BP&R April 2021 by BP&R Magazine

British Plastics

and Rubber

bp&r april 2021

SOLUTION FOR ALL GRAVICOLOR – ONE DOSING AND MIXING SYSTEM FOR PLASTICS PRODUCT

MANUFACTURING APPLICATIONS — SEE PAGE 4 AN ELEMENT OF SOCIAL CLIMBING The new PVC-U recycling facility in Wellingborough leading the way

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AUTOMOTIVE: THE NEXT CHAPTER How the automotive sector is on the cusp of a complete revolution

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editor’s letter

visability is key

www.britishplastics.co.uk Editor: GRACE NOLAN

T: +44 (0) 1244 952 375 E: grace.nolan@rapidnews.com head of media SALES-Plastics portfolio: Lisa Montgomery

T: +44 (0) 1244 952 372 E: lisa.montgomery@rapidnews.com Advertising Manager: MANDY O’BRIEN

We need to make diversity and inclusion more relatable, by ensuring there are visible role models at all levels. There needs to be transparency in progression, by listening and acting upon feedback, and starting early via school outreach initiatives.

T: +44 (0) 01244 952 519 E: mandy.obrien@rapidnews.com Advertising Manager: Gareth Jones

T: +44 (0) 1244 952 370 E: gareth.jones@rapidnews.com Head of studio: SAM HAMLYN

T: +44 (0) 1244 680222 E: sam.hamlyn@rapidnews.com SUBSCRIPTIONS:

T: +44 (0) 1244 680222 E: subscriptions@rapidnews.com PUBLISHER: duncan wood

T: +44 (0) 1244 680222 E: duncan.wood@rapidnews.com PRINT SUBSCRIPTION Qualifying Criteria UK – Free Europe – £249 ROW – £249 FREE digital issues available to view and download online British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2021 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age. PEFC Certified This product is from sustainably managed forests and controlled sources PEFC/16-33-254

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n March, I was excited to chair the ‘Women leading in Sustainability in the Plastics Industry’ session held online as part of the Global Research in Plastics Sustainably Conference. It is clear from the discussion that visibility of role models to encourage more women into the sector is vital and the benefits of mentoring will provide greater confidence in young women (and men!). We’ve been blown away by the support received after the session and are delighted that the industry is engaging in thought provoking conversations, knowledge sharing, and opportunity finding. We need to make diversity and inclusion more relatable, by ensuring there are visible role models at all levels. There needs to be transparency in progression, by listening and acting upon feedback, and starting early via school outreach initiatives. On page 12, Dr Jason Leadbitter, Chair of PVC 2021 Organising Committee and Sustainability and Corporate Social Responsibility Manager at INOVYN tells bp&r readers what we can expect from this year’s virtual PVC event taking place 10-12 May 2021.

He explains, “We need to find ways of ensuring that the plastics we made yesterday are kept in the biosphere for as long as possible.” This issue also features Berkshire based Matrix Plastics. The polymer compound and masterbatch specialist gives readers an insight on how the automotive sector is on the cusp of a complete revolution. This is positive to see after the UK automotive industry has had a difficult couple of years. grace nolan, EDITOR

the big story

ONE SOLUTION FOR ALL

AS EFFICIENCY IN PRODUCTION REMAINS A CRUCIAL ASPECT OF PLASTICS PRODUCT MANUFACTURING, THE MOTAN GROUP OUTLINES WHY ITS GRAVICOLOR DOSING AND MIXING SYSTEM OFFERS AN ‘ONE FOR ALL’ SOLUTION FOR A WIDE RANGE OF TASKS IN INJECTION MOULDING, BLOW MOULDING AND EXTRUSION APPLICATIONS.

ith an optimal price-performance ratio, the GRAVICOLOR metering and mixing units from motan are a prime example of reliability, precision and operational safety. With controlled recipe integrity and high flexibility in processing different materials, the units are suitable for a wide range of applications. With the help of the intelligent control system, they can be easily expanded, networked with other motan systems or integrated into existing productions. The modularly designed units convince not only by their reliability and precision, but above all by their sophisticated technology, which meets the requirements of different applications in injection moulding, blow moulding and extrusion. In the meantime, GRAVICOLOR are in use worldwide - tried, tested, stable. The six models in the series, with throughputs of up to 2,200 kg/h, cover a wide range of production requirements: For the smallest and small throughputs in injection moulding machines, the GRAVICOLOR 30MD (micro metering), 60 and 100 models are used as stand-alone units. For large material throughputs in injection moulding and extrusion plants, the GRAVICOLOR 300, 600 and 1000 models are used - either directly on the processing machine or as a central mixing station. For the best possible mixing accuracy and to prevent bridging, cone metering is used - except for very small quantities. In this case, the patented micro-dosing is used. All GRAVICOLOR dosing systems operate highly flexibly with batch-wise, precise weighing of up to six material components, which are dosed and mixed with the help of the IntelliBlend software function of the GRAVInet control system. This is an intelligent, selfoptimising system with the aim of achieving the best mixing accuracy in the current batch. Among other things, the control system automatically determines the most favourable sequence of all components of the set recipe.

All GRAVICOLOR dosing systems operate highly flexibly with batchwise, precise weighing of up to six material components, which are dosed and mixed with the help of the IntelliBlend software function of the GRAVInet control system.

FAST MATERIAL CHANGES REQUIRE TO HAVE EASY ACCESS TO ALL PARTS IN CONTACT WITH THE MATERIAL TO ENSURE EFFICIENT CLEANING. After completion of each batch, any remaining deviations are corrected in the next. The goal is achieved. Result: a uniquely high recipe accuracy. With the GRAVInet touchscreen control, seven additional conveying units and a blower station can be implemented and operated. This eliminates the need for a separate conveyor control for small applications. The weighing accuracy is not affected from vibrations caused by the processing machine, as these are filtered out by a special algorithm.

