload goods for weeks due to shutdowns. The Ever Given container ship blocking the Suez Canal in March 2021 for six days delayed 16 million tons of freight, affecting industry giants such as IKEA and Lenovo which had products on board. Higher demand for shipping containers due to many of these circumstances have led to an
increase of 350% in the cost of shipping from China to the UK. These events and factors made it clear that the “just in time” model of manufacturing doesn’t cut it anymore; decision makers must now establish the best course of action to shore-up their supply chains and make certain resilience for the short and long term. In the past twelve months, BEC’s enquiries for new projects involving reshoring have increased by 30%. What was once a contributing factor to finding a new toolmaker has become a primary motivator for businesses. BEC are not the only ones - Make UK found that 42% of manufacturers surveyed in 2022 has increased the proportion of suppliers in Great Britain. BEC’s Sales Manager Holly Cummins describes the trends: “More and more we are seeing companies that offshored decades ago for cheap products delivered quickly being let down. After taking a hammering during the pandemic they can no longer take the financial hit- bringing production back makes sense for the long term of their company”. Brexit and the pandemic greatly fractured fragile supply chains the world over
The “just in time” model of manufacturing doesn’t cut it anymore; decision makers must now establish the best course of action to shore-up their supply chains and make certain resilience for the short and long term.
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Flexible Cooling
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A recent reshoring project for BEC Group came from Rolatube Technology - based in the South -West, retailing innovative products for marine and commercial environments. Prior to working with BEC, Rolatube carried out their tooling and moulding in the Far East. Upon getting in touch with one of our toolmakers and discussing the project, Rolatube decided to manufacture many of their tools with us in the UK. When asked why they had decided to relocate their manufacturing, Steve Mogg, Global Partner Executive commented, “The receipt, review and approval of samples has been made substantially easier as a result. In addition, we wanted to minimise the carbon footprint of the product by increasing locally sourced content, something we are continuing to work on”. In deciding to come to a UK manufacturer, Rolatube were able to feel the benefit of greater control over the entire process - both in terms of time and quality. Rolatube have continued to work with BEC on a further six projects from the initial reshoring project. Ecoegg, retailers of an eco-dryer ball decided to bring back tools back to the UK due to the many issues they’d experienced manufacturing in China, including missed deadlines, damaged tools, poor production quality and increasing costs. “We brought our tools back from China after a number of challenges. BEC demonstrated the benefits of keeping production local and proved that cost isn’t the only factor to consider when selecting a supplier” Dawn White, Director at EcoEgg. Many of the tools brought back to BEC were in poor condition, needing modifying and significant repairs. As costs of production and imports rise, often UK manufacturers are competitively priced as well as the benefits of being able to oversee production. At BEC Group, reshoring has been one of many contributing factors in customers working with us for some time. Whilst previous reshoring projects from customers have focused on quality and control, we are now having far more discussions around the increased costs of production and imports as well as long lead times and missed deadlines. Reshoring to a UK manufacturer first and foremost allows for greater control over the entire process, from design through to production. Contrary to many offshore manufacturers, strong communication between toolmakers, moulders and their customers is key to their success; ensuring tools are made to be as efficient as possible, mouldings made to exacting quality standards and every step of the journey communicated to customers. The popular belief for many years has been that it is cheaper and more convenient to tool in the Far East - in more recent times this hasn’t been the case - particularly when the spiralling costs of container shipping and higher wages in Asia are taken into account, as well as the costs from supply chain disruption and missed deadlines. Many UK manufacturers are now competitive, and in some cases cheaper than these counterparts.
One of the projects reshored back to BEC Group, from Rolatube Technology Whilst the initial cost of re-shoring is high both financially and administratively, de-risking supply chains for the short and long term is a wise investment, particularly when political uncertainty and rising costs are taken into account. Dual-supply is another option that reduces risk, but involves a higher initial outlay. It comprises keeping the original manufacturer and sourcing another one closer to home- it can be a great way to take steps to reshore and guarantee a better continuity of supply. The future of reshoring is intrinsically tied to global trends. If geopolitical conflicts continue and inter country relations remain strained, the costs of fuel, electricity and import costs will remain high. In turn, reshoring will continue to grow. In addition, brands have begun to consider the environmental impact of producing and shipping from across the other side of the world and reducing their carbon footprints Environmental levies are likely to be introduced on companies based on their emissions and environmental efforts- the plastic packaging tax introduced this year is undoubtedly the first of many. If UK suppliers and manufacturers are to keep up with the increase in capacity brought from reshoring, skill shortages which have affected many in the industry will have to be plugged, and a focus on British manufacturing as a stable career will have to return. Investments must also be made be made into facilities to keep up with demand. If carried out successfully, reshoring will be a key player in steadying the UK economy in a post-pandemic, post-Brexit world.
Whilst previous reshoring projects from customers have focused on quality and control, we are now having far more discussions around the increased costs of production and imports as well as long lead times and missed deadlines.
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E-mobility is not just a hot topic in the automotive industry. In many major European cities, e-scooters, e-bikes and pedelecs are already an integral part of the cityscape. Material requirements, will continue to change and align with environmental considerations. Developments are progressing in battery technology and in many other components. Along with our experienced partners, ALBIS is your solution provider for new demands on materials and e-mobility applications. Get in touch with us: industrymanagement@albis.com.
Driving e-mobility solutions.
We drive polymer distribution. Easy, smart, passionate.
albis.com
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HOW IS A NEW WORLD ORDER GOING TO IMPACT POLYMER SUPPLY?
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M
he Russian invasion of Ukraine in February 2022 is likely to have significant geopolitical implications, which in turn will impact global polymer supply.
In the Cold War period from 1947 to 1991, trade between the East and the the West was highly constrained with neither block wishing to be reliant upon the other. The ‘thaw’ that took place over the next three decades witnessed commercial opportunities overtake the legacy of political tensions and trade between the blocks has boomed. The West, particularly, has exploited opportunities to obtain raw materials and take advantage of plentiful low-cost labour from the East. Included in this trade is oil, gas and petrochemicals, with about 12% of global crude oil being supplied to the world market by Russia, along with significant volumes of natural gas, petrochemical feedstocks and petrochemical products including plastic raw materials. This interdependence is clearly illustrated by the current energy crisis that Germany is facing due to its heavy reliance on Russian origin Natural Gas.
MIKE BOSWELL LOOKS AT THE NEW WORLD ORDER, AND ITS IMPACT ON POLYMER AVAILABILITY
In considering the implications for polymer supply, it is worth considering the relative ease of transporting hydrocarbons in their various physical formats. The relative ease of distribution of polymers coupled with a relatively disparate customer base of regional plastics converters has led to quite significant penetration of Russian PE and PP into the EU27 and the UK. Partly as a result of a combination of political pressures and import duties being applied by the UK Government on Russian PE imports, a key Russian producer has shuttered its European sales activity. Substitution of US origin PE for Russian PE is both timely and opportune; however, replacement of missing PP volumes is less obvious with countries such as Thailand and South Korea providing potential solutions for the complex portfolio required by European processors.
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
In the longer term, the probability of an East/West global divide will not even drive more local sourcing of existing polymer requirements, but there is the possibility that manufacturing of high value consumer goods currently taking place in the East will increasingly be re-shored to the West with a subsequent boon in polymer demand for typically polymer rich products. For UK plastics converters the current geopolitical events are likely to be disruptive both in the short and medium term and further reinforce the move from ‘Just in Time’ to ‘Just in Case’ purchasing strategies.
This interdependence is clearly illustrated by the current energy crisis that Germany is facing due to its heavy reliance on Russian-origin natural gas.
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21
on the cover DISTRUPOL REFLECTS ON SIX DECADES IN PLASTICS —
AND WHAT LIES AHEAD
P
1979 -
lastic. It’s come a long way in its relatively short life. With its birth story starting in the early 1800s, it’s the much younger and slightly more rebellious cousin of more traditional, BC-discovered materials such as glass and metal.
The first portable phone was released
The fast-paced development of plastic over the last 200 years is remarkable. The first injection moulding machine was patented in 1872, Nylon was patented in 1935, PVC was first produced in the UK in 1940, ABS was produced in 1948, the first acetals were patented in 1956, Distrupol was established in 1963, and the following 60 years saw lightening-speed advancements in technology that supported an explosion in demand for the unique attributes of the polymer family. Wherever you’re reading this right now - in the office, on the train, at your kitchen table – surrounding you will be hundreds of plastic applications serving you loyally. The intricate electronic components inside your phone, the protective food packaging in the fridge, the safety features comforting you in your car, the mechanisms in the window frames, even the clothes you’re wearing right now. Our whole world is a real-life combination of ‘Polymers In Action’ (Distrupol.com/Polymers-In-Action). The lightweight, cost-effective, versatile, strong, safe, reliable and unique features of plastic make it impossible to match. But with great power comes great responsibility. The fast-consuming lifestyle we’ve come to expect in the last 20 years in particular is burdensome. People’s single-use, throwaway nature is undeniably unsustainable. As we stand here as an industry elder today, closing our fifth decade, reminiscing over the last 60 years, looking forward to the next - we have questions. What’s to come? What needs to change? What will improve? How will this affect us? How can we help?
