BP&R May/June 2022 by BP&R Magazine

bp&r may/jun 2022

★ ST H G I A H

ND A R DS

British Plastics

and Rubber

MEUSBURGER EXPLAINS THE VALUE OF STANDARDISING YOUR HOT RUNNER SETUP — SEE PAGE 22 DOUBLE OUTPUT Mega growth for Advanced Plastics

POLYMERMAN Forging a new economy for recyclate

CALM AFTER THE STORM? Broanmain Plastics on the new normal

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www.interplasinsights.com head of content: dave gray

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

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Head of Content

Dave Gray

’m looking forward to International Women in Engineering Day on 23rd June. If you follow me or any of the Interplas Insights social media pages, you’ll know I’ve had the pleasure of travelling the country, meeting with key stakeholders in the plastics industry recently. I’ve been asking people about their current challenges, trying to get to the heart of the kind of content that would best serve our readers. There have been many common themes, but probably none more pressing than the issue of skills, recruitment and diversity in the workforce. At a friend’s wedding recently, I found myself chatting to a student of data science, who had just finished writing a paper on the correlation between various societal influences and the uptake of engineering amongst young women. One key outcome from this work showed that the language used around engineering still depicts an overtly masculine arena. Neutrality of communications could be a key consideration in trying to invigorate diversity among the next generation of engineers. Get It Made, a UK contract manufacturer offering injection moulding, CNC machining and other services, got in touch with me to let me know about their initiative for International Women in Engineering Day. They’re offering a grant of up to £10,000 tailored exclusively to femaleled, engineering, design and

manufacturing enterprises. The recipient will also benefit from business support and guidance from Get It Made – vital for any small business trying to find its feet post-Covid. I’ll be speaking to the team at Get It Made in an upcoming episode of the Interplas Insights podcast. Speaking of which, I’m really enjoying hosting the podcast (which, by the way, is available on all major podcast apps) lately, because we’re getting some fascinating people in from all sides of the supply chain. Take for example a recent interview with Professor Michael Shaver at The University of Manchester’s Sustainable Materials Innovation Hub, and Natalie Mera-Pirttijarvi, project manager at the university’s Innovation Factory, Shaver has been leading a team of researchers in developing a new additive that can accurately detect the presence and concentration of recycled polymers. It’s timely, given the recent introduction of the Plastic Packaging Tax, and while uncertainties still exist (both in the interpretation of the tax, and the availability of recyclate), it’s likely to be a useful technology for the industry to have access to. In another episode, I caught up with sustainability leaders at Inovyn and LyondellBasell, firms that are both backing a cleanup project called Plastic Free Mersey. It’s perhaps not surprising that chemicals firms want to align themselves with these projects, and I wanted to find out how they plan to put words into action. It’s a panel discussion, so you’ll also get to hear from the team at Plastic Free Mersey (the team behind Thames 21) on what they think industry can and should be doing to address the problem of plastic in waterways.

On the Cover

25 FEATURE

Meusburger explains the value of standardising your hot runner setup – See page 22

Regulars and Features

Why there’s more than you think packed within the latest tool-changing tech

15 WOMEN IN PLASTICS

3 COMMENT

27 FEATURE

19 POLYMERMAN

6 CASE STUDY

Gripping experts list the four things to get right in part handling

36 INDUSTRY NEWS

Capital investments at Advanced Plastics pay dividends

33 FEATURE

11 SUSTAINABILITY

Linecross Composites on why it’s making new investments in ancillaries

High standards

Double output

Responsible stewardship

Automatic tool changers have come a long way

Four steps to better part handling

Materials handling

Dave Gray sits down with Bertram Stern, sustainability manager at Arburg

41 MATERIALS NEWS 44 BUYERS’ GUIDE 46 DIRECT FROM THE DIRECTOR

15 REGULAR Women in Plastics

Broanmain Plastics MD Jo Davis on running a plastics business post-Brexit, and postpandemic

39 MACHINERY NEWS

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QUALITY SUSTAINS.

A carbon-neutral future can only be achieved with sustainable products. A good example of this is our latest easy-flowing compound Durethan® BLUE BKV60H2.0EF, in which we’ve replaced 92% of the raw materials with sustainable alternatives. As a result, this material ranks at the top of the list of glass-fiber-reinforced plastics exhibiting the same characteristics as the virgin material and can be processed just as easily. This highly rigid and strong structural material is used in automotive manufacturing for vehicle front ends, brake pedals, and oil pans. In other words, wherever its fossil-based equivalent Durethan® has already proven its worth. Learn more at durethan-blue.lanxess.com

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pioneering plastics

case study

DOUBLE

OUTPUT

for Advanced

T THE UK’S FIRST INSTALLED FANUC ROBOSHOT S450IA INJECTION MOULDING MACHINE HAS DOUBLED OUTPUT ON A KEY RANGE OF MOULDED PRODUCTS FOR ADVANCED PLASTICS LTD, A SUPPLIER OF PRECISIONENGINEERED PARTS TO OEMS IN THE AUTOMOTIVE, MEDICAL, PACKAGING, DEFENCE AND CONSUMER GOODS INDUSTRIES.

nstalled in combination with the integrated Fanuc M020iD35 robot, the success of the installation prompted Advanced Plastics to order a second machine-robot combination from Fanuc UK, which has already been delivered and commissioned. “The combination of the Fanuc robot and moulding machine allows us to seamlessly integrate our processes,” said Rob Anderson, managing director at Advanced Plastics. “This has resulted in a dramatic increase in our output from around 600,000 parts on a particular range up to a planned 1.3 million.”

The UK’s first installed Fanuc Roboshot S450iA injection moulding machine has doubled output on a key range of moulded products for Advanced Plastics

Based in Hull, Advanced Plastics undertakes everything from initial design concepts to volume production of plastic mouldings and assemblies, structural plastic components and technical automotive components. The company has almost 10 years’ experience of using Fanuc equipment, as Anderson explains: “Our injection moulding machines produce high-level engineering parts in various grades of plastic. Since we purchased the first Fanuc robot back in 2012, we now have nine Roboshot machines and over 40 Fanuc robots. We are proud to be the first company in the UK to purchase the Fanuc Roboshot S450iA. We purchased this machine on the back of our experience with Fanuc, as we needed a bigger

AI-Protect allows the moulds to open and close at fast speeds with full protection of the tooling. The tooling can often be just as expensive as the moulding machines so we must protect it.

Plastics

machine that gives us the sensitivity to protect very delicate tooling. This machine perfectly fits the bill.”

Fanuc’s M-20iD35 robot, meanwhile, is a highinertia, high-strength model with a hollow wrist and base that delivers fast movement in all six axes. Its maximum load capacity of 35kg is more than sufficient for the lightweight plastic injection moulded components produced on the Roboshot S450iA at Advanced Plastics. It also has a reach range of 1,831mm, meaning it can cope with stretching into the Roboshot S450iA to extract complex components and load them into a collection point or pallet. Another feature is the Fanuc AI-Protect system for both mould and ejector. This provides mould protection, which in turn neutralises an important potential cause of downtime. By measuring the motor torque, AI-Protect immediately stops the machine if any restriction is detected, shielding the mould during the full opening and closing cycle while having no impact on clamp closing speeds. The same technology

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pioneering plastics

protects the ejector’s forward and reverse movement. AI-Protect also alerts operators when greasing is required, or the mould is worn. “AI-Protect allows the moulds to open and close at fast speeds with full protection of the tooling. The tooling can often be just as expensive as the moulding machines so we must protect it,” said Ed Darling, Advanced Plastics’ process manager. Darling also explained an incident when an apple was dropped between two surfaces of the mould: “Because of the accuracy of the AI-Protect, the apple wasn’t crushed. That shows the precision that we need on these moulding machines.” Other automated features include clamp force adjustment, which checks and adjusts the minimum clamp force to provide increased security, eliminating the need to manually modify this critical BELOW: Fanuc’s M-20iD35 robot reach range of 1,831mm means it can cope with stretching into the Roboshot S450iA to extract components and load them into a collection point or pallet – regardless of the dimensions of the moulded part. BOTTOM: Advanced Plastics undertakes everything from initial design concepts to volume production of plastic mouldings and assemblies, structural plastic components and technical automotive components

ABOVE: The M-20iD35 robot at Advanced Plastics is controlled via the latest R-30iB control system. This integrates more than 250 software functions to ensure industry-leading speed, accuracy and safety

The Roboshot S450iA injecting moulding machine operates with a clamp force of 4,500kN, a double platen die height of between 350mm and 1m, and a clamping stroke of 900mm. Weighing 29.7 tonnes, it parameter. Optimising clamp force also minimises mould wear and increases machine life, cuts component defects, reduces energy consumption and compresses start-up times. The M-20iD35 robot at Advanced Plastics is controlled via the latest R-30iB control system. This integrates more than 250 software functions inside the Fanuc A-cabinet, and the firm’s iPendant Touch control interface. Darling added: “I particularly like Fanuc moulding machines because, being all-electric, they are economical to run; but mostly, I like them because we are a cycle time-oriented business.” As a result of the productivity gains, the company placed an order for a second machine. Anderson added: “We went for the second machine due to the easy installation of the first. The short lead times offered by Fanuc meant we could get products to market extremely quickly. At Advanced Plastics, we like to experience new technologies and look at innovative technologies where we can achieve better results for our customers. In essence, the Fanuc Roboshot S450iA was the only machine that could do the particular job that we needed it to do – and it does it very well.”

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Hilectro robots from Haitian Creating your advantage

Your Sustainable Solutions Provider from Design to Production

FEATURE

E EARLIER THIS YEAR, ARBURG PUBLISHED ITS ANNUAL SUSTAINABILITY REPORT. DAVE GRAY SAT DOWN WITH BERTRAM STERN, SUSTAINABILITY MANAGER AT ARBURG, TO FIND OUT MORE ABOUT ITS EMPHASIS ON ALL THINGS GREEN.