During the dosing of the individual components, the dosing rates are constantly monitored and updated as required, whereby fluctuations in bulk density and material-dependent flow factors are taken into account and compensated for. Tolerances are immediately compensated for by IntelliBlend by precisely adjusting the subsequent component mixes. THE HIGH AND CONSISTENT DOSING ACCURACY OF THE GRAVICOLOR MEANS THAT ADDITIVE AND COSTS ARE SAVED.

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In addition, due to GRAVInet, it is possible to network several GRAVICOLOR units with each other or with other controllers from motan’s CONTROLnet family. Other features that the GRAVICOLOR developers had in mind are easy handling and effortless cleaning: swivel lids and removable viewing windows or demountable storage bins allow complete and thorough cleaning of the bins. The front door, the removable weighing hopper and the easily accessible mixing chamber facilitate material changes. All parts in contact with the material are made of stainless steel. The large viewing windows in the containers and front doors allow visual monitoring of the entire dosing and mixing process. www.motan-colortronic.com

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On the Cover

17 FEATURE

One solution for all

Automotive: the next chapter

As efficiency in production remains a crucial aspect of plastics product manufacturing, the motan group outlines why its GRAVICOLOR dosing and mixing system offers an ‘one for all’ solution for a wide range of tasks in injection moulding, blow moulding and extrusion applications. See page 4

3 EDITOR’S LETTER 12 EXCLUSIVE Q&A

Dr Jason Leadbitter, Chair of PVC 2021 Organising Committee and Sustainability and Corporate Social Responsibility Manager at INOVYN tells bp&r readers what we can expect from this year’s virtual event taking place 10-12 May 2021.

The automotive sector is on the cusp of a complete revolution. Matrix Plastics, a polymer compound and masterbatch specialist based in Berkshire, UK, gives bp&r readers an insight into the vital role plastics play in the advancement of the automotive industry.

20 FEATURE Under Control

Dave Palmer, general manager for UK and Ireland at ICS Cool Energy discusses leveraging the latest in process temperature control technology to achieve consistent, repeatable, and high-quality product in moulding applications.

24 FEATURE An element of social climbing

Sourcing high quality recycled polymers has presented extruders with a challenge. But with a new PVC-U recycling facility in Wellingborough leading the charge, that is changing fast. VEKA Recycling tells bp&r how the company is leading the way in sustainable PVC-U and in doing so, to make it in most respects, an entirely unremarkable part of the plastics industry.

37 FEATURE

“We have built a supply chain to ensure materials are always available”

With the Plastic Packaging Tax on the horizon, the introduction of recycled content can present new challenges in extrusion. How do manufacturers maintain productivity levels using recycled content? Chase Plastics gives bp&r readers an insight in how to do just this.

Regulars and Features 09 INDUSTRY NEWS 14 AUTOMOTIVE PLASTICS 18 TEMPERATURE CONTROL 23 RECLAMATION AND RECYCLING 27 POLYMERMAN 31 COMPOSITES 35 EXTRUSION 39 MACHINERY 41 WOMEN IN PLASTICS 43 SOFTWARE GUIDE 43 BUYERS' GUIDE 46 NEWS FROM THE FRONTLINE

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Introducing Hilectro robots from Haitian Creating your advantage

INDUSTRY | NEWS Polypipe expands manufacturing and infrastructure expertise following Plura investment Polypipe has taken a controlling interest in pultrusion and compression moulding manufacturer, Plura Innovations, expanding its expertise in advanced materials technology. The move will see Plura integrated into the Polypipe Infrastructure & Landscape division to enhance manufacturing capabilities and broaden its product offer to include access chambers

and specialist ducting systems along with unique landscape solutions for urban and suburban environments. A strong strategic fit for Polypipe, Plura will help strengthen the division’s infrastructure portfolio and establish a broader platform for innovation centred on materials and manufacturing processes that support the environment and an efficient circular economy.

LEGO House reveals The Brick Moulding Machine The LEGO Group has unveiled its next LEGO House-exclusive set, 40502 The Brick Moulding Machine. It’s the second set in the attraction’s LEGO House Limited Editions series, following last year’s launch of 40501 The Wooden Duck, and the fifth product exclusively available at Billund. The 1,205-piece model recreates the lime green moulding machine situated at the end of the LEGO House experience, and stands 19cm tall, 15cm deep and 29cm wide. The Brick Moulding Machine celebrates a crucial part of the LEGO Group’s history, when the first injection moulding machine arrived in Billund in 1947. LEGO says: “The Brick Moulding Machine

is representing an era in the history of the LEGO Group going from producing toys in wood into plastic. It is the story about putting all efforts into one focus and leaving your core competencies behind to explore the new possibilities and technologies in producing toys with plastic materials.”

The Brick Moulding Machine is representing an era in the history of the LEGO Group going from producing toys in wood into plastic.

UK Manufacturing R&D spending rose 4.4 per cent last year R&D spending in the manufacturing industry defied expectations with a 4.4 per cent rise last year despite the pandemic, analysis of latest ONS data by business tax relief consultancy Catax shows. The industry spent £15.3bn on R&D in 2020, up from £14.6bn invested in 2019. The increase came despite widespread disruption caused by the Covid-19 pandemic, which had led to fears that levels of innovation could suffer. It also represents a record high. Over the past decade, R&D spending in the manufacturing sector has grown 104.5 percent, up from £7.5bn in 2010. The manufacturing

sector’s performance was slightly worse than the performance of UK industry as a whole. Total R&D spending by UK businesses rose 5.09 per cent to £38.4bn last year. Mark Tighe, CEO of R&D tax relief consultancy Catax, said: “The pandemic stopped businesses in their tracks but those reliant on innovation clearly didn’t take their foot off the gas. Manufacturers, like all sectors, suffered major disruption last year so it’s hugely encouraging that the industry still managed to grow its R&D spend on an annual basis. This will put the sector on a strong footing as the economic recovery gains pace.”

