BP&R May/Jun 2024

Get connected –with solutions from ENGEL

By using iQ clamp control, we were able to reduce the clamping forces of the machine by 33%

Dirk Krines, Manager Factory e-Chain Systems at Igus, Germany

In series production, clamping forces are often chosen based on the machine operator’s experience with the product. However, selecting excessively high forces can damage the mould and waste energy. iQ clamp control determines the optimum clamping force fully automatically and thus ensures safety with minimum energy consumption. The result – stable and e cient series production. Interested? Get connected with our experts.

Contact our Regional Sales Managers: sales.uk@engel.at

www.engelglobal.com/iq-clamp-control

Robin Hornsby Northern Region Automotive

Darren Herron Central Region Packaging

Chris Sta ord South-West & Ireland Region Medical

COMMENT

British Plastics and Rubber

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ISSN 0307-6164

Incorporating Polymer Age and Rubber and Plastics Age.

MOULDING THE MINDS OF THE FUTURE

Nothing brings people together like the spirit of music and sunshine (though in Britain, dry weather might be bit of a gamble!)

The pandemic certainly pushed us all behind a screen filled with virtual events, but they never quite beat the energy of seeing innovation in action and catching up face-to-face.

Plastribution offers a refreshing break from the formality of corporate events. Our cover story in this issue delves into the company’s vision for the Festival of Polymer Innovation – a chance to bring people from all backgrounds of the plastics sector together. The upcoming festival will host a ‘Mainstage’ for industry leaders as well as up-andcoming talent – reflecting a strong sense of industry collaboration regardless of experience.

In the words of Plastribution Group's Phil Little: “It’s amazing to see that industry gatherings have made such a strong resurgence in the post-pandemic years, particularly as I remember murmurings at the time that virtual events and conferences would become the new norm. Happily, I think it’s clear to see we’re all still human and there’s a desire for real-world social interaction!”. Check out this story on pages 16 and 17.

Meanwhile, the plastics manufacturing and engineering industry has experienced a noticeable decline in interest from younger generations. Our conversation with Glyn Olden from Chess Plastics looks at the increasing issue of attracting young talent in the plastics moulding scene, despite the success of apprenticeship programs. You can have a read of this interview on page 34.

Though on a more positive note, PMMDA’s chairman Dave Raine discusses the power of sponsorship for talented, academic individuals. On page 36, Dave’s column reflects how a student design competition win launched the career of a successful CEO.

“Engagement is one thing, but the industry should be providing young minds with the confidence, support and direction they need to adapt to its ever-evolving landscape.”

“Apprenticeships are a theme I continue to champion as a solid and sensible method of replenishing the talent pool in the plastics industry, and anyone who comes into contact with them should consider themselves a mentor and role model […],” Raine explained. You can find his column on page 36.

All in all, this move from traditional conferences to a more dynamic setting is certainly an intriguing one. Fostering collaboration in a fresh format may not only reignite the passion for innovation but also create a space for mentorship –spreading veteran knowledge among the curious.

But this journey is just one piece of the puzzle. Engagement is one thing, but the industry should be providing young minds with the confidence, support and direction they need to adapt to its everevolving landscape if they want to mould the minds of the future.

REBEKAH JORDAN

EDITOR

Next Generation of Servo-hydraulic Injection Moulding Machines

Smart Machine Technology As Standard

MOULD TOOLS

Summit Protech’s latest innovation stems from a joint venture in the UK plastics industry: a comprehensive range of Automation Robots designed to elevate efficiency, precision and productivity across various moulding applications.

Summit Protech stems from the combined expertise of Summit Systems, providers of plastics ancillary equipment, and Protech Automation, specialists in servicing, maintaining, and supplying automation equipment for the plastics and packaging sector.

Summit Systems will source the robots from Well-Lih, a reputable manufacturer, and Protech Automation will then oversee the installation process, ensuring a smooth integration into existing facilities. This dynamic collaboration aims to offer unmatched quality and efficiency for UK injection moulders and various other plastic manufacturing processes.

The new range of Automation Robots offers advanced features for optimal performance, such as highspeed operation, precise positioning capabilities and adaptable payload capacities, ensuring optimal performance across a diverse array of moulding applications.

Key features of Summit Protech's Automation Robots include:

Automation Robots from Summit Protech set to boost operational efficiency

• Enhanced efficiency: High-speed operation and precision positioning streamline moulding processes, boosting production efficiency.

• Improved precision: Automation robots ensure precise component placement, leading to consistent moulded parts and enhanced product quality.

• Versatility: Designed for a range of tasks - from part removal to quality inspection - these robots adapt to various moulding applications.

• Easy integration: With user-friendly interfaces and intuitive programming, they seamlessly integrate into existing production lines, minimising setup time and downtime.

Left: Automation robots boast enhanced efficiency, improved precision, versatility and costeffectiveness.

• Reliability: Built with robust construction and reliable components, these robots offer long-term durability, reducing maintenance needs and ensuring continuous operation.

• Cost-effectiveness: By streamlining workflows and reducing errors, the robots provide a cost-effective solution with a quick return on investment and lower operating costs.

"Summit Protech represents a synergy of expertise and innovation," said Matt Ross, sales director at Summit Systems. "With our combined strengths, we are proud to offer a range of Automation Robots that not only meet but exceed the evolving needs of the plastic manufacturing industry."

Jim Ward, head of Protech Automation, added:

“By combining our expertise in seamless installation with Summit Systems' robust supply and sourcing capabilities, we're poised to revolutionise manufacturing operations across the industry.

"This joint venture signifies our commitment to delivering cutting-edge solutions that drive efficiency, precision, and competitiveness in the plastic manufacturing landscape.”

Automation robots are integral to modern manufacturing, offering unparalleled advantages such as improved cycle times, enhanced product quality, and reduced labour costs.

Furthermore, they can seamlessly integrate into existing production lines, ensuring minimal disruption while maximising efficiency.

“The new range of Automation Robots offers advanced features for optimal performance, such as precise positioning capabilities."

YOU AND

WORKING TOGETHER FOR BETTER MOULDING SOLUTIONS

“Buy a new Yizumi, or a second-hand machine? Our decision was easy.”

Ania Hill, Business Owner, K A Tooling

When K A Tooling decided to invest and diversify its business, brand new Yizumi machines proved a more viable option than buying second-hand.

Business owner Ania Hill, explained: “We wanted a machine for sampling new tooling prior to customer delivery. We originally spoke to STV Machinery about a second-hand machine, but when we compared initial machine costs and longer term running costs, a brand new Yizumi machine came out on top as the most cost-effective and energy efficient solution. We ended up buying not one, but two Yizumi machines together with ancillaries as a package. Their accuracy for optimising tooling is excellent and the after-service sales support from STV Machinery is outstanding.”

A new Yizumi machine could be YOUR most cost-effective solution. Give us a call today, to discuss your application or arrange a visit to our showroom and workshop.

AEROSPACE

Structural adhesives provide strong, loadbearing joints for industrial and engineering applications.

Important properties of a structural adhesive in an aerospace application are strength, toughness, and flexibility, alongside temperature and environmental resistance. When choosing an adhesive, methyl methacrylate structural adhesives (MMAs) may be a good candidate to test, as these adhesives offer strength, toughness, and ease of use when bonding a broad range of materials, including metals, plastics, and composites.