RESPONSIBLE STEWARDSHIP

nown for its green machines, not to mention its HQ in leafy Lossburg, a picturesque town in the Northern Black Forest, surrounded by nature, Arburg has prioritised energy efficiency for many years. Back in 2012, it became one of the very first companies ever to be awarded triple certification for quality, environment and energy. DG: WHY DOES ARBURG PUBLISH THIS ANNUAL REPORT? BS: We at Arburg take our responsibility seriously as a company. Sustainability has been an important topic for us for many years. In our business activities, we are highly committed to the careful use of resources with a focus on people and recycling, both now and in the future. Resource conservation and sustainability are firmly anchored in the DNA of our family business. You could say that it’s in our nature – the location of the company headquarters in the Northern Black Forest in Germany makes it absolutely vital to take a sustainable approach to resources and the environment. Our strategy of globally centralised and resource-efficient production of high-quality technology products has been the basis of our successful business, and not just since the recent discussions about the security and functionality of the global supply and logistics chains. The publication and annual updating of our sustainability report, which has just been released in its 2021 edition, also forms an important part of our work in this area. The aim of this publication is to provide transparency and to inform all stakeholders about the activities we are carrying out in this field, what we have already achieved, what we still want to achieve and how we intend

to do it. In this regard, we are leading the way as a company and demonstrating clear responsibility in terms of sustainability, resource conservation and circular economy. These approaches are also in keeping with our arburgGREENworld program, which brings together the company’s activities in the fields of energy and resource efficiency, circular economy and climate protection. Our aim is to continuously increase the production efficiency of plastics processing, to sustainably reduce its carbon footprint and to promote the use of recycled materials and bioplastics. We continuously analyse our situation, for example by participating in the internationally renowned Carbon Disclosure Project (CDP) and receiving a CDP score. Our debut in 2021 produced an above-average result compared to other machine manufacturers with a “B” score. DG: HOW CAN COMPANIES LIKE ARBURG MEASURE THE CONCEPT OF SUSTAINABILITY? BS: We use various indicators and key figures such as energy requirements, water consumption, waste recycling rate, etc. We derive optimisation measures from these indicators and work hard to implement them and keep moving forward as a company. At the same time, we also use customer and employee feedback in relation to these efforts to find out whether we are acting in line with our stakeholders’ expectations. All of these findings are incorporated into a comprehensive action plan which describes various strategic milestones and concrete measures. In 2021, we used the plan to

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flesh out our understanding of arburgGREENworld as described. Our work on this plan, as in other areas, is focused and ongoing. DG: WHAT WERE THE MOST IMPORTANT FINDINGS THIS YEAR? BS: Sustainability is increasingly proving to be a multi-dimensional, multi-faceted and highly dynamic group of topics which is constantly presenting new requirements and challenges for companies and, in particular, international supply chains. The mechanical engineering industry is no exception. Companies are focusing more on sustainability than ever before. Aside from laws and regulations, increasing public pressure over the past few years has led companies to actively and systematically step up their efforts in the fields of resource conservation and circular economy. In this context, legal measures that are either planned or already in effect in Germany and the EU mean that the global supply chains will be incorporated much more heavily into these considerations in future and will be called on to play their part. Deficits affecting the suppliers will have an increasingly direct impact on the relevant clients. In other words, sustainability is increasingly becoming a deciding factor when awarding contracts, both within the company itself and in relation to the customers of the companies in question. DG: WERE THERE ANY SURPRISES? BS: These days, we have our hands full dealing with numerous different evaluation and supplier self-declaration forms relating to sustainability, which involve a lot of work and take up a lot of time. But we’re not the only ones focusing on this subject – young people in general, employees and especially apprentices and students who work for a company, or want to work for them, spend a

lot of time thinking about these topics. This trend is becoming more and more pronounced and ultimately leads to people deciding how attractive a company is in these respects. This means that, in the future, a company’s attitude to its responsibility regarding sustainable business practices will play a key role in its reputation as an employer. DG: HOW CAN THE FINDINGS BE TRANSLATED INTO ACTION? BS: There can only be one path forward: we need to be proactive in tackling the requirements and challenges facing us as a company. We have been and continue to be a pioneer in the field of corporate responsibility, as in other sectors. Developing and expanding our know-how and expertise with regard to sustainability is part of our work in this area. Put simply, we need to do something because even small steps are better than none at all! To that end, in 2021 we started defining clear responsibilities at Arburg with a Sustainability Manager. Our focus is very much on established standards to make sure that we do not lose sight of what is important. The aim is to ensure sustainable production across all areas – as set out in our arburgGREENworld program.

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FEATURE

SPOTLIGHT The times they are a-changing

D DAVE GRAY CATCHES UP WITH BROANMAIN PLASTICS MD JO DAVIS TO TALK ABOUT LEADING A PLASTICS BUSINESS POST-BREXIT, AND POST-PANDEMIC.

DG: AS A LEADER, HOW WOULD YOU DESCRIBE THE CHALLENGES YOU AND THE BUSINESS FACED DURING THE TURBULENCE OF RECENT YEARS? JD: I would say that for at least four years I have felt threats to our business coming from all angles, relentlessly. Everybody reacts to heightened levels of anxiety in a different way, however normal operating conditions would see those events come and go, and are part of doing the job. Over the past four years, once one disaster was managed and averted, so another came sweeping in. Dealing with these extreme levels of uncertainty and often ambiguity about the future has without doubt affected myself and many of the leadership team at Broanmain. Maintaining the team culture and resilience has been a huge personal focus. Leaders are well used to dealing with problems. However, the uncertainty of so many constant different factors has often made it challenging to keep things in perspective. At times it’s felt like each mountain looms larger and gets tougher to navigate. Trade wars, closed borders, shipment delays, ongoing tariff negotiations, currency fluctuations, material shortages, recruitment challenges, the list just seemed never ending at times. It really has pressure tested how we as an SME and critical service provider focus and address the critical issues as they arise. When there appears to be no perfect path forward, it really underpins the value of being able to collaborate with industry peers. Being actively involved in industry groups through the BPF and other likeminded professionals has helped me personally. I’ve always valued this collaboration within our industry. Sounding boards are vital, especially when trying to maintain a level of normality and run a business during a state of flux.

It’s my hope that these collaborative relationships continue long after the geopolitical climate settles.

DG: AND WHAT LEARNINGS HAVE COME FROM THESE CHALLENGING TIMES? JD: The biggest leadership takeaway is to listen and maintain compassion for what everyone is going through. Our appointment of Eve Clennell to a new senior role overseeing people, culture and strategy came at a pivotal moment - when the pandemic and Brexit uncertainty put employee wellbeing, Good Manufacturing Practices (GMP), and workforce safety into even sharper focus. Safeguarding physical and mental wellbeing is a core objective here and it’s clearly evident that our team recognises the correlation between how it impacts culture and productivity. It’s an area we continue to invest in. Two colleagues during the first year of the pandemic completed the Mental Health First Aid training, which enables them to recognise and assess stress triggers. We also introduced an external counselling service for all team members With such a diverse workforce, largely comprising EU nationals, another immediate priority for Eve involved examining how team members could visit families and safely quarantine on their return. Additionally, Eve assisted team members that wanted support completing their EU Settlement Scheme applications. We have also done a lot of work to introduce cross-team communication and project collaborations. All of which helps our missive to address unconscious biases that continues to be so prevalent within the manufacturing and engineering sectors. DG: CAN YOU TALK ABOUT THE ECONOMIC IMPACT OF BREXIT? JD: What the pandemic has done is mask the full scale of the economic fallout that directly relate to Brexit. The aggregate and amplified effects of Covid have certainly appeared to outweigh Brexit. But from a business context, the tariff uncertainty has been a significant challenge. Particularly when it comes to sourcing raw materials. Like many moulders, we import a lot of our plastics granules from Europe – mainly Poland, but also France and Germany. Being an SME, we don’t have the same level of cash to flex. The procurement challenges, although not purely attributed to import tariffs, have been one of the biggest headaches for injection moulders.

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Absorbing these ever-rising prices as they reached a six-year high while simultaneously overcoming the technical processing, labour and energy hurdles without compromising production quality has been immensely challenging. With the ripple effects continuing. September 2021 was a potential tipping point for Broanmain. That was when the supply chain bottlenecks really started to bite. It was the exact same time of furlough arrangements ending, and we were at risk of not producing one third of our processing business due to material shortages. Fortunately, we navigated our way through. In part testament to the excellent relationships we have nurtured with customers and suppliers. To help offset trade imbalances, we have put a lot of our energy into maintaining longer-term partnerships with trusted material suppliers. It’s my hope that these collaborative relationships continue long after the geopolitical climate settles. Like many peers, I have observed a definite shift in flexibility among suppliers. Especially those that went above and beyond during the worst of the pandemic to keep lines moving. We are certainly attracting more reshoring work and quoting for new business as a result of this adaptable approach. What the material sourcing situation really highlighted are the structural flaws. As an SME manufacturer of technical plastic components, it really demonstrates to us the importance of building out better supply chain resilience. Navigating these instabilities requires a paradigm shift towards better value and risk mitigation. DG: WHAT ABOUT SKILLS IN ENGINEERING? IT CONTINUES TO BE A CHALLENGE ACROSS THE BOARD IN THE UK – HOW IS BROANMAIN FARING IN THIS DEPARTMENT? JD: Brexit and the end of free movement across the EU has also exacerbated the skills and resourcing situation for UK manufacturers. Recruitment and retention has always been challenging, but the loss of EU labour has compounded the situation. We are having to pay premium wages to attract new talent, and the overseas pool of skilled polymer professionals has completely diminished. Prior to the pandemic we attracted several French interns every summer drawing upon our links to the respected Federation of Plastics and Composites Polyvia. The fact our operations manager Thomas Catinat came via this route is not lost on us. However, EU candidates no longer feel welcome, and even those that recognise the opportunities are finding the costs too prohibitive and the bureaucracy of the visa system off putting.