Manufacturers, like all sectors, suffered major disruption last year so it’s hugely encouraging that the industry still managed to grow its R&D spend on an annual basis. This will put the sector on a strong footing as the economic recovery gains pace

www.britishPLASTICS.co.uk

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Tarmac helps Leicestershire’s drive towards greener roads Tarmac is helping Leicestershire County Council to deliver greener roads with the biggest supply to date of a new rubberised asphalt for the resurfacing of the A426 Blaby Bypass. With 4,800 tonnes supplied, the asphalt incorporates rubber from approximately 3,300 waste car tyres. Locally supplied from the company’s Mountsorrel Quarry near Loughborough, the new rubber modified asphalt combines end of life tyres with warm mix asphalt technology, delivering a significantly reduced carbon footprint. The asphalt is supplied at lower temperatures than traditional mixes, which means it reaches the appropriate trafficking temperature sooner, allowing roads to reopen and get traffic moving quicker. Leicestershire County Council was awarded £5 million from

the Local Highways Maintenance Challenge Fund, allocated by the Department of Transport, to carry out the works on a key part of the network which includes resurfacing and strengthening sections of the carriageway at the end of their life cycles. The Council was supported in its bid by the team at Tarmac who provided detailed information on the sustainability benefits of using warm mix and rubber modified asphalt technology. Tarmac’s rubber modified asphalt incorporates the rubber of up to 500 waste stream tyres in every kilometre of highway surfaced, depending on the thickness of the road. This would help to reduce the up to 150,000 tonnes of rubber waste which is exported annually from the UK as fuel for cement kilns, primarily to countries

Cardiff-based Group announces joint venture with Utrecht-based Greencycl Cardiff-based Thermal Compaction Group (TCG) has entered into a joint venture with Dutch sustainability specialist Greencycl. The deal will see the firm’s Sterimelt technology showcased to hospital decision-makers across the Netherlands and Europe. Sterimelt is a machine

that melts polypropylene sterilisation materials, such as surgery drapes and tray wraps, into neat plastic briquettes that can be re-used. As well as reducing waste and saving money, the system also helps reduce carbon emissions by an average of 65 per cent. Because Sterimelt

in North Africa and the Indian subcontinent. Brian Kent, national technical director at Tarmac said: “It’s fantastic to see Leicestershire County Council embracing the many benefits of these new asphalt technologies and become the first authority to use the new material for a project of this scale.”

technology removes all contamination, the resulting plastic can be re-used in a wide range of products. Working with Greencycl, TCG has established a state-ofthe-art showroom in Utrecht, where hospital decision-makers can see the Sterimelt technology in action. Hospitals can also sign up for a ‘try before you buy’ scheme whereby their surgical

It’s fantastic to see Leicestershire County Council embracing the many benefits of these new asphalt technologies and become the first authority to use the new material for a project of this scale.

waste is collected and processed for three months so they can see an immediate reduction in the waste they produce. Greencycl will be engaging with hospital managers across the Netherlands and Europe over the coming months and says that early interest in the technology has been “phenomenal”. Managing Director of TCG, Philip DavisonSebry, said: “Our

Sterimelt technology has revolutionised the treatment of hospital waste, allowing it to be de-contaminated and compressed into sterilised blocks that can be re-used for a wide variety of applications. The benefits to hospitals are numerous, from reducing waste and environmental impact to generating considerable cost savings and creating new income streams.”

Our Sterimelt technology has revolutionised the treatment of hospital waste, allowing it to be de-contaminated and compressed into sterilised blocks that can be re-used for a wide variety of applications.

www.britishPLASTICS.co.uk

exclusive Q&A

“We need to find ways of ensuring that the plastics we made yesterday are kept in the biosphere for as long as possible.”

DR JASON LEADBITTER, CHAIR OF PVC 2021 ORGANISING COMMITTEE AND SUSTAINABILITY AND CORPORATE SOCIAL RESPONSIBILITY MANAGER AT INOVYN TELLS BP&R READERS WHAT WE CAN EXPECT FROM THIS YEAR’S VIRTUAL EVENT TAKING PLACE 10-12 MAY 2021. AS WELL AS HOW PLASTICS CAN BE USED TO AID THE PVC INDUSTRY.

Q: Can you give our readers an overview of what they can expect from PVC 2021? PVC 2021 will be a first for our triennial conference – it is fully virtual; delegates will receive the latest technical developments in PVC from a global perspective all from the comforts of their own homes or offices. The conference has two key themes; innovation and the circular economy. We are delighted to welcome two keynote speakers including Dr Mark Miodownik, renowned UK materials scientist to address the public’s relationship with plastic using PVC as an example, and Cheryl Robb, Zero Waste Scotland, who will present the challenges of transitioning to a circular economy from a regulator’s perspective. Q: What will be the highlights of this year’s event? Day 1 has always been special for these conferences and PVC 2021 is no exception. As well as our keynote speakers, we will be hosting two panel discussions facilitated by Karin Helmstaedt, leading journalist and German TV presenter with strong representation from industry leaders including INOVYN’s CEO Geir Tuft, Vincent Stone, VinylPlus, Jane Gardner from European Resilient Flooring Manufacturers Institute and Charlotte Rober from the European Trade Association of PVC Window System Suppliers.

Day 3 comprises two parallel sessions, the first devoted to additives, with the second session on PVC polymerisation followed by additional sessions on markets, products and applications.