Often referred to as “loadbearing”, structural adhesives hold two substrates together and should bear the forces

BONDS IN THE

SKIES:

MMA structural adhesives in aerospace

Ben Swanson, chief commercial officer at adhesives specialist Intertronics, shares an overview of MMAs in aerospace manufacturing applications.

ABOVE: Ben Swanson, chief commercial officer, Intertronics.

BP&R's editorial advisory board

Richard Brown, Chair of Judges Design

Dr

involved for the product’s lifetime. The substrates may be metals, plastics, glass, rubbers, ceramics, or composites, and be under

constant or intermittent load or shocks.

Compared with alternative chemistries like epoxies and polyurethanes (PUs), the benefits and properties of MMAs as structural adhesives are perhaps less widely known. Because they bond to a wide range of substrates, and have choices of cure speed, MMAs are quite versatile. They are excellent for bonding metals (steel, stainless steel, aluminium), thermoset composites (both carbon fibre and glass fibre reinforced) and thermoplastics

“MMAs are favourable in applications where fast cure speed, strength, and environmental resistance are important."

Robin Kent Managing Director

Dr Carmen

(acrylics, ABS, polycarbonates, PVC, and other engineered plastics). They are favourable in applications where fast cure speed, strength, toughness and environmental resistance are important. Typical aerospace bonding applications for MMAs include repair and maintenance, sealing and gasketing and bonding interiors.

MMA fundamentals

MMAs are two-part reactive acrylic adhesives made up of a resin and an activator, but additives may include elastomeric tougheners and impact modifiers. Mixing at room temperature causes a free-radical reaction that enables fast curing. MMAs are typically available in two mix ratios, 1:1 and 10:1. To suit different process requirements, MMAs are available with a range of working times (5 minutes up to 120 minutes) and fixture times (6 minutes up to 4 hours).

Methyl methacrylate adhesives are readily and commonly available in twopart cartridges from 50 ml to 490 ml in size and can be supplied in bulk for largervolume applications. They are applied through static mixing nozzles, which comfortably give the adhesives an adequate mix.

Due to the fast exothermic reaction that forms them, MMAs fully cure and reach their full strength at room temperature. Compared to other adhesives, their cure is less susceptible to ambient conditions like temperature

Dr Michael Junior Hopkins Managing Director Ross Polymer Services

and humidity. Importantly, the time between mix/application and fixture strength (enough cured strength to allow further processing, sometimes called green strength or handling strength) is short. This offers key processing advantages by reducing work in progress and enabling faster throughput.

Typically, less surface preparation is required when using MMAs compared with other adhesives, as the chemistry can cut through some surface contamination.

A solvent wipe to remove any light oils on metals or composites, or a dry wipe on plastics, is often all that is required with an MMA, although some projects will require the use of a solvent wipe or abrasion. Some MMA products are available that bond metal without the need for a primer which creates a leaner process, removes the risk of error, and can improve health and safety.

Some disadvantages

Acrylic adhesive technology does have a stronger odour than other chemistries, although all SCIGRIP MMAs have GREENGUARD certification for low VOC and chemical emissions. MMAs have lower operating temperature ranges than, say, epoxy adhesives. In some cases, where there is larger adhesive mass or thicker bond lines, understanding of the exothermic heat produced during fast cure is required to avoid potential substrate discolouration or distortion.

MMAs in light aircraft and glider manufacturing

Pravin S Mistry Global CEO PREA Ltd.

One company using MMAs in the manufacture of highperformance motor gliders is Papiorek. Initially, the company used a myriad of chemical compounds to bond the pilot canopies to the structure of the glider, a time-consuming process. Technicians experienced issues with bubbling on the application and had to wait up to 12 hours for the materials to cure.

To overcome the process challenges, Papiorek trialled SCIGRIP’s SG42, a twocomponent, clear, reactive adhesive, and MMA SG5000, a fast-curing, primerless metal bonder. SG42 was used to bond Plexiglass substrates in the aircraft’s cockpit, resulting in a seamless bond line and clear joint that enabled perfect visibility through the pilot’s window. SG5000 was used to secure the Plexiglass canopy to the aircraft’s epoxy frame.

AEROSPACE

There were several benefits of working with these two MMAs: the range of working times enabled greater flexibility throughout the assembly process, and the rapid cure time helped Papiorek reduce production times, all while eradicating the bubbling problems their technicians had encountered with their previous system.

Conclusion

It is important to note that there is no perfect or universal adhesive, and the benefits and disadvantages of each chemistry should be weighed up against the demands of the application and processing environment. Overall, MMAs bring many process and technical advantages to applications in aerospace manufacturing and may be a good candidate to trial when reviewing structural adhesive chemistries.

Professor Edward Kosior CEO and Founder Nextek

Dr Thomas Bennett Research Fellow University of Manchester

Exhibit with us

Interplas will be back in 2026, 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, so ware, 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 o er solutions, showcase innovation and o er expertise to an audience known for its quality and purchasing power.

“Redesigning plastics, for good”

Bold new Benvic advances in sustainable manufacturing

Founded in 1963, Benvic is a global supplier of thermoplastic compounds. From concept to fulfilment, Benvic develops, manufactures and markets innovative and highly customised customer solutions that are used in a wide range of applications and markets. In late 2022, such innovation led the Benvic Group to be acquired by the International Chemical Investors Group (ICIG).

Luc Mertens noted that “our full integration within ICIG will be expressed in our new corporate identity.” This will:

• Underscore our commitment to the upcoming circular economy.

• Broaden our capabilities in PVC compounds.

As the summer gets underway, Europe’s independent polymer compounder Benvic, is thriving. In a recent message to all company stakeholders, Luc Mertens, Benvic Group CEO, announced a new company mission and a new corporate identity: "Our Benvic future begins with the rollout of our new corporate identity. What will such a future look like? We express it simply as: 'Redesigning plastics, for good.'"

• Develop new thermoplastic compounds as solutions for existing and upcoming customers.

economy with recycled and bio-based content.

in all major aspects,” Mertens added.

Today, Benvic operates as part of a larger ICIG grouping that covers a total of twentyeight businesses, served by 6,800 employees worldwide. Benvic currently runs a total of eight production sites in France, Italy, Spain, Poland, the UK and the USA and is fully committed to tailormade polymer solutions and advancing the circular

The latter activity is key for Benvic. “Our circular economy mission has released ICIG investment that will double our overall production capacity in PVC recycling, together with a significant expansion of our EREPLAST SAS subsidiary. In addition, this company will be renamed BENVIC RECYCLING SAS - strongly underscoring the importance of this technology for all our Benvic Group companies,” Mertens claimed.

“Benvic's core values and service will not change: We will retain and develop our commercial strengths - in particular, bespoke customer care and service. Our existing product portfolio will be sustained, especially for PVC compounds where we continue to lead the market >

“The ICIG synergies that are now available to us will also enable Benvic to deliver greater creativity, flexibility, and sustainability to the most important entity in our world – our customers.”

Doubling down on recycled content

Sustainable production solutions are indeed moving quickly ahead for everyone in today's polymer industry. Legal regulations, corporate carbon neutrality targets, and customer choices are triggering the market to quickly adopt manufacturing methods that save nonrenewable resources.

As a polymer compounder, Benvic is fully committed to the business of mechanical recycling. The company’s value-added skills and resources mean the supply of stable performance and availability from heterogeneous and nonrecurrent feedstocks.