Jo Davis (centre) with Broanmain’s senior team Thomas Catinet and Eve Clennell It’s a great loss to us, as this program formed part of our succession planning. Often the interns would return, each bringing exceptional skills, processing insight and always integrated well with our team members. Some led specific process improvement projects. We are exploring avenues to reinstate this program, but understandably there’s not the same level of appeal given that Britain now only accepts fully skilled workers. Attracting domestic workers is proving to be equally challenging and if not addressed will limit our business growth. We are all competing for scarce resources. British supermarkets have much deeper pockets and to attract talent last year increased wages beyond the statutory minimum wage. This bargaining power puts SMEs under immense pressure to match salaries. However, now the cost of living is in effect removing the choice for potential applicants. Combine these factors with the ongoing perceptions about careers in engineering and manufacturing, we clearly need to work harder to change the workplace narrative and showcase the development opportunities. It’s not so much reinventing the recruitment strategy but showcasing the fulfilling aspects. For some time, the industry’s focus has been on ‘Women in Plastics’. Given the urgency of this situation, we should now champion the need for ‘People in Plastics’. DG: AND FINALLY, HOW ABOUT THE RISING COST OF ENERGY? JD: Manufacturing is an energy intensive business. Our ballooning energy bills will likely double to £12,000 p/m from August 2022. Another anxietyinducing cost that needs to be absorbed into an already fragile pricing structure. Looking ahead, Broanmain is already undertaking a number of projects to assess baseline energy consumption, as well as machine demands and capacity. Our ultimate ambition is to migrate to a single site. When this occurs, we’ll seriously consider another all-electric machine investment.

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M MIKE BOSWELL LOOKS AT THE NEW REALITY FACING UK PACKAGING FIRMS POST-APRIL 1ST, AND ASKS HOW IT MIGHT AFFECT PRICING.

TAXING TIMES

he UK was the first European country to implement a plastics packaging tax on April 1st 2022. Other countries including Italy and Spain have delayed the implementation of similar tax regimes until 2023 and other governments are likely to implement similar levies in the near future. In the case of the UK Packaging Tax, there has been widespread criticism that none of the substantial tax income received by HM Treasury will be directly applied to supporting the recycling of UK plastics packaging waste. Instead, HM Treasury has put forward the argument that the tax itself will serve as a sufficient incentive, and that if this is not the case then the tax will be increased further in order to achieve higher rates of recycling. This article considers the economics of this argument, and the risks that higher rates of tax applied by other countries may deprive UK plastic converters wishing to incorporate 30%+ of recycled content of UK produced recycled feedstock. The question of the packaging tax itself being a significant incentive can be considered using the following equation:

TOTAL COST1 OF INCLUDING 30% RECYCLED MATERIAL </= COST OF VIRGIN MATERIAL + TAX2 Total Cost needs to include the cost of the recycled material taking account of any productivity gains or losses and any other associated cost premiums or savings. 2. Packaging Tax is currently £200 per tonne 1.

The following graph is based upon the above equation at a range of virgin material prices. In the case of limited supply of recycled material, recycled material with attract a premium above virgin material of +£200 per tonne up to the premiums provided by the graph. Clearly this a paradigm shift from the view that recycled materials should sell at a discount compared to virgin polymer.

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

Another important consideration is the situation in which other countries apply higher rates of tax and have a deficit of recycled material; subject to the following equation UK recyclers will make better profits by exporting recycled material. The graph explores the effect of the level of tax on the potential price premium that export markets can afford, and where that premium exceeds the return on UK sales, there will be an incentive to export.

EXPORT PRICE – (ADDITIONAL LOGISTICS COST + APPLICABLE TAXES + OTHER COSTS) > UK PRICE

SUMMARY

In the event that demand for recycled material exceeds supply (this is already evident, and a situation that is likely to persist) the price of recycled materials relative to virgin materials could increase significantly, which would mean that HM Treasury is correct in its assertion that the tax in and of itself is an incentive to increase recycling rates. Higher packaging tax rates in other countries may lead to a ‘recycled material drain’, depriving UK plastic converters both economically and of recycled content. Where recycled content is not suitable for applications, converters will simply pay the tax and pass the premium down through the supply chain. The packaging tax will almost certainly cause an incremental cost increase for plastics packaging, irrespective of reaching a 30% recycled threshold, or not. If recycled costs approach virgin polymer costs + packaging tax, there will be less incentive to use recycled content. Historical perceptions of recycled polymer pricing will be challenged.

In the event that demand for recycled material exceeds supply (this is already evident, and a situation that is likely to persist), the price of recycled materials relative to virgin materials could increase significantly.

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is Sw s e ad M

Let Tool-Temp Take Control The Tool-Temp TT-118K is the perfect temperature control unit for rollers, plates, double walled vessels, and other large consumers requiring a very high cooling capacity. Featuring both a standard and plate heat exchanger, this electronically controlled unit offers high precision regulation to meet all manner of specifications. Features include: - Self-optimising temperature control from 25°C to 90°C - Switchable heating capacity between 18kW and 45kW - Corrosion resistant and limescale free - In-built safety devices including level control and maximum temperature limit’s

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FEATURE

PORTUGUESE MOULD MAKING –

WHY IT’S GROWING SO QUICKLY

T THE PORTUGUESE MOULD MAKING INDUSTRY HAS BEEN EXPANDING AND HAS SECURED A MARKET POSITION AT NUMBER EIGHT IN THE WORLD IN RECENT YEARS. INDEED, PORTUGAL HAS EMERGED AMONG THE WORLD’S LEADING MANUFACTURERS OF MOULDS, PARTICULARLY FOR PLASTIC INJECTION MOULDING.

he Portuguese Engineering & Tooling Cluster has a long experience (over 60 years) in the international market, integrating a large value chain to support global clients from more than 80 countries. The UK ranks 6th place in exports in 2020, representing a traditional strategic market for Portuguese industries to support global product development, based on innovation, technology, and co-operation, through design, advanced engineering, prototyping, tooling, and injection parts and components. Portugal continues to be a global reference in the plastics and mould making industries, taking advantage of its engineering and tooling cluster, and exporting to advanced markets. According to Cefamol – the Portuguese Association of Moulds Industry Report 2021, the top ten countries for mould exports are: Spain (19%), Germany (17%), France (15%), Czech Republic (7%), Poland (4%) and United Kingdom (3%), Italy (3%), Romania (3%), Mexico (3%) and USA (3%). Since 2010, under the brand “Engineering & Tooling from Portugal”, the Portuguese Engineering and Tooling Cluster has massively increased its production. The tooling sector includes more than 500 companies and generates over 11,000 jobs. In 2020, the Portuguese tooling industry exported approximately €566m in technology, scoring the third position in terms of plastic injection mould production at the European level, with sales made to 84 different countries. During the pandemic, Portuguese Engineering and Tooling Cluster companies reinforced their capacity by developing a strategy action based on innovation and people qualification, which has resulted in new solutions in design and product development. The cluster also invested in manufacturing - €50m

was spent on research, involving more than 100 companies and 50 research and technology organisations. Despite the recent challenges, Portugal seems to be a resilient cluster for plastic mould making, remaining agile despite adverse conditions. For historical reasons, the automotive industry is still an important market for the cluster, representing 71% of its business, but Portuguese companies are also investing in other strategic areas, such as: packaging (10%), medical devices (4%), and houseware electronics (4%), among others. Pool-Net is the Portuguese Tooling & Plastics Network that represents the cluster and manages the common brand “Engineering & Tooling from Portugal”. Its 96 members are described by PoolNet as “ambassadors for the know-how, innovation and technology, quality and reliability, networking, competitiveness and social responsibility, intrinsic characteristics of the cluster”. The Portuguese Engineering & Tooling Industries continue to be an attractive source of capacity and technology for plastics manufacturers looking to invest in cutting edge mould making and tooling services. This article was developed within the activities of the project CIP_2022 nº46526, which is cofinanced by the FEDER under PORTUGAL 2020 and Notice nº 01/SIAC/2019.

Despite recent challenges, Portugal seems to be a resilient cluster for plastic mould making, remaining agile despite adverse conditions.

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the big story

HIGH STANDARDS

HOW INJECTION MOULDING AND PUR BEING COMBINED FOR HIGH-END AUTO

IN today’s world, standardisation plays a major role for successfully operating a company in most industries. This also applies for the hot runner sector where substantial time and savings potentials are possible through standardisation. The FH hot runner mould from Meusburger is the perfect example. It consists of a complete mould base including a hot runner system.

SURFACE FINISHING IS INTERIORS

A HOT RUNNER MOULD IN JUST A FEW CLICKS Thanks to the specially developed configurator, it can be customised with just a few clicks, ordered as a complete package and is supplied shortly thereafter in the usual high quality. Of course the 3D data is also available for download. The configurator allows the designer to concentrate on other matters during the mould design and thus saves valuable time and costs. Our hot runner experts will gladly carry out a technical inspection of the FH hot runner mould, all the designer needs to do is submit a form. The designer then receives suitable modification suggestions or, upon request, a customised offer. FH CONFIGURATOR UPGRADE Along with the new products in the area of mould making in spring 2022, Meusburger also launched some new functions for the FH configurator. A new type of manifold was added to the tried and trusted standardised hot runner system. Now the manifold type ‘H’ with four nozzles can also be selected and configured in the hot runner configurator. The rheologically balanced system ensures optimal results and the gating position can be individually selected via the parameters L1 + L2. Likewise, the insulating caps can also be selected for all gate assemblies. In autumn 2021 both the nozzle range and the selection of plastics were considerably expanded. Since then, shot weights from 0.5 to 500 g per nozzle are possible. The most suitable nozzle is already preselected, but all nozzles within the range of the specified shot weight can be selected. An additional helpful function is the recommendation of the suitable gate types for the respective plastic material. By default, the ideal solution is already preselected here. Of course the customer can also choose another type. If the combination of plastic and the gate assembly results in a recommendation for an insulating cap, then this can be ordered directly. In addition, the offset of the cooling hole to the manifold cutout can be adjusted in the x and y axis with the same value from 0 to 25 mm. The result is a compact mould size that is optimally matched to the configured hot runner

system. There are optimised default values for every manifold type and manifold size. The safety distances from the cutout to the outer edge have been optimised. The new features enable Meusburger to support the customer even better in the selection of suitable items. More information and our configurator can be found here: www. meusburger.com/fh-hot-runner-mould-update FOUR VARIATIONS With the standardised hot runner moulds, you have the choice between four different manifold series:

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SUCCESSFUL USE IN PRACTICE The FH hot runner mould from Meusburger has already been making waves with its high quality and reliability for a variety of projects. One example of this is the customer Sterk Plast SRL. They used the FH hot runner mould for a project in which different sized lunch boxes were produced. Sterk Plast was able to use the supplied hot runner mould without having to make any adjustment and is very satisfied with this product from Meusburger. You can find more examples of satisfied reference customers on the Meusburger website: www.meusburger.com/fhreferences LONG-TERM COST REDUCTIONS THROUGH THE USE OF A HOT RUNNER SYSTEM The question of whether to use a hot runner or cold runner often arises. Meusburger has developed a decision-making aid that shows that a hot runner system pays off in the long run.