We anticipate that the virtual element will provide a more immersive and unique opportunity for interaction from our delegates.

We will also host additional chat rooms that will allow discussions to continue well after the presentation has been given thereby stimulating much more debate.

The first day will also provide attendees with the most up to date global market’s perspective on PVC by Henry Warren, IHS Markit, with additional input on the paste PVC Market by Juergen Luderer, Vinnolit. A more regional perspective from Domenic De Caria, Vinyl Institute, will cover the North American picture. whilst a Japanese perspective by Hideo Shindo, Vinyl Environment Council Japan will also feature later in the conference Day 2 sees the start of three parallel sessions; the first will focus on sustainability issues, including more papers on circularity; the second on the latest technical developments in flexible PVC including plastisols; and the third on lean manufacturing, machinery and processing technologies.

Approximately 60 papers will be presented, and all delegates will have the ability to watch the sessions live as well as play on demand and at their leisure. Each presentation will be followed with a short live question and answer session and online streaming will allow for questions to be put to the authors during their presentations.

Q: What do you think are the main PVC innovations and key themes this year? PVC 2021 represents the global PVC conference on technical developments across the whole of the industry. Delegates will be provided with the most up to date information including novel bio-based feedstocks whether for use in the PVC resin itself or as new compounding additives. The latest recycling developments will be highlighted addressing how PVC is being recycled into current and new applications and highlighting how the industry is transitioning to a circular economy. Innovation will play a core theme during the latest development of the industry’s VinylPlus Product Label. Indeed, innovation is systemic at all levels over the course of the three days whether it is from new additives and developments in 3D printing to compounding or improvements in the polymerization process.

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that don’t break down easily and won’t reintegrate into nature – that can be a problem if we let these products escape into nature. But this persistence can be turned into an opportunity by looking at plastics as long-term durable products. We need to find ways of ensuring that the plastics we made yesterday are kept in the biosphere for as long as possible. This means finding increasingly more ways to recycle them not just some applications but all applications. Through our VinylPlus programme, the European PVC industry is currently recycling approximately one third of all PVC at end-of-life, this is close to 800KT per annum. This is a huge achievement, but we need to go further. Exclusively this is all recycled via mechanical processes. New recycling technologies are emerging some of which will be discussed on Day 2, and it will be important that the PVC industry is part of that journey. One added complication that remains ours is the issue of legacy additives. These are additives which are no longer used in new PVC applications yet are present in the recycled PVC, a good example includes lead stabilisers. As an industry,

Instead of burying our heads we formed a strong value chain through the various trade associations from resin producers, additive manufacturers and the huge representation from the downstream converters and recyclers. Q: With so much happening in the world of plastics materials in PVC, do you feel plastics can be used to aid the PVC industry? I think this should be the other way around, how is the PVC industry aiding the rest of the plastics industry? As far as the PVC industry is concerned our war on plastics started in the late 90s and early 2000s. As an industry we faced head-on the potential threat of product de-selection and the industry rose to this challenge. Instead of burying our heads we formed a strong value chain through the various trade associations from resin producers, additive manufacturers and the huge representation from the downstream converters and recyclers. We can look back with much pride having now successfully developed and delivered on two consecutive ten-year voluntary commitments, Vinyl 2010 followed by VinylPlus all the way from 2001 to 2020. These successes have been hard earned and I believe the rest of the plastics industry can learn a lot from the experiences of the PVC industry. Q: What sustainability and corporate social responsibility challenges does the industry face? The plastics industry is collectively faced with a huge task of circularity. We are making products

we have demonstrated that these do not leach out either in use or during the recycling process, but more work is needed at an advocacy level to provide reassurance. This will be thoroughly discussed during PVC 2021 and is highly topical. Q: How will PVC 2021 address these sustainability and social responsibility concepts? As well as key aspects from the 1st day’s plenary session, day 2 has a full day entirely devoted to sustainability issues. However, social responsibility is more subtlety addressed in the conference. For example, Hervé Millet, PlasticsEurope will provide a key paper on the importance of Operation Clean Sweep. Sign up to this initiative is critical to the whole of the plastics industry and I cannot underestimate the importance of all companies who are involved in handling pellets, flakes or powders to be signed up to OCS – this is very much our licence to operate. Specific to PVC, Arjen Sevenster, ECVM will also address the responsibilities for resin manufacturing and the relevant industry actions, while Vincent Stone’s paper on the VinylPlus product label will also demonstrate the value of those companies who apply for the label take on board several social responsibilities.

www.britishPLASTICS.co.uk

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AUTOMOTIVE | NEWS Floreon develops bioplastic for automotive industry Floreon, an intellectual property company with global patents for a high performing bioplastic, takes PLA, a plant-based material, and enhance its performance to make it commercially viable in automotive applications. Although suitable for many single use packaging applications, PLA has limited toughness and thermal resistance which previously rendered it unsuitable for durable applications. Floreon compounds offer performance comparable with established oilbased plastics, with a renewable (PLA) content typically between 70 per cent and 90 per cent. Enhancing this bioplastic has made

made from aluminium. By making the vehicle less heavy, commercial vehicles can carry more and make less trips which is overall kinder on the environment. The performance and environmental benefits of Floreon appealed to a recognised vehicle body builder in the UK, with whom Floreon are conducting late-stage trials. Floreon have supported this brand through rigorous testing to get the end-product exactly right. Floreon’s material ten times tougher than standard unmodified PLA, and it is challenging common perceptions. Brands in automotive now have the chance to switch to a renewable bioplastic without compromising on performance. The automotive industry has been under scrutiny in recent years, increasingly being put under pressure to reduce emissions and reduce vehicle weight. Hence there has been a shift, which now sees brands placing environmental action as a high priority. Floreon offers brands a carbon footprint up to six times lower than a common oil-based plastic, ABS. In addition, Floreon is lightweight, meaning it can replace heavier vehicle parts and even those

Floreon compounds offer performance comparable with established oil-based plastics, with a renewable (PLA) content typically between 70 per cent and 90 per cent.