22
2020 -
Global plastic production reaches nearly
www.interplasinsights.com
GOING BACK… We started in the polymer distribution game way back in the early 1960s, known as Ronmar Plastics at the time. Though we’ve been acquired, undergone rebranding, and made several acquisitions ourselves, our fundamental principle of delivering world-class polymer solutions has never wavered.
1963 -
Distrupol was established
1969 -
Our business has seen the introduction of the mobile phone, the first installation of the PVC window, and the rise of autonomous vehicles. Our polymer experts’ knowledge has been instrumental in the development of thousands of plastic products across the medical, automotive, electronics, wire and cable, industrial, consumer and film sectors. We work with major market innovators and inventors. In short, we’ve seen it all.
A Nylon flag was put on the moon
But not everything we’ve seen, we’ve liked.
People’s single-use, throwaway nature is undeniably unsustainable. As we stand here as an industry elder today, closing our fifth decade, reminiscing over the last 60 years, looking forward to the next - we have questions.
1988 -
Green triangle for recycling plastic was introduced
BACK TO THE PRESENT DAY… The last 10 years have highlighted how carelessness is costing our planet. We’ve all seen the photos and the scary statistics; we all know there’s only so much the planet (and specifically its oceans) can take. But each country’s plastic profile is different. Usage, disposal and recycling rates vary drastically, and plenty of data exists which demonstrates exactly where the ocean’s plastic pollution comes from.
1996 -
Salad-in-abag packaging introduced
The rise of bioplastics and recycled plastics provide opportunities to revamp the sustainability of products, bans and taxes contribute to a more sustainable approach, and re-educating the consumer supports more responsible behaviour.
2013 -
App-controlled prosthetic limbs launched
Of course, there is not a single solution. Enhancing product designs and manufacturing processes are also integral to the future of plastics in a modern and sustainable society.
2022 and beyond - ?
We don’t just buy and sell. We never have. We’ve got 60 years of operational excellence under our belts. We innovate. We design, develop, deliver. We provide opportunity to improve. We leverage #ThePositivesOfPlastic to lighten product weights, to extend product life, to fireproof products, to create unique solutions, to save lives. This is the plastic we’re passionate about. We’ve lived the history; it’s been quite a journey. Now it’s time to be part of the future. Here’s to the next 60 years.
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23
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ancillaries
Busch (UK) awakens
V Vacuum technology from Busch is used in the production of the iconic Stormtrooper helmets – a fans’ favourite from the Star Wars franchise. With the help of R5 rotary vane vacuum pumps, the helmets are moulded from ABS.
I
t all began in 1977 with the original Star Wars film and the battle of the dark side of the Force against the light side. Since then, the Star Wars empire has developed rapidly. In addition to numerous films and series, there are also endless merchandise products that have a high demand around the world. Star Wars has become a valuable brand over the years. Fans all over the world spend a lot of money on fan merchandise. This is also the case for the original Stormtrooper helmets. These are still handmade today in Twickenham in England and have a high emotional value for collectors all over the world.
Sporting Composites Ltd produces the Stormtrooper Hero helmets in the Shepperton Design Studios to this day after the original form of 1976. At that time, the original helmet was made by Andrew Ainsworth for the first Star Wars movie. The helmets are still made by hand and even hand painted. Six employees work at the factory in Twickenham and produce not only the Stormtrooper helmets but also original Star Wars armour and props. The Hero Helmets are made of two-millimeter-thick ABS and are cast in the original moulds of yesteryear. To date, the helmets are not completely symmetrical. This can be attributed to the fact that when the mould was made in the 70s, there were neither CNC machines nor AUTO-CAD. The mould consists of two parts, which, at the time when casting the helmet for the Star Wars movie, did not fit one hundred per cent on each other. But since Andre Ainsworth only had two days until the start of filming, he shaved off
When moulding the ABS helmet parts, it is crucial that a clearly defined vacuum is applied to gently pull the material into shape.
one side by hand until the two halves fit together. And so, the asymmetrical original helmet was created, whose characteristic shape has not been changed to this day with the help of modern CAD programs. When moulding the ABS helmet parts, it is crucial that a clearly defined vacuum is applied to gently pull the material into shape. Since the helmets are only two millimeters thick, vacuum technology is critical to the quality of the moulded parts. Previously, a piston unit provided the vacuum needed to produce the Stormtrooper helmets. This was not only enormously loud and thus a noise nuisance for the employees, but it was also no longer state of the art. When the previous solution failed completely, a reliable replacement was needed quickly. The Shepperton Design Studios therefore contacted the vacuum experts at Busch. They were able to offer a suitable solution in the form of the R5 rotary vane vacuum pump. These vacuum pumps are characterised above all by high pumping speeds even in low pressure ranges and thus fast evacuation times. The heavy-duty rotary vane design ensures reliable performance and long pump life. R5 RA vacuum pumps are designed for continuous operation and are resistant to ultimate pressure. They can be operated continuously at ultimate pressure without overheating. This makes them ideally suited for use in plastic moulding. Since the loss of helmet production had to be prevented, Busch provided a loaner pump until the vacuum pump that was actually ordered could be delivered. The new Busch rotary vane vacuum pump used is not only a lot quieter, but also works a lot more efficiently. Shepperton Design Studios is pleased that the production of the Stormtrooper helmets is still secured thanks to the new vacuum solution, meaning that Star Wars fans all over the world can continue to look forward to their faithful collector’s items in the future.
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25
People. Think. Plastics.
K.D. Feddersen – Your Distributor for Vydyne® Vydyne® HiDura® Starflam®
PA 6.6 PA 6 PA 6.10, PA 6.12 PA 6, PA 6.6, PA 6.6/6
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Your contact: Roberta Leech roberta.leech@kdfeddersen.com Daniel Branston daniel.branston@kdfeddersen.com
It’s not just our colour range that’s turning heads... With over 47 years of experience, we are continually meeting the demand for consistent colour matching alongisde new performance-enhancing additives which are being used across a diverse range of industry sectors. Where colour and performance are critical our skill, experience and accuracy will make all the difference.
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Our partner:
Your Sustainable Solutions Provider from Design to Production
recycling
e l b i s s e c c A : g n i l c y c e R
T THE COMPACT, HAND-MADE MACHINERY OF AUSTRIABASED START-UP PLASTICPRENEUR CAUGHT THE EYE OF ROB COKER DURING THE PLASTICS RECYCLING SHOW EUROPE (PRSE) 2022 IN AMSTERDAM. THERE HE LEARNED FROM CEO SÖREN LEX HOW THE EQUIPMENT HAD ALSO CAUGHT THE EYE OF RECYCLING MACHINERY GIANT EREMA GROUP, WHICH HAS ACQUIRED A MINORITY SHARE IN THE BUSINESS.
AUSTRIAN START-UP PLASTICPRENEUR AIMS TO MAKE RECYCLERS OF US ALL Plasticpreneur has shown that compact recycling machinery can make a big difference. How did such a small company catch the eye of a big player such as EREMA Group? We have presented as speakers at a conference and EREMA Group CEO Manfred Hackl was in the audience. Right after the presentation we connected and started a conversation. It seemed that for Mr Hackl it was quite eye opening to work on smallscale, decentralised plastic recycling solutions. Hackl personally congratulated you on your business model. How does it feel to receive such praise from an experienced expert and how do you hope to tap into that experience in order to grow your business? Mr Hackl was open for any kind of support from the first day we met – even when we had not yet started discussions about a partnership or shares. We have gained a lot of insights and motivation through the regular meetings we had with him and others from the EREMA Group. Through its know-how and EREMA’s standing in the recycling industry we hope to be able to connect with other like-minded people and expand the access to small-scale plastic recycling. Your business model is based partly on awareness and education. Is that the missing piece, in your opinion, to the puzzle of re-branding plastics as a positive, sustainable material? We believe that awareness and education is one missing piece, but in general we see that the larger missing puzzle piece is the general approach to simple access to plastic recycling. It’s like a lost or a missing art or craft. Although the entire world talks about plastic and recycling, there is almost no
Although the entire world talks about plastic and recycling, there is almost no access for people to simply and costefficiently take part in it.
access for people to simply and cost-efficiently take part in it. The compact and low-tech aspects of your products must be very attractive to local recyclers. How easy is it for one to acquire and operate the equipment? It is very simple. People without any prior knowledge can recycle plastic waste into new products within minutes. The machines can be operated very simply and, depending on the set-up, they can be even shipped by courier to arrive on your doorstep. That’s why our machines are now in use in more than 70 countries. They come pre-assembled, ready to use, and everybody can become a plastics recycler. Only single-phase electricity is needed; they are light and mobile and therefore simple to move around. Has your participation at PRSE so far been a positive one in terms of exposure and leads? Yes, we have received a lot of positive feedback and through the EREMA partnership also had a very great exposure. Announcing the partnership during PRSE, Manfred Hackl said: «The young founders and their dedicated team exude pioneering spirit, want to shape the future with their work and put their heart and soul into the circular economy and plastics recycling. We believe in this company. plasticpreneur can enable plastics recycling in areas where no recycling is possible.”