The question of whether to use a hot runner or cold runner often arises. Meusburger has developed a decision-making aid that shows that a hot runner system pays off in the long run Resources are always precious – so is plastic granulate. With the use of a cold runner system there are inevitably high costs due to the unusable sprue. It is precisely these costs that must be avoided for more efficient production. Using a hot runner system saves on the cost of the unusable material. You can use the new sprue cost calculator from Meusburger to calculate how much material costs could be saved in the injection moulding process. You can find the sprue cost calculator here: www.meusburger.com/sprue-cost-calculator OTHER ADVANTAGES OF A HOT RUNNER SYSTEM Given the current scarcity of raw materials and the price increase in plastic granulate, economic efficiency is even more important. By using a hot runner system, decisive application advantages can be achieved that have a positive impact on productivity. Although hot runners are often associated with higher procurement costs, there are many other technical and financial aspects that make them preferable to cold runners.

TECHNICAL PERSPECTIVE: • Shorter cycle times, as sprues usually have to cool down for longer • Reduced loss of pressure • Improved reprint effect • Positive impact on shrinkage and warping • Injection from the inside possible • Potential to use stack moulds FINANCIAL CONSIDERATIONS: • Sprue spiders do not have to be sorted • No storage of sprue spiders required • No regranulation required • Less space required for the same production volume FREE KNOW-HOW The Meusburger experts have dealt extensively with hot runner moulds and have written a white paper on the topic. Here, the various possibilities for designing a hot runner system are explained in detail and the differences between a ‘hot runner mould’ and a ‘hot half’ are shown. Components, application possibilities and their limitations are also displayed. The white paper is available for download on the website: www.meusburger.com/ hot-runner-moulds

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+44 (0)1933 235910 | www.jenco.co.uk

Manufacturing without mistakes: start saving today with ColorSave 1000U Making use of innovative design and the latest technology, the ColorSave 1000 Gravimetric Feeder is a highly advanced precision dosing system that can save your business significant time and money. New features of the of ColorSave 1000U Dosing units are just another part of Jenco’s offering along with the range of vacuum products

• Changeable between injection moulding, process extrusion

or blow moulding

• Uses double hopper technology

• Venturi Emptying System • Liad-View - All in one screen to see working status of feeders

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.

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FEATURE

he introduction of industrial robot technology as a production tool revolutionised many manufacturing processes by improving productivity, consistency, and quality, in addition to relieving human operators of some of the most repetitive, difficult, and even dangerous tasks. As the benefits of robotics became widely accepted, users strived to take advantage of the flexibility that robots offered by seeking to configure robotic cells to handle multiple products and perform several different operations. The limiting factor in many cases was the need to manually change end effectors to accomplish these different tasks. The time taken, however, to reconfigure the robot for the new task often resulted in lengthy periods of downtime for the robot. As a result, many robots remained dedicated to their single original application. The advent of the automatic tool changer opened up new possibilities and provided robots with a significant increase in flexibility. Also, the time taken to change end effectors was reduced from the many minutes needed for a manual tool change to just seconds, allowing the robot to maximise productive time. Although fully functional, early robot tool-changers were somewhat basic, with limited connectivity capability for services, in many cases, just pneumatics and signal power. These first-generation systems proved the concept, even if the areas where they could be beneficial were limited.

AUTOMATIC TOOL CHANGERS HAVE COME A LONG WAY

A look at the introduction to automatic tool changers – from their inception, through to the latest technology – they’ve come further than you might think.

Fast forward to today, and just as industrial robots have evolved significantly, along with the introduction of collaborative robots, tool-changers themselves have now reached far higher levels of sophistication. Whether it’s for a high payload robot in the automotive sector changing spot welding guns, or smaller robot systems performing multiple handling or assembly operations, today’s tool-changing technology now makes it possible to achieve the original aim of maximising the flexibility offered by the robot. One firm working on new developments in this field is Stäubli. The company’s MPS robotic tool changers, reportedly increase the productivity for robots in all payload categories from all major manufacturers. Compared to the limited functionality of early day tool-changers, Stäubli’s latest generation systems offer numerous different modules for the transmission of pneumatics, vacuum, signals, data transmission up to 10Gbit/S, shielding, earthing, RFID tool coding and data storage. The ability to combine these different technologies and modules makes it possible to configure a solution for a wide range of applications. The location of the transmission modules is also highly flexible, allowing users to position them as required to suit the individual robot’s cable package. The robot-mounted component of the MPS Tool Changer incorporates all the services required to provide functionality for the various tools which may be used by the robot in production. On the tool change element, the only transmission modules required are those relating to the operation of specific tools. This makes it possible to use multiple, individually configured tool elements with one robot mounted element. Cross-shaped guide surfaces combined with a spring-loaded ball locking system are used to achieve interconnection between the robot and tool sides of the MPS tool changer system. This makes it possible to maintain precision throughout its product lifecycle. The tools always return to their original insertion position with a repeat accuracy of +/-1.5 µm. Stäubli tool changing systems are available for robot payloads up to 1530kg and attach directly to the ISO standard flange of every robot produced worldwide, without the need for an adapter. This drilling pattern is also the same on the tool side for ease of installation. Stäubli’s range of Tool Changer technology comes in three options. MPS COMPLETE offers preconfigured robotic tool changers for immediate use. MPS MODULAR allows the user to determine the configuration, while MPS CUSTOMIZED allows the construction of special, applicationspecific systems.

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People. Think. Plastics.

POKETONE™ The all-rounder We supply the original polyketone (PK) from Hyosung Chemical for injection moulding. This combines the positive properties of many engineering plastics and, thanks to its approvals for drinking water and food contact, offers you an alternative for a wide range of application segments. We are looking forward to supporting your polyketone project needs – including technical services and tailor-made logistics concepts. K.D. Feddersen UK Ltd. Member of the Feddersen Group www.peoplethinkplastics.com

Your contact: Roberta Leech Ian Nott

roberta.leech@kdfeddersen.com ian.nott@kdfeddersen.com

Our partner:

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DEVELOPMENT

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FEATURE

FOUR STEPS

TO EFFECTIVE PART HANDLING Given the diverse nature of plastic components, handling the finished or semi-finished parts requires gripping solutions which can be tailored specifically to the individual component and the material from which it is produced. Automation firm Schmalz explains why it has developed technology that specifically addresses the challenges of the plastics sector. Specially developed high-temperature-resistant materials allow handling directly from the mould tool, leaving few marks even when workpieces are still hot, whilst a range of extremely compact vacuum generators provide maximum dynamics and process reliability.

BELOW: High-temperature-resistant materials allow handling directly from the mould tool BOTTOM: Flat SGPN suction cups operate at a very low volume and are suited to sensitive components

HEAT RESISTANCE

At the end of the moulding cycle, plastic parts are often still very hot when they are removed from the injection moulding machine. This means that it’s not possible to use conventional suction cups. Schmalz suction cups are manufactured from a specially developed HT1 high-temperature-resistant material which is heat-resistant up to 170°C.

NO MARKS

Suction cups can also often leave invisible marks on surfaces during handling, which then prevent coatings from adhering properly to the part during subsequent operations. The special suction cup materials used by Schmalz allow workpieces to be coated completely, even after handling.

DELICATE HANDLING

The diversity of components manufactured from plastic mean that in certain cases the components will be delicate, as is the case with thin-walled workpieces. These items require particularly gentle handling to avoid any potential for distortion. Schmalz flat SGPN suction cups operate at a very low volume and incorporate a supporting surface on the bottom to prevent marking and distortion on the workpiece.

ACCESS TO THE MOULD

With limited access a characteristic feature of de-moulding operations, it is often the case that conventional vacuum generators are too large to be mounted directly on the gripper. In these instances, the extended hose length required usually results in increased compressed air consumption. In order to avoid these losses, Schmalz inline ejectors can be integrated directly into the hose line and used in confined spaces.

With limited access a characteristic feature of de-moulding operations, it is often the case that conventional vacuum generators are too large to be mounted directly on the gripper.

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The safety of the planet. It’s in our hands and our products. As a key material of our modern world, plastic increasingly faces questions about environmental friendliness. PMB understands the need to offer customers better plastic recyclability and more sustainable solutions. These specifically designed materials, now include water soluble, bio based & bio degradable alternatives to conventional plastics. To discuss your requirements please contact any of our experts.