Polykemi and Rondo Plast develop new scratch-resistant PP materials for automotive applications The first COMPLUS Concept from Polykemi and Rondo Plast focuses on a newly developed PP-based material for complex interior automotive applications. The newly developed and virgin raw materialbased compound POLYfill PP EP317R UV has both high scratchresistance and UV stability, together with excellent mechanical properties and unlimited coloration possibilities. Development Manager Anette Munch Elmér said: “The idea came up 14

during a conversation with one of our end customers, being one of the world’s largest vehicle manufacturers. They were looking for materials with similar properties, both based on virgin plastic raw material and on highquality recycled plastic raw material. In some cases, the requirements profile only allows plastic compounds based on virgin plastic raw material, but in other cases, material based on high-quality recycled plastic raw material is the best

In some cases, the requirements profile only allows plastic compounds based on virgin plastic raw material, but in other cases, material based on highquality recycled plastic raw material is the best solution.

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solution.” The COMPLUS Concept offers choices between several different materials, both based on virgin plastic raw material and on high-quality recycled plastic raw material. The materials have similar properties but are adapted for different injection moulded parts within the same construction. An example within the automotive industry is door panels, which are often complex assemblies consisting of several parts, all with their individual specific requirement profiles. In this application, all four material alternatives within the COMPLUS PP Concept can be used.

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Walki’s underbody shields are fit for a sustainable automotive future The automotive industry has been on the hunt for glass fibre free underbody shields, as glass fibre comes with health hazards in the production and is ill fitted for recycling as it’s not an organic material. Walki’s R&D team has been hard at work to come up with a solution that is recyclable, lightweight and free of glass fibre. “The underbody shield fit for the future should not only be free of glass fibre, recyclable and light, it also needs to be thermoformable and of course meet the requirements of protecting the car,” explained: Steven Verheul, Automotive and Steel, Category Manager

at Walki. Walki has developed two solutions for underbody shields: a light version of 160g and a slightly more robust one of 215g. Walki’s solution is a combination of polyester-based materials that are chemically bound during an extrusion coating process. Testing has showed that compressing the different layers is not enough to keep the scrim in the matrix and withstand a severe road test. Walki’s solutions have been tested using the Ford bolt pull through test and the results are very promising: the strength of the material was significantly

increased with the scrim being fully incorporated in the matrix. Walki’s polymerbased materials are thermoformable, making them more flexible both for customers’ production lines but also for getting the right shape for the end uses. These textile-based and correspondingly lightweight underbody shields skins can further be tuned to also absorb noise and therefore simultaneously reduce the interior and exterior noise. “The trend is to move away from glass fibre and go towards sustainable materials that are more environmentalfriendly and recyclable,” concludes Verheul.

The trend is to move away from glass fibre and go towards sustainable materials that are more environmental-friendly and recyclable

Ford and HP turn 3D printer waste into auto parts

Ford and tech firm Hewlett-Packard (HP) have collaborated to transform 3D waste, such as printed powders and parts, into vehicle components. The recycled materials are being used to manufacture injectionmoulded fuel-line clips that will be installed first on the automaker’s Super Duty F-250 trucks. The automotive company noted, the parts have better chemical and moisture resistance, and are 7 per cent lighter and cost 10 per cent lesser than conventional

Distrupol reveals polymer materials to meet automotive VOC targets Volatile Organic Compounds (VOCs) are gasses emitted from various solids and liquids, including polymers. VOCs include a variety of chemicals, some of which may have adverse health effects. That ‘new car smell’ that most of us find charming. The odour is down to VOC emission. Concentrations of many VOCs are consistently higher indoors (up to ten times higher) than outdoors, and three times higher

inside automotive cabins than other indoor spaces. As such, regulations on emission values have become increasingly stringent over the past 5-10 years, with rigorous testing now being an essential component procurement requirement. Dashboards, cup holders, air vents, seat belt components, volume controls, window switches, floor mats, panels – the list of automotive interior

components which are primarily made from plastic is seemingly endless. Fortunately, world-leading producers such as DuPont, BASF, HEXPOL TPE and ChiMei

have focussed on material innovations that are now leading the way in low emission polymers for automotive interior applications. Delrin CPE acetal

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versions. Moreover, the Ford research team has identified 10 other fuel-line clips on existing vehicles that could benefit from this innovative use of material. Debbie Mielewski, Ford technical fellow, said: “Many companies are finding great uses for 3D printing technologies, but, together with HP, we’re the first to find a high-value application for waste powder that likely would have gone to landfill, transforming it into functional and durable auto parts.”

homopolymer (POM), Elastollan TPU, Dryflex Interior TPE and Polylac PA-77NB ABS are all polymers and portfolios which contain specifically developed low emission grades to help designers and manufacturers to meet automotive VOC targets. Taking into account individual OEM testing processes and requirements, these materials are now the benchmark for automotive interiors as the global focus on Vehicle Interior Air Quality (VIAQ) increases. 15

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FEATURE

Automotive: THE NEXT CHAPTER

T THE AUTOMOTIVE SECTOR IS ON THE CUSP OF COMPLETE REVOLUTION. MATRIX PLASTICS, A POLYMER COMPOUND AND MASTERBATCH SPECIALIST BASED IN BERKSHIRE, UK, GIVES BP&R READERS AN INSIGHT INTO THE VITAL ROLE PLASTICS PLAY IN THE ADVANCEMENT OF THE AUTOMOTIVE INDUSTRY.