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27
RETHINK COLOUR PRODUCTION DIGITAL COLOUR DATA FOR MODERN SUPPLY CHAINS Consistent colour for the plastic industry Our innovative spectrophotometers work with the Colibri® Platform for colour specification, matching, formulation and QC with industry-leading support and ongoing service. DELIVER QUALITY, SAVE TIME AND CUT WASTE.
AS INNO VATION k-online.com/k _ as _innovation
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kmd2202_Innovation_190x124_GB.indd 1
12.07.22 10:51
Your Sustainable Solutions Provider from Design to Production
recycling
N NEXTEK FOUNDER AND CEO PROFESSOR EDWARD KOSIOR DISCUSSES THE PLASTICS INDUSTRY’S CHALLENGE OF JUGGLING SUSTAINABILITY, CIRCULARITY AND POLLUTION.
E T A M I T L THE U I N G ACT C N A L A B
T
he direct impact of waste management sits at the heart of climate change. Global waste currently generates over 1.3 billion tonnes of CO2e and more than half of possible CO2e savings from waste will come from increased recycling rates and increased recycled content of all material in the recycling stream. Significantly improving waste collection, sorting and recycling can reduce global GHG emissions by between 2.1 to 2.8 billion tonnes of CO2e per year compared with ‘business as usual’, but minimising our waste will only occur once we unlock the value in the materials in a ‘waste’ stream. Realistically, we cannot eliminate plastic from the supply chain. That would not solve the world’s climate crisis. Quite the contrary. According to a Waste Reduction Model (WARM), if all the 37.4 million tonnes of single-family recyclables were put back to productive use, it would reduce US GHG emissions by 96 million metric tonnes of CO2e. It would also conserve an annual energy equivalent of 154 million barrels of oil and achieve the equivalent of taking more than 20 million cars off US highways. WASTED WASTE There is no one solution that will enable us to claw back our waste or reduce our carbon footprint. We urgently need to combine high-impact solutions from numerous pathways. What is needed is a balance between improving recycling practices, expanding waste collection, and ensuring that disposal
processes prevent plastic leakage. Furthermore, we need to ensure that the chosen solutions don’t have unintended consequences as different solutions have very different GHG profiles. It is a sobering fact that 80% of packaging still goes to landfill or diverted for waste-to-energy, and though many pin their hopes on the optimistic promises of chemical recycling, which will play a role but remains a long way from scaling up – and, in the meantime, still tips our carbon footprint in the wrong direction – diverting waste to either of these solutions, in effect, is wasting waste. There are more impactful uses for plastic that have a much smaller carbon footprint. We need to focus on driving rapid, alreadydeliverable improvements in packaging waste through mechanical recycling meshed with cuttingedge sorting and decontamination technologies. This will buy time for those areas of consumption where carbon reductions are harder to achieve, to enable them to develop and test new technologies and approaches. Organisations have pledged for recycled content, generating a demand in Europe for 10 million tonnes per year of recycled plastics by 2025. Yet capacity is projected to grow to just over 6.4 million tonnes, requiring a further capacity expansion of over 60% in less than four years. What we need are all hands on deck to achieve the kind of targets set out by the British Plastics Federation (BPF) in their 2030 Roadmap. According to their report, if all plastic were recycled globally
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ReFresher
Optimised recycled pellet odour Odour-optimised premium pellets – the result of combining the INTAREMA® TVEplus® and ReFresher opens up a new dimension in quality in recycling and completely new opportunities in the market as a result. So post-consumer plastic can become safe cosmetic packaging or trendy high-end headphones.
erema-group.com
K22 MAIN BOOTH: Hall 9 / Booth C09 OUTDOOR AREA: FG-CE03
CHOOSE THE NUMBER ONE.
British Plastics & Rubber.indd 1
13.07.22 11:52
MULTI PURPOSE GRANULATOR | A120 MAIN FEATURES: A3/A4 Barton Industrial Estate, Faldo Road, Barton-Le-Clay, Bedfordshire, MK45 4RP 01582 883666 info@plmachinery.com www.plmachinery.co.uk
HEAVY DUTY GRANULATORS | G21 MAIN FEATURES: • Solid, heavy duty • High capacity • Easy to clean for ease of maintenance • Sieve changing by pneumatic piston • Open and closing hopper by hydraulic system
Weight
2,000 Kg
Dimensions
1800 x 1300 mm
Height
1700 mm
Motor
11 (15) / 22 (30) Kw/Hp
Blades’ length
1200 mm
Hourly output
180 - 500 Kg/h
Volume
5.81 M³
IN-LINE GRANULATOR | A120/S Optional: 400x150 mm feeding mouth. Weight
23,000 Kg
Dimensions
3000 x 2800 mm
1700 mm
Motor
200 / 270 Kw/Hp
11 (15) / 22 (30) Kw/Hp
Ø rotor
1000 mm
Weight
2,000 Kg
Dimensions
1800 x 1300 mm
Height Motor
• Compact • Silent • Solid • Easy accessible for cleaning and maintenance
Blades’ length
1200 mm
Blades’ length
2100 mm
Hourly output
180 - 500 Kg/h
Mouth
1225 x 2100 mm
Volume
5.81 M³
Hourly output
1500 / 8000 Kg/h
Your Sustainable Solutions Provider from Design to Production
Diverting waste to either of these solutions, in effect, is wasting waste. this could result in mean annual savings of 30 to 150 million tonnes of CO2, equivalent to shutting between eight and 40 coal-fired power plants globally. Major brands have the potential to create transformational change, but they can’t afford to get side-tracked by innovations aimed at the uninformed consumer, otherwise we risk venturing down cul-de-sacs rather than making genuine progress. BEYOND SORTING Those in the recycling sector are keen to adopt the most effective sorting systems that can identify factors such as food-grade or non-food-grade besides the actual polymer, but sorting alone will not solve our recycling challenges. Sorting is only the first vital step in a journey towards a circular economy. We need to go beyond merely sorting waste to make any meaningful shift in how the world manages short-lived materials to minimise and reduce current waste levels. Ultimately, and regardless of how waste is identified and sorted, the world will end up with a pile of well-sorted but low-value plastic unless it can be properly re-used. This requires cutting-edge washing, extrusion, filtration and decontamination. Whether one opts for markers (such as fluorescent marker based PolyPRISM) or digital watermarks, the very fact that the sorting and identification processes can now be enhanced is a key step in the right direction. Decontamination is the next crucial phase. Achieving the vision of near-zero plastic waste requires technological advances, brave new thinking, innovative business models and accelerating upstream innovation. Unlocking the full value of materials will go a long way towards helping organisations honour their commitment to increase the level of recycled material in their packaging – better still, this kind of coherent recycling strategy will have enormous impact on reducing post-consumer waste. 360-DEGREE DESIGN FOR RECYCLING The world needs to focus on closing the loop by taking each facet of the process to ensure a transformational shift. The required technologies exist and can tip the balance, but it is crucial to avoid fixating on one element of the solution and embrace the whole.
Brand-owners need to be responsible for the environmentally sound management of packaging at the end of its life. Each product will need a defined pathway suited to easy recycling and contain high levels of recycled content with the minimum of residual landfill materials. They must also ensure there are acceptable destinations for their packaging in the local market. This is particularly key in Asia where waste management is less developed and regulations are not as rigorous. Likewise, brand-owners need to ensure that all packages are non-toxic, recyclable and/or compostable. This may mean new packaging materials and designs. More thinking needs to be dedicated to making products that can be recycled simply and productively by recycling businesses. That means re-configuring ‘difficult to recycle’ packaging and optimising the composition through low or no pigmentation, mono construction, removable adhesives and labels, and benign inks. If multiple sub-categories of packaging are created in response to the perception that sorting will have the capacity to create narrower fractions of materials, then the economics will diminish and issues of cross-contamination will increase. Ideally, the range of plastics used for packing should be standardised to the ‘big four’ (LDPE, HDPE, PP and PET). REDUCE VIRGIN Any organisation involved in FMCG knows that they are going to have to drastically curb their dependence on virgin plastic if they are to meet recycled content targets and comply with new plastic packaging laws. Achieving this will require a vast and new supply of high-quality food-grade recycled plastics, including the ‘big four’. SUMMING UP Our global, disparate initiatives fall woefully short. Lower-income countries will struggle to meet global targets without significant support in the form of capital for waste management and material recovery – in fact, the vast majority of countries still have much to do to redress the balance. This was recognised by the recent UN Environment Assembly (UNEA 5.2) in a unanimous agreement to develop a legally binding treaty to end plastic pollution. The agreement recognises the need to give governments the flexibility to identify binding and voluntary measures given there is no single approach to solving this global challenge. Ultimately, the fate of recyclable materials rests in the hands of a broad set of stakeholders who must all do something new and different to support the transition to a circular economy. Strong, coordinated action is needed in areas ranging from design, investments, scaled adoption of best management practices, policy interventions, and consumer engagement.