Performance Masterbatches Telephone: +44 (0)1495 310583 Email: customer.service@pmb.co.uk

www.pmb.co.uk

Plastic Sector Solutions From The Vacuum Technology Experts • • • •

Wide range of products tailored to the plastic sector High temperature resistant materials Compact in-line vacuum generators Solutions for thin-walled workpieces

WWW.SCHMALz.CoM T: +44(0)161 266 1115 Schmalz UK Limited - 3000 Aviator Way - Manchester Business Park - Manchester - M22 5TG | schmalz@schmalz.co.uk

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pioneering plastics

FEATURE

IN MARCH, AI DEVELOPMENT SME RECYCLEYE HOSTED A WEBINAR FEATURING TECHNICAL SALES MANAGER PALOMA ALDEGUER, WHO PRESENTED AN INDEPTH OVERVIEW ON HOW AI AND ROBOTICS CAN BE USED IN THE SORTING AND RECYCLING INDUSTRY.

EYE ON AI

How AI could resolve longstanding detection issues for recyclers

ecycleye is a growing technology company using advanced machine learning, computer vision, and robotics to commodify waste. It was founded in 2019 by graduates of Imperial College London, has an exclusive agreement with robotics manufacturer FANUC, and backing from Microsoft, and has received funding from the European Union and the UK Government. The company is currently focused on municipal household waste, working with clients in the UK, France, Italy, Germany and Australia. Aldeguer began her address by introducing automation in waste sorting and explaining automated quality control. Key to this is a vision system powered by deep learning algorithms which focus on image recognition based on material type, as well as by shape and lustre. The vision system then powers the robotic unit which performs the separation of waste materials, including residuals, paper, HDPE and aluminium. Equipping robots with features such as a six-axis mechanism and optimising the algorithms ensure this technology can support the sorting process, according to Aldeguer Aldeguer said: “Manual pickers naturally get tired over an eight-hour shift. With our vision systems monitoring this data, we were able to see that purity slowly decreases over time.” The use of robotics resolved this challenge through consistency and highly reliable performances. “In other words,” Aldeguer added, “there are no toilet breaks or holidays … 24/7 operations also result in 110 per cent more throughput, which means waste treatment more than doubles. If we think big and scale this up, we could absolutely double recycling rates.” Recycleye has been working with Total, Valorplast and Citeo in an attempt to identify food-grade PP with 97 per cent purity, which represents a clear example of where AI comes into its own. Equipping players to align purities with ever-changing legislation is crucial for robotic technology. As a case in point, Aldeguer referenced the

sampling scheme in the UK, which originally required 0.05% of the waste to be sampled. That’s 60kg out of 120 (metric) tonnes of waste. The new EPR scheme, however, has been published and the sampling requirement is now 60kg out of 75 tonnes. Introducing technology like Recycleye’s vision systems could enable 100 per cent traceability on the stream, surpassing the necessary requirements by far. Further discussions with WRAP resulted in the key benefits of ramping up the capacity of sampling frequency without the need to find more space to store bales or find more manpower capacity, as well as the ability to achieve high accuracy on proportions and quantities. This could provide more visibility and enable producers to pay a fair amount for the materials. All of this needs to be supported with high detection accuracies, without which there is no business model. Aldeguer sees AI as complementary to technologies such as NIR as it is also able to detect black items, and base that detection on much more than material type alone. For example, the ability to sort PET trays from PET bottles, which conventional machinery is not capable of, and the capacity to sort aluminium cans from aluminium aerosols. These are beginning to gather interest from materials recovery facilities (MRFs), according to Aldeguer. Elaborating further on plastics sorting, Aldeguer highlighted the flexibility that this technology has. In many MRFs, lines are split in half. What the robot does involves cross-matching and separating HDPE jazz streams, as well as removing residuals from both sides: “The outcomes were absolutely smashing,” Aldeguer said. “We surpassed the expectations by achieving 99 per cent purity in HDPE. These outcomes absolutely justified the need for artificial intelligence in waste.” Aldeguer reconfirmed that AI should remain complementary to other technologies such as optical sorters as Recycleye aims to push boundaries in purity, efficiency and granularity.

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The new HASCO clean break multicoupling system allows the connection of cooling circuits in a single step. Set-up procedures can be carried out quickly and easily without the risk of mixing up the cooling circuits and hoses. The modular structure allows individual configurations as well as integration into existing systems. Central connection of cooling lines Easy and reliable locking Rapid set-up times 6, 12 and 20-point systems available No risk of confusion Can be equipped individually

Multicoupling

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system

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FEATURE

Weathering the

I Innova Solutions, a UK supplier of high strength bonding tapes, photoluminescent materials and structural adhesives, turns 20 this year. Managing director Glenn Dunleavey explains how the firm weathered storms including a recession, Brexit uncertainty, and a global pandemic – and now intends to become a £10m turnover business in the next five years.

storm

hen we first started Innova in 2002, we could not have foreseen the true scale of the challenges ahead. We are well used to ‘bumps in the road’ but have also encountered immoveable objects that required careful navigation. In meeting these challenges, we created springboards for growth, through market penetration and diversification. By taking tough but brave decisions through these challenging times, we created new market opportunities and developed an excellent team through considered investment. As a result, from humble beginnings, with just three of us, sharing a small warehouse and offices with my brother’s company, we now employ a talented team of 22 people, operating from three sites comprising more than 25,000 sq. ft. During the first five years, we focused solely on the signage and graphic market, developing products specifically tailored to their needs. It was important to start with a clear proposition and focus to ensure we could deliver improved production efficiency, finished product aesthetics, and longevity. For this we were rewarded with customer loyalty and patronage that continues today. The past 20 years has seen a steady decline in UK GDP growth. In business, we have always taken everything in our stride, and looking back on 2008, when we encountered the worst global recession in living memory, it was our flexibility and quick reactions that not only saved us but propelled us forward in a way that we didn’t think possible. We reduced our workforce by 20% and diversified into new markets to counteract the drop in order value and frequency that we were seeing in our existing customer base. For three years, we flatlined – in hindsight, a remarkable achievement – but as we emerged from the recession in 2011, growth from our existing and new markets was a beneficial double-whammy, delivering year-on-year growth to double the size of the business in the next three years. On the back of this, we invested £100k in SAP, a business platform that would help take us to the next level, in 2015. It was challenging, but our team immersed themselves in the implementation and we quickly achieved a clear return. The UK’s decision to leave the European Union in the Brexit referendum of June 2016 heralded the start of another turbulent time for our currency. By this time, Innova Solutions was dealing in

both dollars and euros on a major scale, leading to severe pressure on our import/export trading margins. Six years on, we are still contending with the red-tape, hurdles and additional expenses incurred in trading overseas. The biggest game changer came in 2020: global pandemic; a one-in-a-hundred year event; for most, a moment for consolidation, not investment. We were fortunate to have reputable customer base, and whilst we did not lose clients, the volume and frequency of orders dropped significantly. We had already made inroads into the plastic extrusion market and we knew that to penetrate this volumeusing sector in a significant way, we had to invest in our own conversion machinery. At the height of the pandemic, we took the decision to invest over £250k in a new slitter and rewinder, a 12-head spooling machine, and a 10,000 sq. ft. premises in which to house it. This was a calculated risk, but one we were able to take quickly. Once again, fortune favoured the brave and we are already at full capacity on the equipment with plans to invest further to satisfy demand. The best investment we have made is in building the excellent team we have around us. We have continually injected youth into the business, to maintain energy and proactivity levels, and introduced a production-skilled workforce into the operation – a leftfield move for us but built through word-of-mouth referrals from trusted employees. Now in 2022, its seems like just yesterday we were starting this business. But when we break it down over the many game-changing events that we have encountered, the time frame is pronounced. I am resolute that our success has been managed professionally but it is our ability to make quick decisions and take calculated risks, with the flexibility of the whole business to react, that has seen us overcome challenges and turn them into opportunities for growth. We are forever grateful to our loyal customers and supportive supply partners. We have established long-term, trusted partnerships and a reputation for reliability and being a safe pair of hands, earned through successfully navigating choppy waters for the past 20 years. Looking ahead, we hope to build even more partnerships and help support our customers through the inevitable challenges that we will overcome in the next 20.

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COMMENT

Pandemic accelerates automation plans in INJECTION MOULDING

T THE PANDEMIC HAS AMPLIFIED THE FOCUS ON PRODUCTIVITY AND FORCED INJECTION MOULDING DECISION MAKERS TO RECONSIDER HOW AUTOMATION AND DIGITALISED TECHNOLOGIES CAN FACILITATE WORKING SMARTER. NIGEL FLOWERS, MANAGING DIRECTOR, SUMITOMO (SHI) DEMAG WRITES.

ather than a complete pivot, automation was already quite commonplace prior to the pandemic; especially among moulders producing components for the medical, healthcare, aerospace, automotive, electronics and packaging sectors. Scalable, flexible units are in greatest demand. It’s why the Group launched the SAM (Sumitomo. Automation. Machine) robot series at Fakuma last year. With travel restrictions lifted, the 2022 K Show will be the first unveiling to the international audience. The two ‘handle & place’ SAM-C robots launched to-date are designed specifically for injection moulding machines with clamping force sizes between 50 and 500 tons, and for standard applications with cycle times of 10 seconds and higher. So primarily for the transfer of parts, and insertion of loads, applying labels etc. Automation like this can help customers to address the acute staffing shortages. Although labour was a challenge before the pandemic, filling certain jobs is becoming ever more challenging. Jobs being vacated by the baby boomers (which accounts for over 25% of the workforce in some territories) are not attracting the Millennials and Gen Zs, which is another pressure on top of escalating material prices and supply chain issues. Robotics can help make customer applications run faster and more cost-effectively. With take-out times of 0.5 seconds or less, it can sometimes be quicker and more productive to use a robot to remove parts than to let them fall under gravity. Notably, remote machine monitoring was the hallmark of the pandemic. The ability to take live data from moulding machines and use this to

Although labour was a challenge before the pandemic, filling certain jobs is becoming ever more challenging. Jobs being vacated by the baby boomers (which accounts for over 25% of the workforce in some territories) are not attracting the Millennials and Gen Zs.