Bio-based solutions

In some cases, however, the material limitations are significant enough to prevent the use of recyclate. What then? This situation provides the opportunity for the use of bio-based resins, such as Benvic’s Plantura range of compounds – tried and successfully tested for the most demanding of engineering applications.

April’s IOM3 PVC 2024 event in Edinburgh, Scotland also

saw the launch of Benvic’s ProVinyl Infinite range of materials. Specifically developed and tested in Benvic laboratories, Provinyl Infinite compounds now provide bio-based solutions for PVC-related uses and applications.

The immediate advantage of ProVinyl Infinite is that it offers a significant carbon balance drop to users without any major material change or re-qualification.

Thanks to proper certification reporting from Benvic's supply chain, the switch to bio-based resins can give Benvic customers a ready-made environmental solution at minimum cost, inclusive of the same performance, reliability and certification - without the need for additional testing or protocols. This is particularly attractive to the windows, doors and pressure fitting markets, for example.

And since the cost of ProVinyl Infinite compounds is significantly higher than conventional PVC compounds, their use is targeted at specific applications and towards multi-shot mouldings and layered extrusions. For example, ProVinyl Infinite grades can be used:

• As an exposed surface or skin in order to overcome the aesthetics of recycled materials issues (which can then be used as a core material). In this way, both bio-based and recycled solutions can be used in the same application to maximise the environmental impact.

• Where the extra cost can be compensated by the final benefits and the value-added improvement, particularly in

“Sustainable production solutions are indeed moving quickly ahead for everyone in today's polymer industry."

consumer products where environmental concerns are a key differentiator and income generator.

• In all these cases. Benvic materials engineering is needed to design the solution - based on ecodesign considerations and Benvic’s future support and development of these materials.

Provinyl Infinite compounds can directly replace corresponding petro-sourced grades or can also be used in conjunction with other fillers.

Benvic’s ‘mix and match’ commitment to both recyclate and biopolymers technologies means that the company is fast becoming the ‘go-to’ materials supplier for the emerging circular economy.

Engineering a sustainable strategy The whole sustainable strategy is also underpinned by Benvic’s 2024-6 action plan for Environmental, Social and Governance (ESG). The new plan builds upon Benvic’s existing ESG activities and achievements for the past four years.

Environmental success breeds further success. Last year – for the second year running - Benvic was awarded Gold-Level excellence by the international provider of sustainability ratings –Ecovadis.

This ranking continues to place the company among the top 2% in the industry for sustainable achievement and is key to the company's mission to partner with like-minded suppliers and customers and to manufacture for the emerging and growing circular economy.

Celebrating 30 Years of Toolmaking Excellence

Specialists in multi-cavity high production tooling with fast cycle times.

» Multi-award-winning toolmaking and customer service

» Multi-cavity high production tooling specialist

» Complex tooling solutions

» Design for Manufacture principles

» Continual investment in latest skills and technologies

» State-of-the-art 5-Axis, CMM, spark and wire erosion

» Full bespoke tool design service

» Rapid tool modification and repair service

» Measurement and inspection service

» Current SolidWorks/SolidCAM

» ISO9001: 2015 certification

“ Faulkner Moulds are a rare breed in this field. Excellent quality, on time, every time, no exceptions. I have nothing but praise for this professional toolmaker.”

Sales and Marketing Director, manufacturer in leisure and automotive industry

Award-winning oral medical device twin-shot tool.

Broadwater Mouldings Ltd achieves King’s Award for Enterprise

Suffolk-based manufacturing company Broadwater Mouldings Ltd is one of 252 organisations nationally to be recognised with a prestigious King’s Award for Enterprise. On 6 May, Broadwater was recognised for its excellence in international trade.

Founded in 1971, and based just outside the picturesque Suffolk town of Beccles, Broadwater is a design engineering and composites manufacturing company, specialising in supplying high-quality moulded Fibre Reinforced Plastics (FRP), fabricated and finishassembled FRP and vacuumformed components into the medical, industrial and automotive sectors.

Broadwater’s diverse 170-strong workforce encompasses skills ranging

from hand layup, press and spray laminating to engineering and technical design. Broadwater’s main market is Europe, where one of its key customers is based although its products are in daily use worldwide. Broadwater’s market position has changed from purely a parts supplier to a strategic design partner for its main customers and has significantly expanded its manufacturing capabilities and processes in recent years. Overseas sales have grown by 90% over the three-year application period and the proportion of sales exported has increased to 66% of total sales. The company has won the King’s Award for International Trade in overseas sales over the last three years.

Managing director, Matt Herbert, said: “This award recognises the achievements of the entire Broadwater team, some of whom have worked in and have been dedicated to developing the business over decades. We have worked extremely hard

Faulkner Moulds invests in delivering sub-micron surface accuracy

Faulkner Moulds, the multiaward-winning Yorkshirebased toolmaker, continually invests in a range of advanced technologies and techniques to ‘chase the micron’ and create the perfect surface finish. For example, pictured (right) is a triangular bottle cap core, with a high gloss surface finish, being measured using Faulkner Moulds’ Mitutoyo Coordinate Measuring Machine (CMM).

The CMM allows for highly accurate 3D and surface measurements at high speed. The advanced toolmaker can scan any 3D surface with it,

to sub-micron accuracy, to find the true shape of a part. The company has carried out several jobs in which there is an issue with an existing tool made by another toolmaker. The technology is used to measure the part against

the CAD model, looking for surface deviation.

Faulkner Moulds then uses its suite of sophisticated machinery to modify the tool accurately, including a high-speed vertical 5-axis graphite and hard metal machining centre, which enables automation of cavity machining, achieving a repeatable accuracy of 2 microns.

After correcting the tool, Faulkner Moulds then provides a detailed report of results for the customer, which compares measurements before and after the work, to confirm the integrity of the modification work.

In 2024, Faulkner Moulds celebrates 30 years of excellence in mould

to achieve the growth we have seen and this has inevitably presented challenges: every person working at both our manufacturing sites has risen to those challenges. I am extremely grateful to every one of our people and I am looking forward to continuing with them to build on our success. We are incredibly proud to be honoured with this award.”

The King’s Awards for Enterprise, previously known as The Queen’s Awards for Enterprise, was renamed in 2023 to reflect His Majesty The King’s desire to continue the legacy of HM Queen Elizabeth II by recognising outstanding UK businesses. Now in its 58th year, The Award programme is the most prestigious business award in the country, with successful companies able to display the esteemed King’s Awards Emblem for the next five years.

toolmaking. During that period, the toolmaker has established a reputation as an industry leader, specialising in toolmaking technology and techniques and winning UK ‘Toolmaker of the Year’ multiple times in recent years, as well as ‘Manufacturer of the Year’.

With a company motto of “Be Exemplary”, Faulkner Moulds’ expertise lie in multi-cavity, high-production tooling with fast cycle times, translating to increased efficiency and costeffectiveness for its clients. The company's skills also extend to complex tooling such as twin-shot, overmould and unscrewing mechanisms.

They also provide a rapid, reliable response to requirements for tool repairs, modifications or servicing.

The World’s Leading Injection Moulding Machine Manufacturers

Borche’s UK facility, based in the West Midlands offers a wide range of Servo Technology Machines up to 6800ton clamping force which bring substantial energy savings. We have stock machines available for immediate delivery and an experienced team of UK service engineers, with spare parts ready for prompt delivery.