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FEATURE
R
RWC, WHICH ACQUIRED JOHN GUEST HOLDINGS IN 2018, HAS INTRODUCED CHANGES TO ITS WORKFORCE OPERATIONS AS A RESULT OF CHANGING TIMES. DAVE GRAY SPOKE WITH CATIA OLIVEIRA, RWC’S EMEA OPERATIONS SUPPORT AND WOMEN’S NETWORK ERG LEAD
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SPOTLIGHT WHY MANUFACTURERS NEED EMPLOYEE RESOURCE GROUPS DG: WHY DID RWC DECIDE TO ESTABLISH EMPLOYEE RESOURCE GROUPS (ERGS)? CO: The events of 2021, including but not limited to the global pandemic, an overall well-being focus, and cases of social injustice in the US, created urgency for change with a new strategy and approach to D&I at RWC. We moved to a value-driven approach aligned to business goals and positioned it as an integrated enabler to cultural change rather than an independent action in isolation. Rather than being owned by HR, D&I is owned by the business and each colleague. To enable bottom-up ideas and change from our colleagues, Employee Resource Groups (ERGs) were created to support broader top-down infrastructure creation. DG: WHAT DO ERGS DO? CO: Our ERGs are an integral component of RWC’s commitment to help us drive change in diversity and inclusion across the business and beyond. We have learned that when ERGs are established, employees become more engaged in identifying ways to leverage diversity and increase inclusion. As employeeled, self-directed voluntary groups, members serve as champions for diversity and inclusion and help identify opportunities for us to become more inclusive. At RWC, we started with three ERGs in our EMEA region, the Women’s Network, Future@RWC and the South Asian Association. All three groups are aligned to our local and work demographics as well as business needs, and membership to all three ERGs is open to all employees of RWC across EMEA, including the Women’s Network. This is particularly important, because we care about female representation at all levels of the organisation and want to ensure an improvement in overall representation and in senior roles, and to improve female inclusion in decision-making and participation. The ERGs will work to further the mission and values of RWC that represent the interests of all, and support RWC diversity and inclusion goals.
DG: WHAT HAS THE RESPONSE TO ERGS BEEN? CO: Since we established the ERGs, more than 150 volunteers across the three ERGs have offered up their time to build these groups and raise awareness of them. Employees have become more confident to approach and ask questions about D&I, ask for and offer advice, and give support to others. We also had great adhesion on all events related to D&I and ERGs both live and online. DG: HOW HAS THE WOMEN’S ERG BEEN RECEIVED ACROSS YOUR BUSINESS? CO: When we were looking at our local demographics and decided to create the Women’s Network as a pilot ERG, it was clear that we had a fairly balanced distribution of female and male employees across the business. However, when looking at roles of leadership, from Section Leaders to the Senior Leadership Team, the gap became more obvious, with limited female representation above n-2. When we launched on 2nd December 2021, we had an excellent response from employees who wanted to join and work with us to reach the objectives we established: working towards a gender-balanced participation on all areas of the business, allowing RWC women to find help and support to develop their careers, supporting the talent team with attracting and retaining women in RWC, and aligning and engaging with WES (Women in Engineering Society). We currently have 54 members in the group, mainly females, from different backgrounds, departments and countries across our EMEA region. DG: WHAT ARE SOME OF THE ACTIVITIES UNDERTAKEN BY THE WOMEN’S ERG SO FAR? ARE THERE ANY NEW INITIATIVES COMING THROUGH? CO: Firstly, RWC has become a corporate sponsor of the Women in Engineering Society
On 8th March, RWC celebrated International Women’s Day, by exploring what the day means to RWC as a business via a prerecorded video message from EMEA CEO, Edwin de Wolf.
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(WES). Working in partnership with WES, RWC is committed to raising the profile of women engineers and young professionals in engineering, manufacturing and tech. Across our pool of employees, we have identified a group of fifteen female engineers who have been given free membership to WES, including support groups, access to workshops, resources and mentorship programmes. On 8th March, we celebrated International Women’s Day, by exploring what the day means to RWC as a business via a pre-recorded video shared with us by our EMEA CEO, Edwin de Wolf. A purple ribbon was sent to all employees, which everyone was asked to wear during the week, whilst on-site and during video calls, to show support for gender equality and women’s empowerment. The images were also shared across our Social Media channels. We also celebrated #BreakTheBias hashtag across all sites and had a fun online quiz which helped us to raise money for the Ruth Strauss Foundation - which supports families facing the death of a parent, and recognises the gap left by the loss of a mother. Our third milestone was to launch the Family Friendly Policy in the UK on 8th March, which offers enhanced maternity at 100% of salary for 26 weeks and partner leave at 100% of salary for 3 weeks. The policy is also applicable to employees taking adoption leave. It also includes bonuses for those returning to work after maternity or adoption leave, the introduction of an IVF policy with time off for fertility treatment, and other benefits related to childbirth/adoption. This was an important milestone for us and the result of a close partnership with the Human Resources
Department and the commitment and support of our Senior Leadership Team. These new family friendly policies set us apart in our industry and to be involved in implementing this will forever be my favourite moment at RWC. In June, we celebrated Women in Engineering Day with a series of audio interviews featuring three female engineers working at RWC at different stages in their career, and we hosted a fun, informative and interactive event related to engineering and innovations by female engineers. To continue to shape the future for women at RWC, we are working closely with HR to develop training plans for future managers and leaders in the business. We are also working with the other ERGs, Future@RWC and South Asian Association, to hold engagement sessions and focus groups, and to plan a series of fireside chats with internal and external speakers. The first of this series, which is planned for July 2022, will be with the ERG leads, myself, Harmeet Rai, and Huniya Khan. WHAT ADVICE WOULD YOU GIVE TO OTHER MANUFACTURERS LOOKING TO PRIORITISE WOMEN’S REPRESENTATION THROUGHOUT THEIR BUSINESSES? CO: We have learned that it is incredibly helpful to align ERGs with local and work demographics and to start with only a few groups to begin with. Ensure that you have success across these first, create learnings and stories to share, and the rest will follow. It is also important that the business culture reflects the work of the ERGs by showing a readiness for leaders to accept bottom-up ideas and acknowledging that we may not always have all the answers right away; establishing ERGs and running them successfully is a work in progress. Each ERG needs a senior sponsor, who can act as an advisor and mentor to remove obstacles and champion change by being a role model. At the same time, ERGs require time and effort, and everyone involved needs to be happy to volunteer and sacrifice some of their time to make sure that progress is achieved and driven forward. Finally, celebrate the women working in your organisation first – consider all the things you do to support the women working for you and think what you can do to support them better. Once this is achieved, it is easier to branch out and attract more women to your business.
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33
FEATURE
SPOTLIGHT
C
CHIEF COMMERCIAL OFFICER AT TRIBOSONICS CHRISTINA KING ON THE COMPANY’S POLYMERSENSE DATA ACQUISITION SOLUTION AND HOW IT CAN ADD VALUE TO THE POLYMER PROCESSING SECTOR, AND THE NEW WORLD OF MANUFACTURING FOR YOUNG WOMEN.