inform operational decisions and make process improvements has induced greater trust and a change in mindset about remote access tools. Interest in monitoring critical components in machinery is also accelerating. The company recently unveiled a series of permanent conditional monitoring systems. These can be used to determine the wear and tear on injection moulding machines, thus enabling earlier detection and allowing for the preplanning of maintenance costs with a greater degree of accuracy. Currently, the company is focusing efforts on real time detection of abrasion and wear to the screw, the plasticising cylinder and the ball screws on allelectric injection moulding machines. The ultimate goal is full monitoring of all critical components prone to wear. As businesses begin the recovery process, Sumitomo (SHI) Demag is anticipating another leap forward in automation investments and digitalisation. By utilising automation, moulders can minimise their footprint, yet increase their machine estate. Enabling them to boost production capacity, repeatable precision, component quality and efficiency and consequently reduce defects and waste. The company anticipates rolling out additional robot kinematics and adapted options as early as K 2022, and further expanding the SAM platform within this short timeframe.

www.interplasinsights.com

WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

FEATURE

THE MATERIAL

W WITTMANN BATTENFELD UK HAS RECENTLY SUPPLIED TWO WITTMANN GRAVIMAX G34 POLYMER BLENDERS AT STAFFORDSHIREBASED POLYMER SOLUTIONS PROVIDER LINECROSS COMPOSITES.

wo Gravimax Real Time Live Scale (RTLS) polymer blenders have been commissioned by Linecross Composites to help deliver a special project using a mix of highly sensitive polymers, wherein extreme accuracy in weighing, dosing and blending is required before moulding. The Wittmann G34 machines have passed thus proven their reliability to the Cannock-based business. As part of a new tooling programme for one of its automotive customers, Linecross identified a requirement for additive blending equipment with a clear focus on accuracy and flexibility. Linecross then made the decision to purchase the two Gravimax units based on the performance of the equipment and the proven track record of Wittmann Battenfeld over a five-year long relationship as preferred ancillary partner. Wittmann Battenfeld UK has in fact been working alongside Linecross for approximately seven years, supplying a variety of polymer drying and materials delivery equipment. At the Linecross site, a Wittmann DryMax series, Wittmann Feedmax Hopper Loaders and Wittmann Tempro Mould Temperature Controllers have been established for the duration of this time.

Wittmann’s RTLS technology deploys two weighing cells which are continuously active throughout the entire weighing cycle in real time – thus giving the customer micro-based precision and ensuring high quality parts. Wittmann Battenfeld UK’s Joint Managing Director Daniel Williams said: “We are delighted that Wittmann’s materials handling expertise has become so entrusted by Linecross so as to ensure the success of this important and complex project.” Materials handling expertise is often considered as secondary in importance when it comes to converting and manufacturing plastics products, yet each plastics converter knows that knowledge of this key sector can mean the difference between high-quality products and waste, and between cost-efficiency and profligacy, as Williams added: “Our doors are always open to discuss needs and projects in relation to effective and cost-saving use of polymer material – in drying, conveying, blending or in mould temperature control.” Wittmann Gravimax G34 polymer blender

The Linecross Group is comprised of two manufacturing facilities – Linecross Rutland and Linecross Composite, Cannock. The Linecross Group can deploy a mix of plastics processes for its international clients, including vacuum and thermoforming, compression moulding, injection moulding, polyurethane composite work and complex assembly and sequence supply. Both sites employ 260 skilled professionals who deliver solutions for the company’s international client base. Wittmann’s Gravimax blenders come in a variety of configurations and sizes that deliver output from laboratory scale to thousands of kilos per hour. The Gravimax can meter and mix up to eight ingredients in a single batch, and include precision metering valves, interchangeable steel hoppers and an easy to use controller.

Our doors are always open to discuss needs and projects in relation to effective and cost-saving use of polymer material – in drying, conveying, blending or in mould temperature control.

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opinion

C CHARTERED MARKETER LOUISE APLIN CONSIDERS HOW THE RECENTLY IMPLEMENTED PLASTIC PACKAGING TAX IMPACTS PACKAGING MANUFACTURERS AND SHARES THE PERSPECTIVES OF TWO OF HER INDUSTRY SPECIALIST CLIENTS ON REFORMULATING PACKAGING TO INCLUDE RECYCLED CONTENT.

ack in late 2018, then Chancellor of the Exchequer Philip Hammond announced the introduction of the UK Plastic Packaging Tax (PPT). At that stage 2022 seemed quite a way off. Fast forward three years and despite a global pandemic and subsequent trade and supply chain uncertainties, many packaging manufacturers have adapted their products to incorporate at least 30% recycled content to avoid incurring the tax. Reformulating packaging products to incorporate recycled content has been a new experience for many and for some it was a steep learning curve. Prior to the PPT, using recycled content was an ambition for many businesses working towards more sustainable manufacturing but this was often considered technically challenging. This challenge has become more difficult to achieve as it has now been clarified by HMRC that companies are not able to include industrial waste. Recently updated HMRC guidance states that pre-consumer plastic ‘does not include scrap or regrind which can be reused in the process from which it was generated after only minimal reprocessing’. The Guidance goes on to say ‘where waste material is recovered and requires reprocessing involving melting and extrusion into pellets at a reprocessing facility before it can be reused, it can be treated by manufacturers as recycled plastic for any process.’

“Although initially perceived as just another tax, the PPT has accelerated many companies’ desire to embrace the Circular Economy.” comments David Harris, Chief Executive at Chase Plastics, a UK manufacturer of post use recycled polythene pellets. “Prior to the tax, those considering the use of recycled polythene pellets would often start the conversation with ‘What have you got?’ or ‘What’s your price?’. Now, the conversation has moved towards ‘I want to achieve X – what is the best way to achieve it?” He continues: “Customers are now more aware that choosing the wrong recycled content can have a hidden cost in terms of manufacturing efficiency and productivity. They understand that choosing an unsuitable raw material can cost a lot more to process and negatively affect the quality and performance of their products. They are also more aware of the importance to the Circular Economy of buying locally from a recycler with EUCertPlast accreditation.”

As of April 2022 however, including 30% recycled content is key to remaining competitive through avoiding the £200 per tonne tax. Two organisations operating within the sphere of manufacturing sustainable plastic packaging are Chase Plastics and Greenacre Consulting.

In general, high quality recyclates have fewer impurities and purer recyclates both run better throughout the manufacturing process and perform better within the finished product. Manufacturers need to be aware of the consequences of poor quality recyclates and their impact on finished product integrity.

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EUCertPlast accreditation recognises the highest standards of material traceability, quality and process control in plastics recycling. The scheme focuses on traceability of plastic materials (both throughout the entire recycling process and the supply chain) and on the quality of recycled content in the end-product. Being aware of the types of recycled content available and understanding how they impact both product and processes are aspects of sustainable manufacturing that were not always top of mind prior to the PPT. Efforts to manufacture packaging more sustainably generally focused on minimising production waste, reducing energy consumption or making the product go further through initiatives such as downgauging (weight reduction) – and rightly so. However, the advent of the PPT means that the sustainable manufacture of plastic packaging has stepped up a gear through the modification of the product itself to incorporate at least 30% recycled content. As technical adviser on the design of sustainable plastic packaging, Greenacre Consulting helps companies solve complex packaging problems and reduce the environmental impact of plastics. “Understanding plastic recyclates is critical to a successful outcome” remarks Gary Buchalter, Managing Director at Greenacre Consulting. “In general, high quality recyclates have fewer impurities and purer recyclates both run better throughout the manufacturing process and perform better within the finished product. Manufacturers need to be aware of the consequences of poor quality recyclates and their impact on finished product integrity. As with virgin materials, parameters such as material composition, tensile strength, density and melt flow rate all have to be considered during product reformulation. A further challenge is the significant potential for product variability both within a batch and from batch to batch. Equally important is examining the interactions of machine set-up and processing with the chosen recyclate.” He continues: “While it is not just a straightforward material swap, once you have successfully reformulated your packaging product, it is rewarding to see the valuable resource that is recycled plastic being reused purposefully rather than going to waste.” The PPT was designed as a financial incentive for manufacturers to use recycled content and while the additional taxes are unwelcome, the packaging industry should embrace the challenges it presents in order to remain successful and ensure society yields the benefits of more recycling and less waste.

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

INDUSTRY | NEWS Six finalists announced for Design Innovation in Plastics 2022 The panel of industry judges for the 2022 Design Innovation in Plastics (DIP) competition, has praised the quality of entries they received in the light of ongoing challenges university students have faced in the past year. The six DIP finalists just announced following preliminary judging delivered “a number of innovative products” for the healthcare sector according to chairman of judges, Richard Brown. Design Innovation in Plastics, supported by the Institute of Materials, Minerals and Mining, the Worshipful Company of Horners, and headline industry sponsor, Covestro, is the longest running plastics design competition of its kind for university undergraduates in the UK and Ireland. 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.

Brown said: “The fact these entries were produced during another abnormal year for the students is quite encouraging, and once again showcases the talent there is within the design faculties of the UK/Ireland universities. “The judges were impressed with the interpretation of the brief, and felt the overall quality was high.” In a lengthy day of deliberation, which produced “a good debate” amongst the judges as to how the students had interpreted the brief, a final six was selected as follows:

Get It Made offers grants for female-led engineering enterprises In preparation for International Women in Engineering Day (23 June), London-based manufacturing specialist Get It Made has announced a new grant to encourage the growth of female employment within UK engineering, design and manufacturing industries. The initiative is tailored exclusively to female-led, engineering, design and manufacturing enterprises, with the grant recipient set to receive up to £10,000. In addition to financial support, Get It Made will also be offering its expertise to help guide

DANIELE DI PAOLO, LONDON SOUTH BANK UNIVERSITY, with CIRRUS, a training aid to improve breathing CHARLIE GOULD-HOCKING, BANGOR UNIVERSITY, with CRUTCH, an adjustable shower or bath stand for amputees ZARA KING, TEESIDE UNIVERSITY, with EASYMODE, a reusable bed pan DIMITRI MCGRATH KARVELIS, LONDON SOUTH BANK UNIVERSITY, with ANAP, a double capacity inhaler KENNETH THORNTON, EDINBURGH NAPIER UNIVERSITY, with CATHETER BAG HOLD, a reusable portable catheter bag DANIEL WARREN, LONDON SOUTH BANK UNIVERSITY, with CURA +, a burns kit for first responders

young female-led businesses through the challenges facing any young company in a post-covid environment. Founder Luke Smoothy said: “We are delighted to be able to offer our support to the continued efforts of increasing female representation within UK engineering. We have seen encouraging signs that female employment within manufacturing has grown over the last ten years, however, we believe that there is still much work to be done for women within manufacturing to acquire the opportunities they deserve. We are hopeful that this grant will enable us to remove barriers standing in the way of female-founded enterprises within UK manufacturing, now and in the future.”