Expert of Intelligent Two-Platen IMM

ON THE COVER

PLASTRIBUTIONBREAKING THE CORPORATE EVENTS MOULD

It’s official, festival season is now here and, despite our very British ability to remain chirpy through what felt like the drabbest of winters, it’s difficult to deny that there’s much more positivity in the air with a little sunshine.

With this in mind, we sat down with Phil Little, Plastribution Group’s newly appointed Technical & Business Development Manager, alongside other industry peers to discuss the vision for the Festival of Polymer Innovation (FOPI) - a groundbreaking festival-themed event that will bring people from the plastics sector together like no other.

From Glasto to Plasto: A new spin

Taking inspiration from the likes of Glastonbury Festival, FOPI aims to boldly side-step the more conventional style of corporate events in favour of something novel.

“It’s amazing to see that industry gatherings have made such a strong resurgence in the post-pandemic years, particularly as I remember murmurings at the time that virtual events and conferences would become the new norm. Happily, I think it’s clear to see we’re all still human and there’s a desire for real-world social interaction!” said Little.

“Our ambition with FOPI is to deliver something different that combines educational, networking and social aspects in equal measure. We are hosting an event with a broader appeal to showcase everything exciting that’s going on in polymers, regardless of what sector you operate in or your role.”

British festivals have always united people, regardless of generation or background. With FOPI, Plastribution aims to replicate some of that spirit, creating a welcoming atmosphere for people at all levels of business, fostering an environment where all feel inspired to ask questions, learn and share interesting thoughts and ideas.

Monomers of rock: A line-up for the ages

Plastribution took little time in onboarding industry allies, signing up the likes of the Ministry of Justice, Ducor Petrochemicals, Notpla, UBQ, Engel and Summit Systems to their ever-evolving line-up of exciting acts, all of whom will be present as part of a mini-exhibition.

Wayne Ball, sales director at ENGEL UK, said: "This event allows us to be involved in something really exciting, the chance to showcase our latest technology to people in a truly different way."

Similarly, Ewan Hyde, business development manager at Avalon Plastics, added: "We are really looking forward to seeing something different in the industry. It’s important to us to meet new people and share ideas."

Welcome to the ‘Mainstage’

In true festival fashion, the centre-piece of FOPI will be the event’s ‘Mainstage’a platform for industry influencers from manufacturing and material development to take the spotlight and share their company's latest technologies and innovations.

The mainstage will feature talks and demonstrations on the latest pioneering solutions in material handling, process cooling, and intelligent machinery systems. A range of Plastribution supply partners will also be on hand to share their latest innovations including edible materials, climate-positive solutions and highly technically demanding compounds for the most extreme of needs.

Presenters will be given 20-minute, fully compered slots, allowing for short and punchy solutions-focused presentations with no time for B-sides. In addition, the festival will feature entertainment throughout the day, including bands and musical talent from familiar faces across UK plastics.

A space to innovate Phil and the team explored many venue options for FOPI, ultimately leading to

what they believe to be something special at the Heart of England Conference Centre.

“The space is large, which affords us a lot of freedom to open the event to a large number of guests. With this in mind, we also encourage our show partners that exhibit to use this space creatively,” he added.

“The venue has plenty of parking and it’s only 10 minutes or so from Birmingham airport, alongside its associated train station and hotels. Accessibility is great too, so we hope to be able to attract a diverse crosssection of the industry.”

Setting a new standard for industry events

Plastribution's Festival of Polymer Innovation represents a significant leap forward in industry collaboration and innovation. By creating an environment that is both informative and inclusive, FOPI sets a new standard for how industry advancements are shared and celebrated. Just as ‘Glastonbury’ has become an iconic event in the music world, FOPI aims to become a landmark event in the polymer industry.

Phil summarised in his own words: “We can’t wait to welcome guests through the door at the Heart of England events centre on 4th September 2024. Although we can’t guarantee the sunshine, I have no doubt that our team can put together a fantastic celebration of UK polymers.”

To find out more and to secure your free ticket, visit www.polymerfestival.com

Tool-Temp ensures that your processing facilities are kept at the ideal temperature – o ering over 60 standard models and enough individual solutions to satisfy any special requirements you may have.

Main features of our new MATIC temperature control units

 Simple operation

 Modular Control that is easily expandable

 Preset actions and easily configurable recipes

 Anticipatory behavior & predictive maintenance

 Connectivity

 Energy e icient control

Please contact us on 01933-442633 or info@tool-temp.net to speak with a member of the Team.

Who are you and what do you do?

At Labfacility Limited, we are a UK-based manufacturer and supplier specialising in temperature sensors, thermocouple connectors, and associated temperature instrumentation. Since our establishment in 1971, we have built a reputation for excellence in temperature measurement and control. We serve a diverse range of industries, including aerospace, automotive, pharmaceuticals, and food processing. Our extensive product range and bespoke solutions are tailored to meet specific customer requirements, ensuring we provide high-quality products and services that cater to the varied needs of our customers.

What key benefits can customers expect when they partner with Labfacility?

When customers partner with Labfacility, they can expect several key benefits. We are dedicated to delivering highquality products that ensure accuracy and dependability in temperature measurement. Our tailored solutions meet unique customer specifications, guaranteeing optimal performance for specific applications. With an extensive product range that includes thermocouple/PRT temperature sensors, connectors, Thermocouple/PRT Cable

Who are you and what do you do?

IMM Projects is a plastic injection moulding maintenance and service micro business. Currently, the company operates as a husband-and-wife duo originally from South Africa: Michael brings the technical expertise whilst Chileen oversees the administrative and strategic aspects, keeping the business on track. For IMM Projects, creating a healthy worklife balance is a priority. We believe in a positive and supportive work environment, allowing us to focus on both family and our clients' needs. Our business provides an all-around service to the plastic injection moulding community by offering machine services and maintenance to a wide variety of machine brands, axillary equipment and robots.

What are the biggest challenges and opportunities IMM Projects faces in the current injection moulding machine parts and servicing industry?

Like many small businesses in this current climate, IMM Projects faces challenges in establishing itself within a competitive market. As a micro-business, tasks like updating our website, social media,

Labfacility Limited

MARTIN RIDDETT, managing director, Labfacility Limited

and instrumentation, we provide comprehensive solutions for all temperature measurement needs. With decades of industry experience, we bring profound technical knowledge and expertise to help customers overcome complex temperature measurement challenges. Our efficient manufacturing processes and quick turnaround times ensure that products are delivered promptly.

meet high standards, which helps build long-term trust with clients. Additionally, we value customer feedback and actively seek it to improve our products and services, demonstrating our commitment to continuous improvement and customer satisfaction.

What are Labfacility's long-term goals? Are there plans to expand the team or services offered?

How does Labfacility approach customer service, and how does it build trust with clients?

At Labfacility, we focus on our customers and work hard to earn their trust by providing great service. Our customers receive support from experienced professionals who understand their specific needs and challenges. We offer expert technical assistance to help customers select the right products and solutions for their applications, ensuring optimal performance and satisfaction. Stringent quality control measures ensure that all our products

IMM Projects

CHILEEN DE BEER, partner and administration manager, IMM Projects UK

and networking efforts can feel like you are being stretched in all sorts of ways especially as we navigated the lack of motivation after the pandemic. It can feel isolating at times, but recently, we found inspiration and encouragement through the six-week Small & Mighty Enterprise Programme for small businesses. This program has been a game-changer for us, providing us with new insights, support portals and tools, that have revitalised our approach to marketing and business growth. We now look forward to the Plastics Live 2024 exhibition!