TALKING SENSE WHERE DO SENSORS AND TECHNOLOGY SUCH AS THAT PRODUCED BY TRIBOSONICS FIT INTO THE POLYMERS PROCESSING SECTOR AND IN WHAT WAYS DO THEY IMPROVE FUNCTIONALITY? We are a sensing technology company working with customers on process optimisation in the polymer sector in particular, working alongside OEM’s and processors in injection moulding and extrusion. The technique we use in the polymer industry is ultrasonic sensing where our sensors sit on the outside of the system and send a wave in so that we can sense change. It is encoded with waveform data that we can translate into a measurement and provide the customer with data. We can measure and monitor anything from component wear to product and process parameters. In the polymer sector specifically, our service focuses on screw and barrel wear. This was a problem for manufacturers as they didn’t know where and to what extent their screws and barrels were wearing without shutting down the machine and dismantling it to make a visual assessment, thereby wasting time and money through excessive downtime. ENGEL, for example, wanted a system whereby they could measure wear in-process. We developed a system for them that they’ve now integrated into their machine monitoring system. With these additional insights it makes it easier for a processor to change things in process to make efficiency gains and reduce wastage. THAT ENGEL CONTRACT MUST HAVE BEEN SOME ACQUISITION FOR TRIBOSONICS. Yes, we used our experience and technology expertise to build a partnership with ENGEL to develop the technology and tailor it for ENGEL’s needs. In order to reach a wider pool of other polymer processors, we needed a different approach. What we wanted to do was lower the barriers of technology adoption such as upfront development costs and time to give other polymer processors access to our technology in a shorter cycle. AND HOW DID YOU ACHIEVE THAT? We created a servitisation approach in which we provide the system and install it, charging them on a subscription basis for the data used rather than
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for the cost of the equipment and installation. This gave them greater access to using our technology in their manufacturing processes. IS IT FAIR TO SAY THAT THIS TECHNOLOGY IS GOING TO HELP DRIVE A MORE SUSTAINABLE FUTURE FOR MANUFACTURERS? Absolutely. You need data to drive sustainability – especially where energy savings are concerned. We’re helping our customers and partners on the road to digitisation by focusing on generating the data that will create the value. There’s no point measuring or monitoring something if it’s not going to create value, so we have commercial conversations before we talk about the technology, discussing cost and energy savings and making a process more sustainable; from this point we can help the customer to focus on where the big savings and sustainability gains will come from. WHAT KIND OF SCIENTIFIC AND ACADEMIC EXPERTISE GOES INTO DEVELOPING TECHNOLOGY SUCH AS THIS? It was certainly not developed by a single person in a workshop, let’s put it that way, it was a real collaborative effort due the numerous elements involved. We have an incredible mix of PhD scientists, engineers, data scientists and commercialisation experts. Approximately 30 people work for Tribosonics in three distinct areas: The R&I lab; the commercialisation hub; and the manufacturing side, but it’s our customers that are the real experts when it comes to machinery and processes. It’s our job to bring everything collaboratively to extract the data and value generation opportunities. I IMAGINE THAT THE MAJORITY OF TRIBOSONICS’ PARTNERS HAVE EMBRACED INDUSTRY 4.0?
Data is the new oil – only probably more valuable – because we’re living in a digitalised society.
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A lot of companies will say they have but, in reality, it might not be quite like that. The companies we work best with are those actively seeking changes in their business and who are open to collaborating with external technology providers (like ourselves) to accelerate digital transformation in a true “Industry 4.0” sense. I’ve found that the mid-market enterprises are the ones embracing it the most. They have scale and global reach but have agility and an appetite for collaboration. Everyone we speak to is interested because we’re opening data streams that you can’t currently get from commercially available sensors. If we can provide that and give access to the value and sustainability gains as a result, then that’s always an interesting conversation to have. HOW CAN THE POLYMERSENSE ADD VALUE TO THE RECYCLING SECTOR? One of the things we’ve found with recycling is that there is variability with feedstock and other factors that mean processors can’t get material output of a consistent quality, which creates issues downstream. Even the automotive sector is pushing for more recycled plastic content that maintains quality, strength and performance. This all has to be done by 2030 – which is not long from now – so you’re going to have to have some insights to help with testing and development, etc. We can help by working with those companies to alleviate that through in-line process monitoring so that less time, and less material, is wasted. This would ensure that decisions can be made quickly and that higher quality materials can find their way to manufacturers who need it. HOW DID YOU BECOME INTERESTED IN DATA COLLECTION AND ANALYSIS TECHNOLOGY? I think data is the new oil – only probably more valuable – because we’re living in a digitalised society where everything is captured and digitised. Some would argue that
there is too much data but if you’ve got focused data that you can analyse, use and leverage, then you’ve got quite a lot of power to be able to move a business forward. I came into the business as Head of Strategic Partnerships and have had a considerable number of conversations about technology development and adding value, and matching commercial needs to our technology, which I find very fascinating. WHAT WOULD YOU SAY THEN TO ANY YOUNG PERSON ASPIRING TO A CAREER IN DATA MANAGEMENT AND TECHNOLOGY? As long as you’ve got an interest and excitement for this type of industry and a passion for change, there’s a role for you because it needs a multidisciplinary approach. The main thing is finding what you’re passionate about, finding role models in that industry, and finding out as much as you can about it. ARE YOUNG WOMEN LIKELY TO BENEFIT CAREER-WISE FROM THIS DIGITALIZED WORLD WE NOW LIVE IN? Yes, there is definitely a shortage of all kinds of engineers and scientists, including data scientists. All this data coming in needs people to develop ways to collect, transmit and analyse it in a cloudfirst world to help corporate management teams and engineers understand what that data means. It’s a whole new skill set and an area that is only going to grow. Manufacturing is gradually becoming a more diverse and inclusive field, which will attract young women back into that sector. We have women engineers and scientists here doing their PhDs in that area, so applying that academic knowledge to real world scenarios will see more young people coming in, experiencing it and immersing themselves in all the aspects of the business, which I think is great. I would have loved to have started out that way because you get to know more quickly which area you want to specialise in. The UK technology industry is innovative and growing and therefore a great opportunity for young people.
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26-28 SEPTEMBER 2023
Exhibitt with Exhibi wit ith 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
injection moulding
Advanced Plastics makes a well-timed
ENERGY SAVING INVESTMENT
I INJECTION MOULDER ADVANCED PLASTICS HAS A NEW SMARTPOWERBASED INJECTION MOULDING MACHINE FROM WITTMANN.
T
he SmartPower 400-tonne locking force machine was supplied and installed together with Wittmann 4.0 capability, B8 Unilog control and fully integrated mould cooling. Hull-based Advanced Plastics provides a range of technical injection moulding products for blue chip clients across a wide range of market sectors. Now in its 30th year, the company has instigated a continuous reinvestment programme at its Sutton Fields site, which means that Advanced is able to meet new challenges in manufacturing. Lean manufacturing is the norm at the business with automation, kaizen and poka yoke methods all playing their part in efficient daily production. Wittmann Battenfeld moulding technology accounts for over one third of the fleet of machines at Advanced’s disposal. Founder and managing director Rob Anderson said:
Advanced Plastics’s reputation for tight tolerance technical plastics has led to a rapid expansion at the company over the past three years. Anderson said: “Our mission is to be the preferred supplier of technical plastics to world class customers who also share our values. “The past two pandemic years have actually accelerated that process and those customer relationships to the point where we are now poised to make fresh investments in the months ahead. We are fortunate to have a partner supplier such as Wittmann who is able to help us stay ahead of the curve with innovative and costsaving technology.” “Our planned investment programme is allowing significant additional projects to be added through 2022. This will give us additional capacity across the moulding range from 45-1600t, making this available for further new business for existing and new customers.”
“Our new SmartPower 400 ticks the boxes in just about every respect; footprint, connectivity, large platen area, ease of use - and, of course, price.”
The latest SmartPower injection moulding machine from Wittmann - pictured here at Advanced Plastics
Anderson added: “Needless to say, the in-depth work that Wittmann has done in creating moulding machines with ultra-low energy consumption is now more important than ever: Energy cost is rising fast everywhere for all manufacturers and the Wittmann SmartPower will help us keep it to a minimum.” Advanced Plastics already operates four Wittmann EcoPower machines. The new SmartPower works on the same energy-saving principles. Advanced Plastics was also able to specify all its ancillary production needs from the same source. Wittmann mould temperature controllers, besidethe-press granulators and material drying systems are all in use at Advanced Plastics in order to keep manufacturing running smoothly.
Our planned investment programme is allowing significant additional projects to be added through 2022. This will give us additional capacity across the moulding range from 45-1600t, making this available for further new business for existing and new customers.
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injection moulding
UK moulder powers injection moulding machine exclusively
I IT’S NO SECRET THAT INVESTMENT IN NEW MACHINES IS GOING TO BE ESSENTIAL TO HELP MOULDERS LOWER THEIR ENERGY COSTS IN THIS TIME OF SPIRALLING PRICES. BUT NOW, ONE FIRM IS EVEN MANAGING TO RUN A MACHINE USING ONLY THE POWER OF THE SUN.
ABOVE: Tom Reardon, production coordinator and robotics engineer at Bloom-in-Box.
VIA SOLAR PANELS
F
ollowing its investment in a Fanuc Roboshot injection moulding machine, eco-conscious plastic products manufacturer Bloomin-Box says it is well on the way to becoming carbon neutral. By means of servo technology and ‘intelligent power regeneration’ capabilities, the Roboshot S150iA installed at Bloom-in-Box’s Burscough facility uses 3kW per hour, permitting it to be powered exclusively by renewable solar energy. “Our goal at Bloom-in-Box is to become carbon neutral over the next 12-18 months. We have been working with all-electric machines for the last 20 years to reduce power consumption and emissions. Solar installations and our new Fanuc Roboshot were the next steps to achieving this. Thanks to these latest investments, our current carbon emissions as a business are estimated to be less than 10 tonnes of CO2 per year, with our ultimate goal to achieve net zero,” said Tom Reardon, production coordinator and robotics engineer at Bloom-in-Box. BORN AGAIN PLASTICS Bloom-in-Box is a third-generation, family-run plastic injection moulding business focused on designing and moulding recyclable products from recycled materials. In 2018 Bloom-in-Box earned a place in the final of Best Recycled Plastic Product of the Year for its Bloomie floristry box. The Bloomie is made from 99% recycled material and is 100% recyclable. Any boxes that mould incorrectly are chopped up, passed through a grinder and made into security spikes. Other products made by the business include laundry pegs, scoops and measures.