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The finalists will be asked to present their products to the judges in London on May 27, with the final award ceremony, announcing the results, to take place on July 1. Students are in with a chance of winning a top prize of £1,000, plus supporting cash prizes for their universities, and work placements for each finalist, with leading design and industry sponsors, who include Brightworks, Innovate Design, PDD and RJG Technologies.

Project Manager Aiza Sadirbayeva added: “From my personal experience, the more women you see within the industry, the more I hope it encourages and inspires other women to take the lead and not be intimidated. Entering a maledominated industry has not taken away from my own femininity, but has actually made me braver and stronger.” The grant is available to female-founded or female-led engineering enterprises with fewer than ten employees. Applications for this grant close at midnight on 31 July 2022, and can be submitted through the Get It Made website.

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

UK contract moulder now processing a range of bioplastics Despite some reservation in the industry, BEC says it has found bioplastic mouldings to require little machine adjustment from typical thermoplastics and to produce a very similar end product. The BEC range includes bioplastics made from raw materials of renewable sources that are compostable (meaning the material converts entirely to nontoxic material such as CO2) either in an at home composting environment or through industrial compostability in line with the EN 13432 standard. A spokesperson for the company told InterplasInsights.com that the new materials are all in part, or fully plantbased. The spokesperson also confirmed that there are three materials available in the range, one of which is industrially compostable to an EN 13432 standard, another which decomposes entirely to C02 in 12 weeks with a wall thickness of 0.5mm, and a third material which is also home compostable. The company is in the process of testing the home compostable materials to determine accurate timelines for compostability and wall thicknesses, they added. Material selection dependent, the range

can be used for both single use and multiple use applications. Typical applications include enclosures, golfing tees, containers, carrying straps. The range is also appropriate for food contact such as cups and cutlery. Bioplastics are plastics made from at least some renewable source with varying degrees of compostability. They can be derived from sources such as sugarcane, soybeans, and straw amongst many others. Currently accounting for around 2% of the plastic produced globally each year, the bioplastics market is predicted to grow by 11% in the next eight years. Paul Holland, BEC’s Head of Design and Innovation said: “Bioplastic formulations and their compostability have improved enormously over the last few years. BEC are therefore delighted to be able to provide our customers with plastic alternatives that are better for the environment whilst maintaining many of the necessary properties of the plastics typically used. We’re always happy to discuss new specific applications and projects for bioplastics, so feel free to get in touch.”

COMMENT

The word from Hird

R 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.

uring April, I attended one of the regular ‘Service Managers’ Group meetings, which the PMMDA set up in 2016 to assist our members with the dayto-day technical issues that they face, and to keep up to date with current Health & Safety legislation. Just as importantly, it’s a great opportunity for those working with plastics machinery to get together and compare notes, share information and take guidance. So far we’ve produced useful documents and generic forms to assist with risk assessments, method statements and safe working in general as well as providing regular updates on safety standards. We’ve also been able to organise HSE led courses on machinery safety and will do this again in the future. Of course, one of the hot topics has been the post-Brexit transition to UKCA markings for machinery coming in from January 2023. Although our members must choose how to comply, the association

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is there to offer general guidance by arranging courses and pointing them in the right direction. So far it hasn’t been easy to get to grips with the changes and there remain a few uncertainties – watch this space… Another hot topic around Health & Safety that has recently been highlighted through the SIMPLC strategy is Mental Health within the workplace, especially as we come out of the pandemic and with ‘Mental Health Awareness week’ taking place in May. Having discussed this topic with a number of members and customers alike, it is clear to see that there are some very good initiatives being developed by forward thinking companies who recognise the benefit Mental Health Awareness has on the wellbeing and productivity of their workforce. By supporting the development of mental health awareness amongst our members, we are aiming to ensure that the plastics industry is leading the field. 37

26-28 SEPTEMBER 2023

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

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

MACHINERY | NEWS ART Ltd discusses the ART of bespoke machinery At the heart of Automation and Robotic Technology Ltd (ART) is an innovative approach to special purpose machine building and automation to improve quality and speed of response. This philosophy has resulted in highly successful projects for their customers. Founded on over 50 years of combined experience, ART has created an innovative approach to bespoke automation. Maintaining only a few active projects on the books at any one-time, ART is able to provide greater technical and project focus. Here, Directors and Co-Owners Richard Matthews and Richard Pryle explain how this has resulted in an improved customer experience. ‘We are the main points of contact at all times. Being directly involved in all company and project processes, ART’s lean management structure enables speed of response, which is always a key factor in time-critical projects. Decisions can be made and acted upon immediately to address any requirements …

Pentagon anticipates that the ZERES will provide estimated annual savings of 47,352kWh in energy consumption and upwards of £6,000 per annum against older presses of similar size. Therefore, customers can have absolute confidence that their project will be delivered with exceptional quality and attention to detail. ‘Our business model is simple but highly effective. Having provided a detailed and comprehensive quotation to establish all the project requirements, we then secure resource from a large pool of trusted, highly experienced and successful independent sub-contract companies. Confident that this labour resource meets our exacting requirements allows us to build the team around the specific demands of each project. Therefore, from a technical and industry sector standpoint we always have the appropriate level of resource and expertise available to us.’ From its new-build 3,200sqft industrial unit in Peterborough, ART has completed several large projects for leading UK and

European manufacturers within the pharma sector, who have returned to ART for further automation and robotic systems. Typical projects undertaken include a combination of technologies such as robot systems, machine vision, servo operated mechanisms, controls systems and safety guarding. One such machine required a fourteen camera 100% vision inspection of medical pipettes at the rate of 600 parts per minute, including removal and replacement of out-oftolerance components. With the everincreasing skills shortage in the UK, together with the existing business pressures that are part of system integration, ART’s low overhead and stable business model plays a key role in the longevity of the company’s flexible approach to bespoke machine design and manufacture.

Pentagon makes another pressing investment Pentagon Plastics has invested £35,000 in a ZERES (Hybrid) 40 tonne injection moulding machine. Purchased in early April 2022 from longterm supply partner Premier Moulding Machinery, the new addition will see Pentagon increase its electric and hybrid machine range. The press size complements the lower clamp forces in Pentagon’s range and will be widely utilised for medical components, as well as supporting other industry sectors for technical moulding production. Selection parameters have included energy efficiency and Pentagon anticipates that the ZERES will provide estimated annual savings of 47,352kWh in energy consumption

and upwards of £6,000 per annum against older presses of similar size. To accommodate the new press, the company has revised the layout of its manufacturing facility in Horsham, West Sussex, where the production offices have been relocated to a neighbouring building to provide additional workspace. This represents the next stage of expansion for Pentagon as the company aims to make maximum use of its existing floorspace whilst increasing productivity and looking towards is 50th anniversary in business. Pentagon has also recently invested in three new conveyors from TH Plastics, and two new water heaters (model TT181) from Tool Temp to improve mould tool temperature control.

One such machine required a fourteen camera 100% vision inspection of medical pipettes at the rate of 600 parts per minute, including removal and replacement of out-of-tolerance components.

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MATERIALS | NEWS Engineered for possibility 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, 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,

Interface Polymers and Flexipol win UKRI Smart Sustainable Plastic Packaging grant

Interface Polymers and Flexipol have jointly won funding through a competition run by UKRI’s Smart Sustainable Plastic Packaging challenge. The £850,000 grant is to finance the ‘Recycle

Ready’ multi-layer barrier plastic packaging films, to provide fully recyclable LDPE multilayer packaging, suitable for upcycling into high value applications. This project brings together Interface Polymers’ patented Polarfin additive technology that overcomes inherent molecular level noncompatibility between polyolefins to enable them to be recycled, and Flexipol’s film

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”.

technology expertise and flexible packaging manufacturing capabilities. The project is looking to address socioeconomic pressure for more sustainable product alternatives. The new Recycle Ready range will enable packaging manufacturers to offer technically superior multi-layer barrier packaging products that will meet RIC “4” and “5” classifications. The project’s key aim is to offer the packaging industry fully scalable alternative LDPE multi-

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 [...] and the materials for these will likely be in powder form.

layer barrier films for the commercial production of food approved multilayer flexible packaging that can be repeatedly recycled using existing pure plastic waste streams sorting and separation processing plants. The Recycle Ready project is initially targeting multi-layer polyethylene and polyamide food packaging vacuum bags and thermoplastic films, a submarket sector worth £95m per annum, with the overall UK multi-layer barrier plastic packaging market

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annually estimated to be in excess of £750m. In addition to the film qualification and production scale-up of the Ready Recycle multi-layer packaging products, Flexipol will be working with established bulk food processors to ensure that the entire value chain is included in the project. The longer-term objective is to leverage solutions coming out of this project into other multi-layer barrier film packaging sectors using alternative polymers, such as PP, PET, EVOH and PA.