Our long-term goals at Labfacility include continuous innovation and the development of new products and technologies to remain at the forefront of temperature measurement solutions. We are always looking to expand our presence in international markets, reach a broader customer base and explore new business opportunities. We are committed to implementing sustainable practices in our manufacturing and operations to reduce environmental impact and enhance corporate responsibility. By focusing on these goals, we aim to strengthen our position as a leader in the temperature measurement industry and continue providing exceptional value to our customers.

prioritise breakdown availability which offers our clients flexibility around production demands. To save our current clients time and money, we often reach out by phone before a site visit to see if any issues can be addressed remotely. Listening attentively to understand each client's specific needs allows us to deliver exceptional customer service, a cornerstone of our business philosophy.

What are IMM Projects' long-term goals?

Are there plans to expand the team or services offered?

How does IMM Projects approach customer service, and how does it build trust with clients?

Having been around for a few years now, we have cultivated many professional yet personal relationships with our customers. We offer a high level of expertise and

Looking towards the future, IMM Projects has ambitious goals for growth. Currently, we are working on a collaboration effort with Sierra 57 Consult to secure certified training programs within hydraulics, electro-mechanical maintenance & robots. Our goal is to address industry gaps and disseminate invaluable knowledge that comes from hands-on field experience. We believe that this initiative will not only enhance our capabilities but also contribute positively to the industry as a whole.

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EXPANDED POLYSTYRENE (EPS)

Many prevailing environmental opinions are based on common misconceptions, such as the belief that paper is always preferable, and plastics are inherently bad. Life Cycle Analysis (LCA) offers a way to correct and counter notions like these.

One of the key advantages of LCA is its ability to provide a side-by-side comparison of materials or products. LCAs measure the environmental impacts of a product throughout its entire “life,” including various stages such as manufacturing (materials and energy use), transportation, usage, and disposal, capturing how it interacts with the environment at each stage. Using this kind of analysis to evaluate materials covers a broad range of ecological consequences and relies entirely on data, removing the possibility of subjective interpretation.

Global uptake of LCA is one of sustainability’s great victories. While it doesn’t

Betsy Bowers, executive director at Global EPS Sustainability Alliance, explores how LCA can be used to compare the environmental impact of different materials throughout their life cycle, from manufacturing to disposal.

Sustainable material comparisons using LCA

often make headlines, LCA explicitly underpins many environmental policies and laws, including U.S. tax credit programs, Canada’s Clean Fuel Regulations, and a host of initiatives in the European Union, China, Japan, and elsewhere. And for an even wider range of public programs, LCAs have evolved from a suggestion to an option, and now, increasingly, a requirement.

When conducted in accordance with recognised standards, LCAs are one of the best available tools for ensuring that the actions

taken by companies, government, and society achieve meaningful results. To guide more sustainable choices, broader and more comprehensive adoption of Life Cycle protocols can replace opinion with facts.

LCAs & EPS transport packaging

Expanded Polystyrene (EPS), a material wrongly identified as an environmentally bad actor, offers a prime example of the important role LCA can play in this capacity.

EPS transport packaging is the gold standard for protecting

products that touch our daily lives: food, medicine, electronics, and much more. It is heavily relied upon to preserve product integrity across the global supply chain.

Despite these advantages, EPS faces misconceptions that can be dispelled through rigorous LCA studies. For example, contrary to public opinion, cardboard fish boxes may not offer environmental advantages over EPS. This is supported by numerous peerreviewed life cycle studies on fish box packaging systems. A 2024 life cycle study by SGS Intron reports the Product Environmental Footprint (PEF) for cardboard fish boxes is 1.55-2.91 times greater than EPS, and the environmental impact due to potential global warming from changes in land use is 38-75 times greater for paper-based fish boxes.

Another study concluded paper packaging faces sustainability challenges

EXPANDED POLYSTYRENE (EPS)

due to the increased use of coatings and other composites that allow it to meet the function of plastic packaging. These paper materials have lower recycling rates and can pose a disruption to existing waste management processes.

The study’s findings reveal an inconsistency in EU policy objectives. Plastic packaging reduction goals outlined in the Packaging Ordinance contradict the Green Deal's intention to reduce net greenhouse gas emissions by at least 55% by 2030. Replacing just one-tenth of plastic packaging with other packaging materials could increase the amount of packaging waste by 10-20%. There is a lack of understanding surrounding the complexities of packaging function, total environmental impacts, and end-of-life outcomes. Businesses that consider public opinion alongside LCA data will be able to develop more effective packaging that delivers true environmental benefits aligning with consumer expectations.

Using LCA for sustainable building material choices

Environmental Product Declarations (EPDs) are a method of comparing products by using LCA data, widely used in the built environment industry. EPDs are defined by common denominator

criteria covered under a Product Category Rule (PCR), which is a consensus-based standard outlined under ISO 14025, Environmental Labels and Declarations. EPDs must be conducted by a qualified service provider and undergo a rigorous peer review to ensure impartiality.

In the building and construction industry, EPDs are used by businesses to qualify products for environmental certification programs and to substantiate environmental performance claims. They are used by architects and specifiers to make material selections using novel sustainability reporting tools such as Carbon Footprint Calculators and Environmental Indicator Calculators.

For plastic building materials like EPS insulation, EPDs and LCAs are particularly valuable.

These tools help demonstrate the environmental benefits of EPS insulation, including its energy efficiency and recyclability. By providing detailed, product-specific environmental data, EPDs enable a more accurate comparison between building materials. Without the more detailed life cycle protocols delivered by Product Category Rules and Environmental Product Declarations, packaging LCA is often used in a generalised fashion by engineers and procurement officers, potentially overlooking the specific advantages of materials like EPS.

LCA trends

Life Cycle methodology and scope are continually evolving. Interdisciplinary collaboration among researchers, industry, and governments is shaping a

robust research landscape. Circular economy is leading to a diversification of end-of-life options not covered under today’s typical Life Cycle parameters. With specialised recovery processes on the rise, like chemical recycling, pyrolysis, and biodegradation pathways, additional data will be needed.

A call to use less plastic has garnered popular appeal in the drive to combat climate change and ocean pollution. But alternative products often have more severe environmental impacts that need to be quantified to avoid increased food waste, loss of product protection, or increased carbon emissions.

LCAs demonstrate that care must be taken when formulating policies or interventions to reduce plastic use. We must be mindful not to attempt to fix one problem by removing working solutions for others.

LCA will continue to play an essential role in driving innovation towards sustainable packaging solutions, influencing material choices, design decisions, and end-of-life strategies. It is an essential tool to help companies embrace environmental responsibility, make informed decisions, and create a world where businesses thrive while protecting the planet.

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Manual to zero-defect: The automation of composites manufacturing

Fibre-reinforced polymer composites are used in different sectors because of their light weight and excellent mechanical performance. However, many of the manufacturing processes for composite materials are manual and excessively labourintensive.

Automated composite manufacturing processes are essential to reduce costs and defects resulting from manual process variations. One of the enabling technologies for automation in many composite manufacturing processes is photopolymerisation, also known as UV curing, which is widely used in highproductivity sectors for polymer coatings, printing inks and adhesives.