We had reached a plateau. Our older machines were slower, causing production bottlenecks, and lacked the precise temperature control needed for working with biodegradable plastics,
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Bloom-in-Box has been involved in injection moulding for more than 20 years and has always been an advocate of electric moulding machines on the basis that they use up to 80% less energy than their hydraulic counterparts. When significant growth meant the company had reached maximum production capacity last year, it took the decision to invest in a new electric machine that would enable it to increase capacity by 25-40%. “We had reached a plateau. Our older machines were slower, causing production bottlenecks, and lacked the precise temperature control needed for working with biodegradable plastics,” said David Reardon, director of Bloom-in-Box. CARBON NEUTRAL AMBITIONS At the same time, the company had embarked on a roadmap to become carbon neutral, starting with an assessment of its carbon footprint. This
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revealed electricity accounted for 95% of its total carbon emissions. To address this situation, in November 2021, Bloom-in-Box installed a 40kWp solar system that feeds directly into the factory. During daylight hours this generates on average 10kW per hour, with the potential to produce even more electrical energy during the summer months.
RIGHT: The Roboshot S150iA
Therefore, when it came to deciding which injection moulding machine to invest in, Bloomin-Box wanted this machine purchase to support its carbon emission reduction ambitions and to be powered exclusively by the new solar panels. This search led Bloom-in-Box to Fanuc’s Roboshot range. Fanuc says its Roboshot consumes 10-15% less energy than other allelectric machines. This, the firm says, is attributed to a combination of Fanuc’s proprietary servo technology and smart energy recovery.
RIGHT & BELOW: Products from the Bloom-in-Box portfolio
“All our competitors buy their servo drives from a third-party manufacturer, whereas we build our own, meaning they are as energy efficient as is physically possible. This also enables us to specify servo drives that are the perfect match for each machine’s target performance, ensure they deliver exactly the amount of power to the motor that it needs,” said David Raine, Roboshot sales manager UK and Ireland. In addition, the Roboshot’s power regeneration feature enables intelligent energy recovery: when an axis decelerates, energy returns to the power source, adding to the overall savings. “When the equipment starts to decelerate and the motor is no longer required to drive a process, it automatically switches to being a generator, feeding the electricity that is generated back through the system to another location on the machine where it is needed,” said Raine. The 150T clamp force Roboshot S150iA in operation at Bloom-in-Box runs at 2.9-3kW per hour for a six-second cycle (the longer the cycle the less energy consumed), reducing energy consumption by 20% versus previous generation electric machines in the plastic processor’s fleet. “This represents a huge saving both in terms of CO2 emissions and energy bills,” said David Reardon. As well as being well on track to becoming carbon neutral, Bloom-in-Box is well-placed to expand its garden, scoops and measures ranges and to develop new medical and PPE products.
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Messe Frankfurt Group
SHEET LINES
PIPE/PROFILE
50mm Kerke Model KTE 50B/60055-36 Twin Screw Extruder
Alpine Ro28/60 Edge Trim Granulator
1220mm wide Welex sheet extrusion line
Small Pipe Line. 50mm Gillard extruder, water bath and haul off
5 station Maguire Model WSB 950T Gravimetric Blender
1650mm Wide Welex 3 Roll Polishing Stack
THERMOFORMING
PELLETISING
GRANULATORS
15 – 18 NOVEMBER 2022
T: +44 (0)1793 827666 E: sales@transxl.co.uk W: www.transxl.co.uk
FRANKFURT / GERMANY EXTRUDERS
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We know that Additive Manufacturing offers undreamed-of potential. In addition to the printer, however you also need the upstream and downstream processes plus the expterts, who have mastered the technology. You’ll only find all this at Formnext! formnext.com
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NEW & REFURBISHED SCREWS AND BARRELS
Screws PARTNER COUNTRY FRANCE
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Single or barrier flights and mixer screws available in either nitrided or superior high wear resistant bimetallic options.
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Refurbishment of main flight available in 7-10 days.
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Stock of bimetallic barrel blanks up to 50mm bore allows for new bimetallic barrels to be manufactured in 7-10 days. Barrels up to 305mm bore will take slightly longer.
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Partial re-sleeves within 7-10 days.
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Tie bar repairs within 7-10 days. New chromed or non-chromed tie bars available.
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sales@nickersoneurope.com Ring us on 01536 403886 • Email sales@nickersoneurope.com or visit our online store www.pmseurope.com Nickerson_A5_Flyer_CMYK.indd 1
10/03/2022 16:45
sustainability
LYONDELLBASELL SETS
SUSTAINABILITY G AHEAD OF K
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D DURING A PRE-K PRESS CONFERENCE IN ROTTERDAM, ANDREA BROWN, DIRECTOR, GLOBAL SUSTAINABILITY FOR LYONDELLBASELL, ANNOUNCED PLANS TO MEET SUSTAINABILITY GOALS. ROB COKER WRITES.
e’ve been much more vocal in terms of how we view our opportunity to address some of the world’s biggest challenges,” Brown told reporters, “including ending plastic waste, addressing climate change, and supporting a thriving society. We’ve come up with a number of ambitious goals that we will aim to achieve over the course of the next decade, starting with ending plastic waste where we aim to produce and market two million metric tonnes of recycled and renewable-based polymers annually by 2030.” CATALYTIC CAPITAL Brown then went on to discuss the ‘catalytic capital’ of LyondellBasell, which will be essential to creating new financing models that can help address the challenge of plastic waste. For example, she said that for every dollar invested in venture funds, the company could help catalyse a further five dollars from co-investors. The commitment to zero pellet loss continues to be extremely important for Brown and LyondellBasell. Its goal of zero plastic pellets lost from its facilities leaking into the environment continues to be a strong focus for the company under its collaboration with Operation Clean Sweep. Brown also said that she believes that plastics will continue to play a key role in society, but added that plastic waste is a critical challenge that has to be addressed – and the firm has plans to expand in this area too. “If we don’t,” she said, “all of the benefits that plastics offer won’t be realised at scale. If we address the problem of plastic waste by moving towards a circular economy, where resources and materials are circulated back into the economy, then we will be able to start to unlock the full value of plastic waste. We are leveraging our expertise in R&D to create innovative solutions and growing our capabilities in both mechanical and advanced recycling, as well as the use of alternative feedstocks. We are very much focused on this concept of catalytic capital and how we can engage with others to pool new financing models that can help unlock different opportunities to address waste management infrastructure and recovery, particularly in the US and Europe.” A COLLABORATIVE EFFORT Initiatives such as these require collaboration across the value chain. It’s important, Brown added, that it is not undertaken in isolation as no single company can solve such challenges alone: “Collaboration is critical. We’ve been stepping up in terms of how we collaborate into value chain platforms that can help create scale and address this challenge.” LyondellBasell is a founder member of the Alliance to End Plastic Waste (AEPW) and partners
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with the UN Environment Programme in recognition of the urgency of climate change and support of the Paris Climate Agreement. “We believe that net zero climate greenhouse gas emissions will require products and contributions from the plastics and chemical industry and consider our commitment to net zero a credible pathway towards 2030.” This pathway, according to Brown, will also support the climate ambitions of LyondellBasell’s customers’ in helping them reach their own sustainability goals. “We’re going to continue to integrate proven solutions and known technologies to be more efficient and effective as we look towards our 2030 goals,” Brown continued, by which she meant the implementation of energy efficiency technologies, process efficiency improvements and fuel switching, as well as integrating more renewable electricity into its portfolio through power purchase agreements (PPAs). As the world begins to look beyond 2030, industry is inclined to accelerate the scale-up and deployment of breakthrough technologies that will help decarbonise chemical processes. To do that, policies to integrate climate change into a wider business process will be required. When considering the technological solutions that will be critical towards reaching net zero, Brown stressed the need to understand what novel and low-carbon production processes will be critical in the production of LyondellBasell’s portfolio. “We’re therefore looking at hydrogen and the electrification of crackers,” she concluded, “but we want to make sure that electricity will be sourced from renewable sources. We’re looking at low-carbon steam in order to support the heat requirements that we have, and we’re looking at circular and renewable feedstocks to help move away from virgin fossil feedstocks.” As industry progresses towards 2050, businesses are pursuing these different technology options that will, in some capacity, continue to form part of solution portfolios as they aim for net zero. The trick is to ensure that what is possible now can be progressed, scaled-up and implemented with efficiency.
We’re going to continue to integrate proven solutions and known technologies to be more efficient and effective as we look towards our 2030 goals.