K sales of new petrol and diesel cars will end by 2030 and all new cars and vans will be fully zero emission at the tailpipe from 2035. It is the true end of an era after 160 years of combustion engines, and it will be bittersweet to bid farewell to the enchanting fumes and thrilling roar of a good old petrol engine fresh off the manufacturing line. But of course, the drive for this transition is imperative; the impact of vehicle pollution on global warming is severe. Tackling carbon dioxide and nitrogen oxide emissions to improve air quality has been a top priority for the Department for Transport in recent years. The future? Electric vehicles. Autonomous, connected, updateable – the rise of electric vehicles is largely down to the incredible advancements in technology and materials that we have been witness to since the turn of the century. Now far safer, sleeker and more sustainable than when they were first innovated in the 1800s, electric plug-in cars accounted for more than 10 per cent of UK car sales in 2020. Plastic plays a vital role in the success of modernday vehicles (both combustion and electric). Plastic components make up one third of the components in a standard combustion engine vehicle (around 10,000), with that proportion being even more significant in their electric cousins. Automotive polymer usage includes battery cases, seat belts, fuel lines, bumpers, dashboards, air bags, lighting, switches, air conditioning housing, electrics, and much, much more. There are approximately 40 different types of basic plastics and polymers used in automotive manufacturing, with polypropylene, polyurethane, polyamides and PVC making up around 70 per cent of all plastics used. Plastic has fast become the material of choice in the automotive sector.

Base polymers like the aforementioned are incredibly useful; however, the real magic happens when additives are introduced. We like to think of polymer additives as the ‘special effects’ of the plastic world. Additives give plastic superhero powers in order to produce practical, innovative and sustainable plastic products. It goes without saying that this is of huge importance in the automotive sector. In both combustion and electric vehicles, plastics are subjected to various extreme conditions that can potentially cause degradation: light, heat, stress and strain, chemicals, human interference etc. In order to stabilise and even further improve the properties and longevity of automotive plastic components, a huge range of polymer additives can be applied with incredible results. Examples of this are as follows: UV stabilisers prevent UV degradation for components which are exposed to light; antioxidants prevent oxidation which can weaken plastic; heat stabilisers prevent the damage that heat can cause; antistatics reduce the charge of plastic and possible risk of shock; laser marking additives enable the industrial marking of plastic parts for identification purposes; anti-scratch additives reduce the risk of scratching (particularly for automotive interiors); and of course, colour can be compounded into plastic to improve design and safety features. Becoming increasingly popular, partly in response to the Covid-19 pandemic, are anti-microbial additives for high-touch areas such as handles, steering wheels, switches and carpets. These additives help to reduce and kill harmful bacteria, viruses and other microbes that are easily transmitted by touch. This rise of technology in this field shows that no matter what requirements are demanded of polymer materials; they can rise to the challenge. Of course, the stringent regulatory requirements and approval processes in the automotive sector also pose a challenge. Materials must comply with international and local directives and legislation to guarantee user, public and environmental safety. Polymer materials and manufacturing partners should be well versed in this area.

There are approximately 40 different types of basic plastics and polymers used in automotive manufacturing, with polypropylene, polyurethane, polyamides and PVC making up around 70 per cent of all plastics used.

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Technology for challenges of the future | www.motan-colortronic.co.uk

temperature control | News MGS Technical Plastics purchases double drying capacity from Summit Systems MGS Technical Plastics has invested in new desiccant dryers and central system hopper loaders, supplied and commissioned by Summit Systems. The company’s Blackburn headquarters houses modern, fully automated machines, ranging from 35 tonnes to 900 tonnes and producing parts on a 24/7 operation.

The MGS team’s primary focus is on technical capability, quality, and service delivery; this approach has positioned the company as a preferred partner to some of the world’s leading brands. Manufacturing thousands of different polymer grades for over 45 years, you can find their parts in cars, hospitals, retail stores, and building worldwide. MGS Technical Plastics moved to its current Blackburn facility in 2013 and has already invested more than £2 million in the new facility. This latest investment with Summit Systems includes two Vismec low-energy rotor wheel dryers with 200-litre drying hoppers and central system hopper loaders. These highly efficient dryers are the best-selling dryers in the plastics market, utilising the newest technology with a Material Management System to save energy

Wittmann reveals TEMPRO plus D120 temperture controller Following the introduction of the the pressurized TEMPRO plus D100 temperature controller in 2019, targeted market research revealed a similarly great demand for a directly cooled pressurized unit of the same size. In 2020, Wittmann presented its new, directly cooled TEMPRO plus D120, in a single zone as well as a dualcircuit version. The latter is the first directly cooled dual zone appliance from

Wittmann. Wittmann says the TEMPRO plus D120 dual zone temperature controller offers the advantage of two independent temperature control circuits with high cooling performances. Direct cooling imposes stringent demands in terms of wear-resistance on the cooling valve which, depending on the application and the specific temperature control required for

and prevent over-drying. The investment doubles MGS’s drying capacity in this area of its manufacturing plant, as well as exponentially increasing efficiency in its material handling capability by reducing changeover times. The added capacity is to facilitate the company’s

growth journey, which involves a turnover target of £10 million in the 2021/22 financial year. Judson Smythe, Technical Director at MGS Technical Plastics, said: “MGS Technical Plastics continues to demonstrate our commitment to

investment in the future of UK manufacturing and are proud of our advances in the industry over the last five years. We have more exciting developments in progress and are looking forward to the benefit that this will bring to both valued customers and to MGS.”