Overcoming limitations with sustainable opportunities Photopolymerisation has several shortcomings that impede its widespread use in industrial processes. These include the need to use thermosetting resins, the lack of photoresins derived from renewable sources, the inability to work with opaque fibres, the impossibility of using inorganic fillers, and the low

Javier Vallejo, manufacturing processes, IDEKO, discusses the drawbacks of photopolymerisation and the zero-defect advances being made in the FOTOPOL project.

incidence of zerodefect manufacturing processes.

In this sense, having materials from sources other than oil is essential to boost the sustainability of composites, eliminating one of the major drawbacks: their dependence on polymers derived from crude oil. Additionally, the recyclable nature of composite structures enhances the fundamental end-of-life aspects and facilitates both repairability and recyclability.

This requires research into new sustainable processes based on new photocurable materials. Although current manufacturing processes based on photopolymerisation are versatile, R&D

work is required to integrate the new materials. Beyond incorporating bio-based materials that facilitate repair and recycling, achieving circularity and sustainability requires taking into account digitalised processes that minimise defects and rejects.

In addition, it is crucial to introduce innovative concepts for extending endof-life as well as for reusability. The advantages of photopolymerisation in repair processes can be combined with the recyclable features of the new materials to develop more energy, productivity and waste-efficient repair processes.

Furthermore, the ease of separation of the different components of the composite will allow access to simpler and more costeffective recycling processes, boosting the circularity of photocomposites.

FOTOPOL paves the way to zero-defect processes To overcome the challenges arising from the application of photopolymerisation in the production of composites, IDEKO is leading the Spanish FOTOPOL project, in the framework of the Elkartek programme of the Basque Government, to develop new zerodefect, efficient and sustainable processes for manufacturing,

repairing and recycling without limitations in the use of reinforcements.

The project will focus on optimising frontal photopolymerisation for composites with opaque fibres, investigating the influence of filler addition and adapting prepreg and additive manufacturing processes to the newly developed formulations.

Another challenge will be to transform traditional composite manufacturing processes into ZDM (Zero Defects Manufacturing) processes. In particular, the research will focus on the development of multi-physics models and robotic control strategies for UV-curable assisted pultrusion and monitoring methods, process and product inspection and physical models for the design of adaptive controls of prepreg manufacturing processes.

All the developments developed within the framework of FOTOPOL will be validated in a demonstration unit to test the complementarity of the new materials and production processes developed. The primary sectors of application will be automotive, rail, shipbuilding, energy and construction.

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@POLYMERMAN ON PRICES

On-purposemonomer production

BP&R’s resin pricing guru Mike Boswell (aka Polymerman) writes.

As a result of reduced cracking of Naphtha for ethylene, coupled with lower demand for petrol for passenger vehicles, European polypropylene producers may need to look for alternative feedstock sources.

The increased penetration of US polyethylene into the European market is reducing demand for polyethylene produced from the oil refining derivative Naphtha here in Europe. US polyethylene is produced from ethane, which is derived from Shale Gas where the economics are highly competitive and polyethylene granules can be readily exported. The process of cracking Naphtha primarily results in the production of ethylene, from which propylene and other feedstocks are by-products. The ratio of ethylene to propylene can only be adjusted within a narrow tolerance with ethylene remaining the majority. The FCC (Fluidised Catalytic Cracker) process of refining petrol for automotive fuel also results in the production of propylene, however, the increased penetration of EVs in Europe is quelling demand for petrol and

Who is ‘Polymerman’?

in turn restricting PP feedstock availability.

In order to address any imbalance in propylene availability, OnPurpose Production Technologies are available that only produce propylene feedstock. So far, the following technologies have been commercialised:

Propane dehydrogenation (PDH)

In the PDH process, propane gas is directly converted into propylene and hydrogen. This is a highly efficient process that enables a direct and cost-effective route to propylene.

Feedstock = Propane

Metathesis

Involves the rearrangement of ethylene and butenes to produce propylene.

Feedstock = Ethylene & Butenes derived from the Naphtha Cracking process.

PDH Process

Propane Propylene

Metathesis Process

Crude Oil Naphtha Propylene

The point of differentiation between these processes is feedstock. Providing that propane can be accessed easily and economically then the relatively lower cost of a PDH unit compared to a Naphtha Cracker and a Metathesis Plant will lead to lower costs. However, the Metathesis approach can effectively shift the output dynamics of the Naphtha Cracking process towards the relatively higher demand for propylene. It should also be noted that propylene is not the only co-product of Naphtha cracking and that the capability of these

other products to contribute to the Naphtha cracking process economics may be significant.

So far, not much is happening in Europe in terms of on-purpose propylene, apart from Grupo Azoty which is currently commissioning a PDH plant in Poland to supply a new PP plant. The limited investment in Metathesis plants suggests that the economics of this approach are currently less favourable. However, this approach is a good solution where a structural imbalance between ethylene and propylene exists.

The concern for European PP converters will be the continued access to the diversified range of PP grades produced here in Europe, which may become restricted if local PP capacity is shuttered and more reliance is placed upon imports. In particular higher flow and high impact strength PPCP for packaging and automotive applications may become more difficult to source.

From an economic perspective increased feedstock costs are likely to be passed through in terms of higher polymer costs and this is most likely to apply to the more specialist grades, where the impact of imports is likely to be more restricted.

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

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TESTING AND INSPECTION

Film inspection systems play an important role in plastics technology as they contribute to quality assurance and process optimisation. Camera inspection systems can detect surface defects such as scratches, cracks, gels or discolouration. The inspection systems can be used both on the end product and for quality control of materials. The data collected by inspection systems can be used to analyse and optimise production processes. On the one hand, this helps to identify the causes of errors and to continuously improve processes while maintaining a high level of quality. With over 30 years of experience in the field of line scan cameras, COLLIN Lab & Pilot Solutions uses both, area scan and line scan cameras for its film inspection systems.

Advantages of the GigE Vision Interface

COLLIN presented a new film inspection system with a line scan camera at NPE 2024. While camera systems with camera link interfaces were

Dr. Friedrich Kastner, CEO & managing partner, COLLIN Lab & Pilot Solutions GmbH, highlights how its new inspection system enhances quality control for variable film properties.

COLLIN optimises postprocessing with advanced film inspection system

previously used, the new system presented is a camera with a GigE Vision interface. The new interface protocol offers several advantages over the previously used protocol. For example, standard Ethernet networking hardware can be used instead of special frame grabber cards. These standardised network cards, routers and switches are much more readily available and also more cost-effective. The data transfer rate of up to 1 Gbps is available for many industrial applications and is therefore easier to integrate

into existing network infrastructures. Standardised IP protocols can be used with this technology. Additionally, the new standard also offers advantages in terms of scalability and expansion of the system to multiple camera solutions via simple networks. Meanwhile, the data transfer via CAT5e or CAT6 cables can be routed over long distances of up to 100 metres, whereas previously it was limited to approx. 10 metres. Any disadvantages in latency can be compensated for by optimised evaluation algorithms.

Powerful data analysis

The raw data read out by the camera is transferred in a standardised format. This standardised interface enables the data to be exchanged with a wide variety of applications, including web applications.