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Specialists in technical polymers | www.cjpsales.co.uk
INDUSTRY | NEWS DIP 2022 winner announced: Student uses reaction moulding to create bedpan solution for healthcare settings A student from Teesside university has claimed top prize in the 2022 Design Innovation in Plastics (DIP) competition, after designing a re-usable bedpan. DIP, supported by The Institute of Materials Minerals and Mining (IOM3), The Worshipful Company of Horners and headline sponsored by polymers manufacturer, Covestro, is the longest running plastics design competition of its kind for university undergraduates in the UK and Ireland. Product design undergraduate, Zara King, designed EasyMode, a re-usable bedpan for a pulp liner to fit inside, providing a safe and comfortable base for people to use in any healthcare setting. The bedpan is moulded with a wide base so that it sits comfortably into
the bed and presses down into the mattress, and when the patient is rolled off, it doesn’t tip. Product design undergraduate, Zara King, designed EasyMode, a re-usable bedpan for a pulp liner to fit inside, providing a safe and comfortable base for people to use in any healthcare setting. The bedpan is moulded with a wide base so that it sits comfortably into the bed and presses down into the mattress, and when the patient is rolled off, it doesn’t tip. Zara used reaction injection moulding to create her product, which is made from polyurethane. She designed it after hearing first hand from a nurse about the awkwardness of using existing bedpans, and the distress it often causes. Chairman of judges, Richard Brown, said
1st - Zara King, Teesside University, with EASYMODE, a reusable bedpan.
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Finalists with Kate Harrison - IOM3, Keving Jackson - Covestro, Mike Birrell - Horners and Marting Sixsmith - DIP.
Zara was a worthy winner who had tackled a sensitive issue and come up with a product which was already fit to go to market. “She impressed the judges with her methodical approach to solving a major problem in the NHS,” he said. “Her holistic approach incorporated both user and patient issues, to come up with a solution which met both needs. She gave due consideration to sustainability, manufacturing and the materials used and has registered this product as her intellectual property, so that it is market ready, should she want to take it forward.” Zara said: “Since entering this competition, I have enjoyed every moment, especially the thought of helping people with a product I’ve designed. Healthcare is definitely a field I’d like to stay involved in. This is one of the proudest moments of my life.” The judges awarded second place to Kenneth Thornton, (Edinburgh Napier University), with his product Catheter
The bedpan is moulded with a wide base so that it sits comfortably into the bed and presses down into the mattress, and when the patient is rolled off, it doesn’t tip. Zara used reaction injection moulding to create her product, which is made from polyurethane.
2nd - Kenneth Thornton, Edinburgh Napier University with CATHETER BAG CARRY, a reusable portable catheter bag.
Bag Carry, a reusable portable catheter bag holder which conceals and protects the catheter bag. Kenneth used silicone (NinjaFlex) for the bag holder and polypropylene for the belt.
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In third place came Charlie Gould-Hocking Bangor University), with Crutch, a shower stand for amputees with a lower limb loss that allows them to stand whilst showering. He used a combination of reinforced PET with a 30 per cent blend, SEBS and silicone rubber, to create his product. Highly Commended awards go to three students from London South Bank University: Daniele Di Paolo, who created Cirrus, a device to help with breathing exercises to promote relaxation; Dimitri McGrath-Karvelis with Anap, a double capacity inhaler for asthmatics that combines the preventer and reliever medication in one compact twistand-carry device; and
Specialists in technical polymers | www.cjpsales.co.uk
COMMENT
The word from Hird
3rd - Charlie GouldHocking, Bangor University, with CRUTCH, an adjustable shower or bath stand for amputees.
Finalist - Daniele Di Paolo, London South Bank University, with CIRRUS, a training aid to improve breathing.
Finalist - Dimitri McGrath Karvelis, London South Bank University, with ANAP, a double capacity inhaler for asthmatics.
Finalist - Daniel Warren, London South Bank University, with CURA, a burns kit for first responders
Daniel Warren, with Cura, a first aid kit for first responders, incorporating a new way of assessing and treating burns. Students were asked to design a product made primarily
of plastics, for the healthcare sector, which can be used in demanding applications, but which also exploits the longevity of plastics. The competition winner receives a £1,000 cash prize, a placement with a DIP sponsor or an industrial course and an invitation to the Lord Mayor’s Banquet as a guest of the Worshipful Company of Horners, along with a year’s membership of IOM3. The other five finalists also receive cash prizes along with placements or industrial courses and a year’s membership of IOM3. DIP is also supported by work placement sponsors, Brightworks, Innovate Product Design, PDD and RJG Technologies.
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RICHARD HIRD, CHAIRMAN OF THE POLYMER MACHINERY MANUFACTURERS AND DISTRIBUTORS ASSOCIATION (PMMDA) ON THE TOP PRIORITIES OF THE DAY FOR SUPPLIERS AND BUYERS OF PLASTICS MACHINERY.
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s we’ve now reached that point where we are halfway through 2022 (how did that happen?), I invited our members for comments on how they felt about the first six months of the year, and what are the challenges that they are currently facing? Kevin Horne reported from Renmar Plastics Machinery Limited: “We are still seeing a high level of enquiries and activity for recycling plants, shredders and granulators from within the plastic processing sector and other areas like logistic companies and waste management companies, some are purely exploratory, but others seem to have serious intentions.” Michael Swanton of Dynisco Ltd said that “Business levels have remained strong for incoming orders in the first five months of 2022; however, we did see a bit of softness in June. The challenge remains to increase shipments and reduce the backlog.” T H Plastics Sales Manager, Jonathan Pankethman mentioned “Despite the global challenges with part sourcing, lead times, increasing raw material costs and shipping issues, we have found the market to be buoyant and plastics manufacturer are looking to invest in the latest technology, especially in recycled content and validation procedures to take advantage of energy savings and
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scrap re-use”. Matthew Ross, Sales Director, Summit Systems Limited said: “The first six months of the year have been very positive with recycling and the plastic tax having a big impact on sales. The one issue that does not seem to be getting any better is the supply of equipment from Europe and China. World economic problems are having a big issue on pricing with rises being fed through from suppliers on a more regular basis, main area of price increases is raw materials. There does seem to be more of an acceptance within the industry that there will be longer delivery times however if the market confidence remains the same with hopefully the restart of the automotive industry, I see the remainder of 2022 being very positive.” All in all, 2022 has got off to a positive start despite the global concerns around supply issues and increases in costs, mainly due to climbing fuel prices. The concern is that we are entering a challenging period towards the latter half of the year due to these issues and to increasing inflation, which will put undue strain onto our customers operating costs. However, it has been reported recently that the continued investment in energy efficient equipment will help to mitigate some of the climbing energy costs.
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MACHINERY | NEWS Vector - ‘The future of extensometry’ Tinius Olsen’s Vector Extensometer is capable of replacing multiple contacting and noncontacting sensors with a single, industry specific instrument. Integrating adaptive AI capabilities with optical hardware, Vector reduces test throughput times and complexity, automating the process of capturing strain, improving measurement accuracy, data consistency and operator safety. It’s stereoscopic sensing detects
machine or specimen misalignment and negates out-of-plane errors, with the onboard processing delivering seamless and simple integration and eliminating all external control platforms. Tinius Olsen describes the new Vector Extensometer as ‘a real a step change in extensometer technology’. A fully automated, ‘groundbreaking’ solution, its stereoscopic sensing detects machine or specimen misalignment and negates out-of-plane errors, with the onboard processing delivering ‘seamless and simple integration and eliminating all external control platforms’. Features include increased testing efficiency for highly fragile materials, improved test success rate, and an on-board that AI enables a zerotouch operation.