MGS Technical Plastics continues to demonstrate our commitment to investment in the future of UK manufacturing and are proud of our advances in the industry over the last five years.

the individual process, switches over with varying frequency. Wittmann has taken this into account by installing a durable piston cooling valve in the TEMPRO plus D120. This valve withstands a considerably larger number of switching cycles without maintenance, and consequently offers a much longer service life than a conventional membrane cooling valve. Apart from the 9 kW standard heating capacity, capacities of 12 kW or 16 kW are also

available, depending on the production heat required for various applications. In its choice of pumps, Wittmann relies on highquality stainless steel pumps with wear-free magnetic couplings, covering a range of maximum flow rates from 40 to 90 l/min. As a specialty, the choice includes a frequencycontrolled pump with 1.1 kW / 50 l/min / 9 bar. The advantage of a frequency-controlled pump installed in the directly cooled TEMPRO model is its

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high flexibility in control parameters, since it offers a choice of being controlled either by motor speed, pressure or flow rate.

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FEATURE

D DAVE PALMER, GENERAL MANAGER FOR UK AND IRELAND AT ICS COOL ENERGY DISCUSSES LEVERAGING THE LATEST IN PROCESS TEMPERATURE CONTROL TECHNOLOGY TO ACHIEVE CONSISTENT, REPEATABLE, AND HIGH-QUALITY PRODUCT IN MOULDING APPLICATIONS.

emperature control and stability are critical to manufacturing processes because they have a direct effect on cycle times and output. With all mega trends in the plastic-processing industry, for instance light-weight construction, alternative drive concepts, environmentally compatible energies and optical applications, economic success depends to a high degree on the development of reliable production and energy-efficient solutions for mould temperature control and machine cooling. Plastic injection moulding – used to make millions of products of repeatable shapes and forms every year - is a great example, where maintaining precise, stable, controlled temperatures is of particular importance to obtain the desired and consistent quality of the end product. In medical, automotive or any other precision moulding application, product consistency and process repeatability are especially vital. Unwanted temperature variances can lead to hotspots developing within the mould cavity, which can in turn impact product quality, such as mechanical resilience, surface quality, dimensional accuracy, cracking, shrinking or warping. This causes wastage, and in turn has significant effect on energy consumption and production costs. It can also cause tangible damage to the reputation of the manufacturer through the release of substandard product. The manufacturers want to ensure consistent and easily repeatable quality of the final product, which would allow them to increase the speed of production and eventually their profitability. To achieve this, controlling and maintaining process temperature within the various stages of the process is critical. SYSTEMATIC TEMPERATURE CONTROL The key to systematic temperature control and cooling is in the intelligent combination of different technologies that are tuned to the products to be manufactured, the moulding substances to be processed, the injection moulding procedure to be used and the infrastructure and climatic boundary conditions of the production operation. To provide accurate and reliable process temperatures for equipment that is designed to operate at high temperatures creates a real

challenge. It’s not only because of the extremely high operating temperature range required, but also because each composite and product being manufactured on the machine requires a precise temperature. Traditionally, a Temperature Control Unit (TCU) has three main functions – to heat, to cool and to control. It works alongside a process-grade chiller to provide enhanced cooling power, and at elevated temperatures provide accurate temperature control with minimum temperature deviation. It does so by regulating the heating elements contained within the TCU, teamed with the cooling capacity provided by the chiller. Until recently, all the manufacturers could do to set up the moulding process with a standard TCU was setting a temperature range, flow rate and running a test batch to proof the quality of resulting product. If the quality was unsatisfactory, settings were adjusted and the test batch repeated. Once the desired quality was achieved, the day’s production could carry on. The next day these settings would have to be repeated. The problem was, that if the next day, for example the water’s flow rate was different, the final mould wouldn’t be repeatable. This then required another finetuning of the settings, test batches and additional waste. Today, manufacturers producing syringes for medical use, car parts or operating any other precision moulding application, can finally benefit from a more intelligent approach.

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www.motan-colortronic.co.uk | Technology for challenges of the future

ADVANCED TEMPERATURE CONTROL CONDITION MONITORING, DATA LOGGING, PROCESS ANALYSES AND DIAGNOSTICS The latest developments in the TCU’s controllers capabilities, have brought precision temperature control to a new level. Intuitive interface allow for easier monitoring and real time adjustments, while the ability to utilise full data logging, gives users more information about their process than ever before. The latest TCUs feature Euromap 82.1 specification that provides a standardised interface between the TCU and their peripherals (dryers, conveyers etc.). This standardisation ensures that the units will be able to interact with the existing plant equipment with minimal interference and possibility of human error. Advanced TCUs can be pre-set for each particular type of product and manage the entire moulding process following the precise parameters that the moulding needs - from both the moulding machine’s and the TCU’s point of view. Instead of programming the moulding machine and the TCU separately for each particular mould, advanced TCU controllers allow the operator to simply chose the pre-set recipe of the product that is about to be made, and the moulding machine will communicate directly with the TCU – eliminating the possibility of operator’s error.

KEEPING YOUR PROCESSES RUNNING In the continuously changing environment, the manufacturers face many challenges embracing and understanding the new technology, skills shortage and wanting to provide customers with the best quality products whilst reducing their operating costs. Engaging with a partner that knows the inside and out of process temperature control can help manufacturers in every step of the away from surveying the sites to understanding where efficiencies can be made – recommending bespoke, fully packaged, process-designed chillers and TCUs based on tried and tested processes. Such a partner can bridge the gap between the roles of the facilities and process managers, who usually separately manage the two sides of the temperature control application: the chiller and the TCU. Ideally such partner should also ensure contingency plans for the process cooling and chiller operations, without which the production would need to stop.

Advanced controllers not only set accurate temperatures, but also monitor the entire process every few seconds. Operators can see on the screen how the temperature profile is keeping the pace, what the flow rate of the water (or oil) is - allowing them to act and make adjustments if needed. This ensures the system is reaching the correct temperatures exactly when the particular process requires, helping to maintain product consistency and repeatability whilst lowering energy consumption and wastage.