This makes the system very open and independent of the programming language of the HMI client. The data architecture also results in very simple scalability for applications with several cameras. The data from the line scan camera is combined to form an image and this image is linked together with various boxes of properties to form messages. The message boxes are transferred to the HMI and can be further processed there. These message boxes contain several property levels, which are superimposed on each other and contain all the information about the image and its properties. This makes it possible to analyse the data from the camera online or to store it in parallel as raw data memory. The raw data memory can be analysed again at any time.

The entire image analysis is divided into three sections:

• The first section concerns the camera and light settings, such as aperture, exposure time, etc. Understandably, these values cannot be changed retrospectively and determine the appearance and quality of the image.

• The second section contains the evaluation algorithms for the individual pixels and pixel gradients. Various parameter sets are available here, which can be saved in templates and used to analyse images. Saved image data can be subsequently analysed with different parameter sets. This means that you can specifically influence the image analysis, e.g. to react to changes in the film

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properties or changed lighting conditions. One example of this is that the appearance of defects in transparent films is different from those in slightly translucent or opaque films.

• The third section contains all the necessary models for classifying the defects. These include defect sizes, aspect ratios, thresholds, brightness, etc. The 14 error criteria and 10 error classes of the previous evaluation software have been retained. These parameters can also be subsequently changed and thus, postprocessing can be carried out with saved raw data.

Post-processing therefore offers an enormous advantage in the development of quality criteria, even with variable film properties. One example of this is the quality control of films made from recycled plastics. Despite the possibility of subsequent optimisation, there is no need to forego the rapid informative value of an online measurement with known evaluation criteria.

In summary, COLLIN uses the latest camera and data transmission technology with its new film inspection system and builds this on proven know-how from over 30 years of experience.

The entire evaluation software was developed and programmed in-house at COLLIN. A real highlight is the post-processing function, which enables the subsequent optimisation of evaluation parameters using the raw data stored in the camera. The 4k camera remains the standard application for quality assurance in the technical centre, but the inspection system is also able to process data from 8k and 16k cameras.

Finally, it should also be mentioned that a new user interface was also developed as part of the new development, which was designed in the style of the COLLIN machine controls in a modern and very intuitive way.

Adding Value - What does it mean for the automotive supply chain?

As cost pressures tighten and demands for improved quality increase, OEMs and others in the automotive supply chain are increasingly looking for ‘added value’ from strategic supply partners as a way of delivering innovative solutions effectively and reducing overall costs without compromising quality.

A tale of two approaches

Suppliers can approach a project in one of two ways.

They can review a specification and provide a solution that meets it, with a focus on improving a specific aspect of the design that impacts performance, functionality or cost.

Or they could look at it from first principles and ask probing questions. Are the material choices the right ones? Has every eventuality been considered? What is

Wayne Matthews, head of sales at Tecman, addresses the meaning of ‘adding value’. What does it involve? And how do you know if you’re getting a value-added solution?

the end-use scenario? What conditions does the part need to operate in? What is the customer trying to achieve? This consultancy approach is the kernel of a valueadded methodology.

That is because adding value is about creating more than the sum of the parts. The output should not just be designs and manufactured products, but advice and support to help OEMs and customers to rethink and reengineer potential solutions.

Getting the process right To offer consultancy effectively, suppliers need to have a strong design and development process in place. It is the process, as well as the use of the most effective advanced materials,

that is important when considering how they can add value to projects. When this process is complemented by hands-on, practical manufacturing knowledge and expertise, OEMs gain invaluable insights about project scalability and the application of different material options.

During my career, I have seen how this ‘first principles’ approach can lead to the development of ground-breaking solutions. We recently worked with a customer in the automotive sector, where we applied lessons in thermal management from the electronics sector, to develop a product that exceeded objectives and is now being integrated across their EV range.

Done well, this should involve collaboration between supplier and customer to understand needs, challenges and expectations and engaging in co-design and co-development with OEMs to generate ideas and prototypes.

OEM engineers working on niche or siloed challenges are often experts in that particular field but can find it difficult to integrate broader knowledge to enable concepts to become reality. Strategic partners add value by bringing perspective, cross-industry insights and practical knowledge to help OEMs contextualise their challenges and adopt a contrarian approach to identifying solutions.

It is this kind of approach, rooted in practical knowledge, that fosters long-term relationships, which in turn helps unlock innovation and leads to the development of superior solutions that deliver a competitive advantage.

Added value can also be capability-driven in some cases. For example, we worked with an injection moulder whose supplier could no longer supply a particular component. In this context, adding value involved reverse engineering a part to understand how it was constructed and where improvements can be made. The ability to do this augmented the customer’s internal capabilities and was a source of added value to what was a broader project.

Interpret beyond the specification

In addition, a broad interpretation of the project objectives can be a tangible source of added value.

If automotive suppliers factor in issues like durability, aesthetics and the environmental impact of a solution, as well as adhering to the core specification criteria, they can develop better end products that have greater longevity as the priorities of OEMs shift over purchasing cycles. This long-term view

“OEM engineers working on niche or siloed challenges are often experts in that particular field but can find it difficult to integrate broader knowledge to enable concepts to become reality."

helps create an atmosphere of trust between engineering teams that long outlives an individual project and can have powerful cultural effects.

Close collaboration and teamwork are the missing links in many projects that limit how much value can be delivered, especially when both parties look at a relationship as transactional and price-driven. Cost is an important factor, but it doesn’t have to come at the expense of quality and innovation - the two are not mutually exclusive.

Ongoing support

Finally, adding value is a comprehensive, end-to-end process. I talked about how it starts at the design stage –rethinking the spec from first principles – but it also carries on after the project has been completed and products have been delivered.

Follow-up technical support and guidance throughout the project lifecycle, from design to testing and implementation, can help

OEMs get more out of a solution and ensure they get long-lasting value. This after-sales service boosts customer satisfaction and loyalty, and just like the broad interpretation of objectives, helps to create a bond between the two parties.

Final

thoughts

When two companies work together, there is a fork in the road at the very start of the relationship.

One pathway leads to the development and manufacture of a part, according to a

The other is more conversational and collaborative. It involves understanding, questioning, probing and the development of new ideas. OEM and suppliers come together as partners willing to innovate and rethink old solutions.

Adding value means choosing the second pathway.

Moreover, it requires a rigorous design and development process designed to evaluate, test and refine different solutions that are scalable and affordable.

It also requires suppliers to do some of the intellectual heavy lifting – interpreting the specification beyond the narrow confines of particular materials and anticipating OEM needs that may not have been explicitly set out.

tightly defined spec, and is transactional in nature.

Q&A

GENERATIONS OF INNOVATION IN CHESS PLASTICS

Chess Plastics is a British manufacturer of medium to large plastic injection mouldings utilising modern machines and robotics. The company’s history dates back over 50 years ago when it started out as a family-run business before steadily growing into a respected name in the industry.

Q. Can you tell us a little bit about the history of Chess Plastics?

Chess Plastics was founded in 1968 by my parents; my father worked for Scammel Lorries and my mother worked for Battenfeld.

Originally, they began by refurbishing used machines in a chapel in Tring, Hertfordshire, then moved into production, starting off with just two machines. The business grew steadily and in the 1980s it moved to a larger, purposebuilt 12,000 sq ft factory in Chesham.

In this interview, BP&R’s Mandy O’Brien speaks to Glyn Olden, MD of Chess Plastics, discussing the company's expansion into different markets as well as the current pain points of the plastics manufacturing industry.