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packaging speaks green conference highlights

greenplast, milan

A summary of highlights from the Packaging Speaks Green Conference held during Greenplast, Milan (3-6 May 2022) MANILO DI STEFANO, Undersecretary for Foreign Affairs (via video) Di Stefano affirmed Europe’s global leadership in the fight against climate change. Italy is ready to innovate and provide solutions. ROBERTO LUONGO, General Director, Italian Trade Agency “We are in the house of innovation”. We cannot talk about innovation if we are not in a circular economy. DARIO PREVIERO, AMAPLAST President Greenplast brings a focus on sustainable plastics and circular economy where exhibitors bring environmentally friendly solutions. RICHARD COPE, Mintel Sustainability Barometer Says consumers have been sold a lie about going ‘plastic-free’ through biodegradable plastic bags, for example, because it’s easier to discuss. Consumers don’t have to engage with the ‘plastic-free narrative’ because retailers don’t want to have these kinds of conversations. Cope said companies should just “stop bullshitting consumers with greenwashing”. NERIDA KELTON, VP Sustainability and Safe Food, World Packaging Organization (WPO) Sustainability and circular design is an opportunity to rethink packaging. The balance should be between sustainable packaging targets and

ABOVE: Former Plastics Recycling Ambassador Gian de Belder consumer expectations. Looking for a ‘sweet spot’ in minimal materials and environmental friendliness. Anything underpacked will produce food waste, anything overpacked is a waste of materials. Mentioned the positivity of the work of the HolyGrail 2.0 programme, the Perfect Sorting Consortium, Recyclass and CEFLEX. FRANCESCA STEVENS, MD Europen Highlighted the importance of the EU single market in the circular economy. There will be big regulations coming in from the EU in order to ensure companies cannot greenwash their products or processes.

brought him to invite the audience to question whether products are really circular. DR RUDOLF KOOPMANS, Plastic Innovation Competence Center Industry experts need to think about how we organise and rethink energy use and materials to create a healthy society to live in. Co-operation and communication are key. The latter on a level that enables people to understand the science behind circularity.

Koopmans expressed frustration by affirming that sustainability is not a new topic as he had been discussing it for 40 years. Credit is due to Koopmans and his longstanding passion for sustainability because here he was, still speaking, still engaging and still thinking about ecodesign. The simple answers are useless and the correct answers are difficult but will lead the industry to the right destination. ALESSIA GAETANI, Project Manager CEN and CENELEC Touched upon the ubiquity of plastics to illustrate the responsibility of technical committees involved in bodies such as CEN and CENELEC. It is inevitable, Gaetani said, that standardisation will focus on packaging plastics and on how European standards will fit into a circular economy.

GIAN DE BELDER, P&G The former Plastics Recycling Ambassador and brains behind HolyGrail 2.0 reminded his audience that no single European country is collecting enough plastics for recycling, and that Holy Grail technology should be able to help improve this. The brand-owner aims to reduce petroleumbased plastics in its products by 50 per cent, and digital watermarks will provide the information on these products to sorting technology without affecting the brand image. Holy Grail 2.0 tests will be going live in Denmark this year, with industrial testing in Copenhagen already showing good results with 99 per cent detection rates and 95 per cent ejection rates, resulting in a purity of 96 per cent.

The simple answers are useless and the correct answers are difficult but will lead the industry to the right destination. - Dr Rudolf Koopmans

FABRIZIO DI GREGORIO, Plastics Recyclers Europe and Recyclass Brands are not currently designed for recycling but for functionality. “Quality means being good enough to make virgin plastics obsolete." Circularity is abused by industry and greenwashing is still rife in the market, which www.interplasinsights.com

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TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

SCREWS & BARRELS

www.magog.co.uk Cavity pressure measurement systems and sensors for control of the injection moulding process and automatic hot-runner balancing, provides zero-defect production with 100% quality control. T: F: E: W:

01256 741550 01256 741551 sales.uk@kistler.com www.kistler.com

Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries. • Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks Contact us to find out how we can help you Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.co.uk

PRINTERS OF INJECTION MOULDED PRODUCTS & COMPONENT PARTS Looking To Outsource Your Branding? – We Can Help. Specialist Sub-contract Pad, Screen, Digital and Laser Engraving Services. Premier Impressions Ltd Units 10-11, E.Plan Estate, New Road, Newhaven, East Sussex, BN9 0EX T: 01273 512512 E: sales@premierimpressions.co.uk W: www.premierimpressions.co.uk COMPONENT PRINTERS TAMPO.SCREEN.FOIL Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 44

www.interplasinsights.com

BP&R BUYER’S GUIDE MACHINERY & EQUIPMENT DRYERS

FILTRATION

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

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

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

Tel: 01366 383398 E: goldcrestengtech@gmail.com

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519 Exhibiting at Interplas on stand DD10 Hall 3A

www.goldcrestengtech.co.uk

new & used

second hand & re-conditioned

BUSINESS FOR SALE

Buying, Selling, Merging? Whatever your business needs, Richmond Capital Partners are the industry experts with a proven track record of guiding acquirers or sellers through the process of buying, selling and merging. Contact Paul Holohan in complete confidence on 07798 530684

Ultrasonic Plastic Welders

Business for Sale Small Plastic Injection Moulding Business Supplying The Electrical Trade In North East Wales

Call for Details

richmondcapitalpartners.com

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

07767290539

New & Used

Refurbished machines with fault and leak free guarantee.

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

For Sale & Wanted Branson-Mecasonic-Telsonic

We buy & sell all manner of plasscs equipment.

Sonotrodes (Horns) all Frequencies Fixtures, Repairs, Service, Parts Sub-Contract Welding, Hire & Consultancy

Visit our workshop in Wellingborough, Northants.

Tel; 07730 413197 Tel; 01258 459257

01933 272747

als.ultrasonics@gmail.com www.als-ultrasonics.co.uk

sales@stvmachinery.co.uk www.stvmachinery.co.uk

SERVICES TESTING/CONSULTANCY MONITORING

SOFTWARE

Improve OEE Reduce downtime Increase throughput Reduce scrap

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

60 Day Free Trial www.intouchmonitoring.com

BP&R SOFTWARE GUIDE MONITORING INTOUCH TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

T: 01604 537100 E: enquiries@ intouchmonitoring.com www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 www.interplasinsights.com

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from the director

P PHILIP LAW, DIRECTORGENERAL OF THE BPF, TELLS BP&R ABOUT THE FEDERATION’S LATEST ACTIVITIES, INCLUDING ITS PLANS TO ENLIGHTEN GOVERNMENT ON THE MASS BALANCE APPROACH FOR INCORPORATING PLASTIC RECYCLATE.

t’s been a week of ‘Annual Assemblies’. The BPF’s own Council and AGM combined on 18th May, which resulted in the re-election of the BPF’s President, Karen Drinkwater, for a further year in office, and it also elected Nigel Flowers, managing director of Sumitomo (SHI) Demag as Vice-President. Nigel has 35 years’ experience in the industry and has served as the President of the Plastics Machinery Manufacturers and Distributors Association.Karen is looking forward to a busy second year in office which will include a visit to the BPF’s stand at the K Fair in October, in her official capacity. At EuPC’s Annual Assembly held in Brussels on 20th May there was a ‘changing of the guard’ as Benoit Hennaut of the French Herige Group succeeded Renato Zelcher of Crocco as President. Renato’s 4 years Presidency was particularly demanding as it was during this period that the European Commission fully developed it’s plastics agenda. Benoit has been Chairman of the Building Division of the French plastics Association, Polyvia. At the BPF’s AGM I described our programme forwards into 2023. This has three major thrusts. One is enhancing the competitiveness of the UK plastics industry in the post-Brexit world of global competition and uncertain markets, building on the successes of the BPF’s Productivity Committee. The second is to drive changes in the industry by specific initiatives which further improve the industry’s sustainability credentials, Operation Clean Sweep, the BPF’s pellet loss mitigation programme, being a leading example. The third is

the communication of the industry’s sustainability achievements through the BPF’s powerful web presence and social media activity. The launch of the BPF’s new logo will assist our approach. It is clean and fresh with a colour scheme in blue, green and yellow, redolent of a pristine environment. A significant development during the month was the visit made by Environment Minister, Jo Churchill, to the BPF for discussions on plastics recycling. Defra Ministers are especially difficult to pin down and we felt the discussion was very positive and she offered to host a roundtable on Chemical Recycling to enable greater understanding in government of its potential to deal with ‘hard to recycle’ waste. I am sure that she found her visit highly informative and that she came away with a picture of a constructive and imaginative sector striving to meet society’s expectations of a highly innovative and contemporary industry dedicated to achieving a circular economy. We have plans to consolidate this progress with the government and wider Parliament further. We are having an exhibition stand in the House of Commons on May 24th and a breakfast meeting with a group of MPs and Lords on June 22nd to explain mass balance methods as a means of verification for chemical recyclate in plastics packaging. Our Annual Parliamentary Reception will be on November 23rd. We are also hoping to arrange a regional event bringing local MPs into contact with plastics firms in their area, a model we used successfully preCovid with Teesside MPs.

I am sure that she found her visit highly informative and that she came away with a picture of a constructive and imaginative sector striving to meet society’s expectations.

www.interplasinsights.com

YIZUMI D1 SERIES

Yizumi D1 Model Range from 500T – 2400T

EFFICIENT, COMPACT, HIGHLY ACCURATE D1 Yizumi’s D1 series is a compact, two platen machine with high quality components: • Energy efficient • European servo drives • Austrian KEBA controller with touchscreen interface • Small footprint compared to three platen designs • Dedicated in-house UK service team

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...and at STV, we’re engineers who speak your language. Call us for a chat on 01933 27 27 47 or find out more at www.stvmachinery.co.uk

MORE THAN MACHINE ENGINEERING. WE ALSO PROVIDE DIGITAL SOLUTIONS TO MAXIMIZE YOUR PRODUCTION EFFICIENCY. With our complete digital solutions for increasing efficiency, monitoring production, and controlling processes, we are paving the way for you to the future of plastics and rubber processing. Find out more now: kraussmaffei.com/digitalization

BP&R May/June 2022

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