Husky launches control algorithm that elevates performance of Altanium mould controller Husky Technologies has announced the launch of a second-generation control algorithm for its line of Altanium mould controllers. The Advanced Reasoning Technology (ART 2.0) software reportedly delivers speed, accuracy, precision, and repeatability. ART 2.0 incorporates advanced auto-tuning and heat-up strategies which deliver higher outof-the-box performance. Husky says it consistently delivers high accuracy and control precision, significantly reducing variability in the moulding 44
process shot-after-shot and mould-after-mould. Test results show that ART 2.0 delivers up to 42 per cent faster heat- up times with 30 per cent less energy use. Aurelien Bastien, Husky’s President of Hot Runners, Controllers & Medical, said: “The allnew tuning and control solution enhances performance while increasing productivity and significantly impacting a moulder’s bottom line.” ART 2.0 includes two complementary heating solutions that upgrade Husky’s original ART
UNTHA shredder at the heart of Meplas’ plastic recycling operation Yorkshire-based bespoke plastic recycling company Meplas has invested in an LRK1400 shredder from UNTHA UK to process the 600 tonnes per month of hard and soft plastics it receives from the UK’s post-industrial manufacturing outlets. The single-shaft, hightorque machine will enable Meplas to meet its 1.5 tonnes per hour processing requirements for hard plastics – in particular, HDPE, PP, and PO mix materials – using a 40mm screen size. Marcus Brew, Managing Director of UNTHA UK, added: “At UNTHA UK, we’re committed to helping unlock and drive the growth potential of the country’s waste and
Classic control solution. The primary heating strategy is UniStart which offers uniform and homogeneous heating while promoting even thermal expansion of components in the hot runner. UniStart distinguishes itself by finding the right balance between applying full power to the slowest heating zone and controlling overshoot to minimise heat-up and stabilisation time, according to Husky. A complement to UniStart is AltaStart, a patent pending advanced algorithm which staggers heating so that all zones reach process temperature simultaneously. AltaStart
The single-shaft, high-torque machine will enable Meplas to meet its 1.5 tonnes per hour processing requirements for hard plastics – in particular, HDPE, PP, and PO mix materials – using a 40mm screen size. recycling operators. With large in-feed volume and easy maintenance, the LRK1400 is the most powerful model in this range, and we’re extremely proud to see it pushing the plastic recycling agenda forward at facilities such as Meplas’s.” Meplas has the processing capabilities to recycle over 8,000 tonnes per year of recovered UK plastic packing film waste materials and hard plastics. The firm is also looking to invest in a further, larger shredder from UNTHA UK over the coming months.
also reduces energy consumption by bringing the fastest responding zones, such as the tips, to temperature last. The ART 2.0 system has more available tuning choices to deliver high level control. It uses individually adjustable P, I, and D values for selection during the autotuning routine, increasing the chances of arriving at an optimal result by limiting any gaps that a zone may fall into using the one-parameter method. Bastien added: “Based on the benchmark testing, we start making good parts sooner than conventional control systems. We achieve a faster payback because
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we produce more parts in a shorter period of time.” An expert operator achieved a 64 per cent increase in productivity based on understanding the steps to execute adjustments and the number of button presses to complete the steps versus competitive technologies.
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MATERIALS | NEWS Lucofin improving impact properties in recycled compounds by 97% in injection moulded applications
Polyplastics Group has introduced a new series of engineering plastic fine powders compatible with a broad range of manufacturing methods. The company has expanded its line-up with its trademark DURAST Powders, which go beyond traditional manufacturing processes such as injection moulding and extrusion, targeted for low-volume production of complex parts utilising sinter forming, compression moulding, and 3D printing. Made from polyacetal (POM), polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), and liquid crystalline polymer (LCP), the DURAST range of powders have a unique spherical shape and are controlled for fine, narrow particle size distribution (10μm200μm). Engineering plastics in powder form permit the use of manufacturing methods that were previously impossible with pellet shapes, making it possible to impart the strengths of engineering plastics and additional performance attributes. Dr Yoshiaki Taguchi,
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Fine Powder Business Promotion Office, said: “As time goes on, many different types of processing methods other than injection and extrusion moulding are being proposed when processing small quantities with many varieties or complicated shapes, as opposed to just mass production, and the materials for these will likely be in powder form. DURAST Powder can be finely dispersed in an epoxy resin. This is not possible with pelletshaped polymers.” DURAST PPS, a linear PPS with strong toughness and heat, chemical and radiation resistance, can be used to mould porous structures through sinter formation. It can also withstand rigorous electrical requirements. Could such a novel material with properties like this at some point be utilised by a future generation of astronauts that perhaps need to develop customised tools on the Moon or Mars? Taguchi wouldn’t get carried away by going into too much detail, but he did concede that it “won’t be impossible”.
To microgravity and beyond: AIMPLAS-ESA project to develop new materials in low-Earth orbit The Advanced Materials Accelerator was created as an initiative of the Business in Space Growth Network (BSGN) Programme of the European Space Agency (ESA), where plastics technology centre AIMPLAS is working to drive the development of new materials under the microgravity and vacuum conditions of space. This is the centre’s first aerospace project and thus opens a new research area on advanced plastic materials whose quality and performance are much better than materials developed on Earth. The BSGN accelerator is being developed by a European consortium of six leading space and materials companies, the Centre for Process Innovation (CPI), Satellite Applications Catapult, Innovate UK’s Knowledge Transfer Network, Deutsches Zentrum für Luft- und Raumfahrt (DLR) Institute of Materials Research, the National Composites Centre (NCC) and AIMPLAS. The first phase of the project, led by Satellite Applications Catapult, will focus on generating interest and demand in the growing in-orbit servicing and manufacturing industry so that advanced manufacturing companies can explore the possibilities that space has to offer and get involved in the programme. The project focuses on five advanced
This is the centre’s first aerospace project and thus opens a new research area on advanced plastic materials whose quality and performance are much better than materials developed on Earth.
materials technology areas: superalloys and hybrid materials; nanomaterials; advanced ceramics; novel polymers and fibres; and functional coatings and thin film systems. Carolina Losada, AIMPLAS’ Principal Investigator for the project, said: “At AIMPLAS, we’re very proud of participating in this groundbreaking programme, which will allow us to explore the conditions for manufacturing new polymers and fibres in space to obtain improved advanced materials compared to products developed on Earth.” Future phases will focus on upscaling the opportunities identified in phase one in each
area, including in-orbit demonstrations and the delivery of prototype products. The first phase has a budget of €411,000 (~£353,000). The programme aims to guarantee at least €1m in funding for future phases from ESA up to a maximum of €5m. The ESA’s BSGN Programme is aimed at stimulating non-space sectors for their potential to develop and deliver scalable, space-enabled applications, services, and products. The programme therefore favours the participation of private industries and research centres to adapt their know-how and capabilities to the aerospace sector and boost a new low-Earth orbit economy.
[The project] will allow us to explore the conditions for manufacturing new polymers and fibres in space to obtain improved advanced materials compared to products developed on Earth
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P PHILIP LAW, DIRECTORGENERAL OF THE BPF, TELLS BP&R ABOUT THE FEDERATION’S LATEST ACTIVITIES, INCLUDING ITS RESPONSE TO THE ‘BIG PLASTICS COUNT’, AND PLANS FOR K SHOW LATER THIS YEAR.
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very encouraging development was the publication recently of a study carried out by McKinsey and Company, ‘Climate Impact of Plastics’. McKinsey studied a range of plastics applications in packaging, building/ construction, consumer goods, automotive and textiles, comparing them with alternatives. The key point was that in 13 of the 14 applications analysed, plastics had a lower Greenhouse Gas (GHG) contribution than the competition. The analysis covered the entire life cycle, from raw material acquisition to end-of-life, including value chain impacts like food spoilage and packaging breakage. Although based on the situation in the USA, the authors performed sensitivity analyses to extend the GHG assessment to other regions such as Western Europe and China. Among the specific plastics products registering superior performance were grocery bags; wet food packaging; soft drink containers; fresh meat packaging; soap containers; municipal sewer pipes; residential water pipes; insulation; furniture; hybrid fuel tanks; BEV (Battery Electric Vehicle) battery top enclosures; carpets; and t-shirts. This is certainly a third party study we can use in discussions with government and customer industries. BPF issued a robust statement in response to the ‘Big Plastics Count’ emphasising that we believe in using packaging only when it is necessary and that we support the growth of reuse systems. Considerable change and innovation is underway in the plastics industry and work is ongoing to scale up technologies and collection systems so that almost all the plastic commonly used for packaging can be recycled. However, promoting a message
that ‘recycling doesn’t work’ is unhelpful and could demotivate people from doing the right thing. Last year 51% of plastic packaging in the UK was recycled and the amount of plastic recycled has increased 2.4 times since 2006. In 2021 the UK recycled more of its plastic within the country than it exported for recycling – actually the first time this has happened. Simply substituting plastic packaging with other materials may not be the best for the environment, as stated in a 2020 study by Imperial College London. Turning to the commercial world, the K Fair is soon upon us. Leading the British Pavilion in Dusseldorf is part of the BPF’s heritage and we have been exhibiting there since the 1950s. A valuable addition to our stand will be the incorporation of a dedicated space for UK visitors to hold meetings free of charge. This will be supported by the UK Department for International Trade (DIT). This British Visitors Networking Area is in Hall 5, stand number 5A28. On the first day of the exhibition, October 19th, a drinks reception will be held there between 4.30 pm and 6.00 pm. British visitors who wish to pre-book space for a meeting within the UK Visitors Networking Area can e-mail Justyna Elliott at JElliott@bpf.co.uk. Alternatively, UK visitors can come and use the space without booking, subject to availability. The BPF’s view is that it’s crucial for UK firms to establish a strong export footing post-Brexit, and we are supporting our stand with promotional initiatives such as our newly published BPF Industry Directory and several sustainability initiatives that demonstrate the industry’s role as a thought leader. For more details about the British Pavilion at K 2022, visit www.bpfevents.co.uk.
In 2021 the UK recycled more of its plastic within the country than it exported for recycling – actually the first time this has happened
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