In 1990, the business moved again to Droitwich to support a major customer’s requirement of having their moulder on the doorstep. My brother, Gareth, and I took over the ownership in 2005 and we have invested in refurbishing the entire factory, replacing all machinery and expanding the site to 52,000 sq ft. Customers demand high-quality products on time and as such, we have implemented real-time monitoring and MRP systems along with BSI accreditation to IATF 16949 & ISO 9001 quality management systems.

Q. Is Chess Plastics still a player in the automotive market?

Currently, about 75% of our business is in non-automotive industries which is a big shift

from being nearly exclusively automotive in 2005 when we took over. We've deliberately diversified to avoid relying on a single sector as we had seen the decline of the vacuum cleaner business in the late 1990s followed by the 2007 drop in the automotive sectors. This steered us towards a change in focus which enhanced the business’ growth.

For example, our smallest machine is now 500 tonnes which is a leap from the 400tonne machines we had in the 1990s. Now, Chess can offer machines up to 1,400 tonnes with eight machines measuring more than 1,000 tonnes and are accredited to the IATF 16949 automotive quality management system.

Q. What are the current challenges that the moulding industry is facing?

One major concern is the lack of young people entering the plastics moulding scene. We've tried running apprenticeship programs to attract new talent and, whilst this has been successful previously, we’ve recognised a considerable decline in applicants, so there’s definitely a skills gap that needs addressing.

Another interesting development is the competition from Chinese machinery manufacturers supplying the UK market. Their machines are often significantly cheaper than European equivalents, and the quality has improved dramatically in recent years. We've had to adapt and prioritise the suitability of the machine for the job at hand, rather than focusing on brand names to keep our manufacturing costs lower.

Q. Do you see a future for trade shows like Interplas? Certainly. While there are some challenges in attending shows in Europe due to its changing regulations, they are an ideal opportunity to connect with potential customers face-to-face. This is especially important with our overseas customers. The key is to have a broadly developed marketing strategy whilst adapting to the changing landscape, whether that be exploring alternative locations for trade shows or investing more in a strong digital presence. Saying that, we just launched our revamped website a couple of weeks ago which showcases the services that we offer to our customers.

COLUMN

Dave Raine

Dave Raine, chairman of PMMDA, reflects on the benefits of sponsorship; how a student design competition win launched the career of a successful CEO.

The power of sponsorship

As Chair of the PMMDA, I'm often asked:

“What do you guys do?” which, whilst we in the Association have a clear understanding of what we’re trying to do, is sometimes difficult to quantify directly.

However, earlier this month, we received a communication via e-mail - totally out of the blue - which served as a perfect reminder of what was, in essence, a small gesture. But, to the individual concerned, became a turning point in his career.

Third-year industrial design student, Rob Newman, who was at the time studying at Coventry University, won a 3-year sponsorship prize from the PMMDA at Interplas 2002 for his trolley backpack. He then, subsequently, won a three-month internship to work with highprofile design company SWERVE, based in New York, USA. Rob was selected from a large number of students and graduates, from many countries, for the annual summer internship program. Speaking at the time with their managing partner, Martin Short confirmed: “Rob is a bright and creative individual with keen design skills and a sharp ability to learn. He is proving a great addition to the New York team.”

After almost 22 years, Rob very kindly reached out to us here at the PMMDA, saying: “I wanted to take a moment to share a bit

of my journey and express my gratitude for the role the PMMDA played in shaping my career. Back in 2002 ish, I was fortunate enough to be sponsored by the PMMDA after winning a design competition during my university years. Winning that award was truly a turning point for me. It gave me the confidence and the means to pursue an internship in New York as a designer.

"This opportunity was the first significant step in my professional life. Following my graduation, Sandy Weaver and the PMMDA continued to support me, which helped me secure my first job in the industry.

“That first job was more than just a position; it was the beginning of a fulfilling career. Over the years, my career evolved and grew in ways I had only dreamed of. Today, I am proud to be the coowner and managing director of Carveco Ltd., a software company that serves a wide array of clients.

“I’m not sure if you're seeking stories like mine, but I felt it

important to highlight how pivotal the PMMDA’s sponsorship was to my journey. Without that crucial support during my university days, I wouldn’t be where I am today.”

Rob’s story has served as a timely reminder of the impact a seemingly small act can have on an individual. Apprenticeships are a theme I continue to champion as a solid and sensible method of replenishing the talent pool in the plastics industry, and anyone who comes into contact with them should consider themselves a mentor and role model – I, for one, remember my first days in the industry and looking to the experienced and positive engineers around me for advice, reassurance, and above all, support and direction.

We plan to contact Rob and thank him for his kind words– clearly, our influence on him has made a difference, and he’s kindly reciprocated – on behalf of the PMMDA, thank you, Rob.

Dave Raine chairman, PMMDA

COLUMN

Philip Law

BPF’s Philip Law explores efforts to promote collaboration between the plastics industry and universities and foster innovation in sustainable plastics solutions.

Building bridges with academia

One of the key dates in the BPF’s Annual General meeting is always in May. We were delighted to unanimously reelect Nigel Flowers of Sumitomo Demag Plastics Machinery as president for a second year of office. Nigel has done so much to establish ‘productivity’ as a key BPF theme, particularly important in the wake of Brexit and the increasingly harsher world trading climate. We look forward to another year of progress under Nigel’s leadership.

We have also elected as vicepresident, Martin Hitchin, the CEO of Rehau Limited in the UK, who brings a wide-ranging experience in windows, pipes and automotive markets. Additionally, he has experience with the European associations for plastics, particularly those relating to PVC.

BPF continues to thrive and has now won 590 member firms. We also have 17 universities in membership. We will be formally launching the ‘BPF University Network’ in the next couple of months and will be publishing a detailed ‘Capability Guide’ providing the specialist areas within these universities, as well as a detailed guide to the testing equipment they have inhouse. The network will enable us to better connect industry with academia to drive both innovation as well as improve the skills gap that we continue to see in the sector.

The key is to interface them with companies in the industry.

On June 4th, we organised our first ever ‘Meetings Day’ which saw over 140 members from 10 different business groups in the Federation converge in a Midlands hotel for a day of group meetings, networking and shared sessions. Also, we are already planning an online ‘Meet the University’ day for November to enable more members to continue the dialogue, discussing the latest projects and future collaboration.

Building on our desire to better connect industry with academia, BPF is partnering with Innovate UK Business Connect to run GRIPS 2024 (Global Research and Innovation in Plastics Sustainability), which we are staging at Sheffield University on 19 September 2024, hosted by the Grantham Centre for Sustainable Futures.

Over 60 expert speakers from industry and academia will

address the latest developments in innovation and sustainability. The event is in its fourth year, having been run online twice (attracting up to 3,000 delegates each time) and once as part of Plastics Sustainability Live. GRIPS 2024 is expected to attract over 500 people and we already have over 200 people booked, so I would strongly encourage people to book online quickly if they wish to attend.

Crucially, due to a generous gift from Jane Williams, in memory of her husband David Williams, past president of the BPF and past Master of The Worshipful Company of Horners, the Horners are sponsoring the GRIPS 2024 conference. This has meant the event is completely free which we really hope will maximise attendance and drive further conversations and collaboration across the industry. We are still looking for extra sponsors, so if you are interested please contact the BPF's Events team.

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