There is just a handful of expert companies that would look at the manufacturer’s critical processes, and deliver a detailed, documented plan to keep his operations running. If it came to the worst and a chiller broke down, that partner should be able to say exactly what, when and where happened – which exact unit had caused the problem, what are its connectors and hoses etc. – and provide a solution to keep the plant up and running in matter of hours. Either by fixing the issue or providing a contingency, hire solution to fill the gap.

In case of an emergency, the latest controllers also allow the service technicians to dial in through the ethernet from a remote location and immediately check what is happening with the process. Thanks to data logging, all the details related with the particular product batch are recorded, stored and can be shared through the ethernet.

The fact that around 60 per cent of a plants’ total lifecycle cost can be attributed to process cooling and refrigeration systems, makes it a vital investment that shouldn’t be overlooked. This is the part of the production that directly influences whether a plant can maintain the quality, keep their production running and keep their end customers satisfied.

The full data logging is particularly important in case of a quality dispute related with a concrete batch of product. Having all the data monitored and recorded, the manufacturer can clearly demonstrate the precise settings for the product in question, proving they were the same as last time when the product batch was correct. It proves to the end customer that the manufacturing process is consistent and done against a specification agreed upon and repeated.

Today, manufacturers producing syringes for medical use, car parts or operating any other precision moulding application, can finally benefit from a more intelligent approach.

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RECLAMATION AND RECYCLING | NEWS Wilko launches the UK high-street’s first face mask recycling scheme A sustainable singleuse facemask recycling scheme is set to launch in 150 Wilko stores across the UK. Customers doing their essential shopping will be able to bring their used disposable masks and safely place them in the collection bins at the

front of the stores. The single-use face coverings are set to be recycled into sustainable building materials, furniture and PPE collection bins. The facemask material, made primarily from polypropylene, is sent to Yorkshire based recycling partners ReWorked for processing. After a minimum 72-hour quarantine period, the PPE is washed and shredded into 5mm pieces before being mixed with other waste plastic to a specific recipe.

Alpla UK to focus on regional PET recyclate From May, Alpla UK will source food-grade polyethylene terephthalate (rPET) plastic pellets from the Biffa recycling plant in Seaham, County Durham. The recyclate will be used for the manufacture of home care packaging and

Robinson joins ground-breaking NEXTLOOPP project

Robinson has joined forces with NEXTLOOPP to deliver for the first time a supply chain model to close the loop on food-grade recycled polypropylene (rPP). The objectives of the two-year NEXTLOOPP project are: demonstration of innovative sorting technology; preparation of protocols for EFSA and US FDA; implementation of sorting requirements for packaging in the recycling stream; mechanical reprocessing facilities for rPP food-grade as raw material in packaging. Lubna Edwards, Sustainability and Marketing

aims to promote a local circular economy for plastics in the United Kingdom. As such, the amount of recycled plastic used in day-today household products such as washing-up liquid and cleaning product bottles will increase. Tasos Pourloukakis, UK Country Managing Director at Alpla Group, said: “The collaboration with Biffa goes along with our

Director, Robinson, said: “Demand for this high value recycled material will continue to rise as we continue to transition away from using virgin material. Much of our UK business depends upon PP and this project gives us the opportunity to tap into cutting edge technology, learn from industry partners and trial the material for use in our packaging. It is particularly ground-breaking in that we are working towards ensuring a secure, stable, and cost-effective supply of high quality rPP while increasing consumer recycling and preventing the leakage of plastics into the sea or going to landfill.”

aim to push worldwide closed-loop systems on a local level. This approach guarantees the highest possible collection rates, recyclability, and quality of the materials. It also reduces the logistical effort related to our packaging solutions. This helps us to achieve the overall objective of reducing CO2 emissions and actively bringing the circular economy forward.”

Construction begins on ‘landmark’ recycling site in the North East Plans to build the world’s first commercialscale plastic recycling plant in Teesside using innovative hydrothermal upgrading technology have taken a major step forward. ReNew ELP has appointed Wood as its engineering, procurement and construction contractor on the multi-million pound project. Work on this innovative site will start later in the Spring and the first phase will see the construction of one of four Hydrothermal Plastic Recycling Solution (HydroPRS) recycling lines, each

able to process 20,000 tonnes of plastic waste per year. The remaining three lines will follow in quick succession. On completion, the plant will recycle 80,000 tonnes of waste plastic, including packaging items such as flexible films, pots, tubs and trays. ReNew ELP’s plant will use a groundbreaking advanced recycling process called HydroPRS developed by UK-based Mura Technology, ReNew ELP’s parent company. HydroPRS uses water in the form of supercritical steam to convert plastics back

into the chemicals and oils from which they were made, the equivalent of fossil resource. These products can then be used in the manufacture of new plastics and other materials. There is no limit to the number of times the same plastic can be recycled using HydroPRS, entering plastic into a circular

economy and helping to reduce plastic pollution. ReNew ELP’s Managing Director Richard Daley said: “We’ll soon see construction start on the plant - which will be the first of its kind in the world. The development of this first site marks a landmark event for both the recycling industry and the environment.”

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The development of this first site marks a landmark event for both the recycling industry and the environment.

feature

S SOURCING HIGH QUALITY RECYCLED POLYMERS HAS PRESENTED EXTRUDERS WITH A CHALLENGE. BUT WITH A NEW PVC-U RECYCLING FACILITY IN WELLINGBOROUGH LEADING THE CHARGE, THAT IS CHANGING FAST. VEKA RECYCLING TELLS BP&R HOW THE COMPANY IS LEADING THE WAY IN SUSTAINABLE PVC-U AND IN DOING SO, TO MAKE IT IN MOST RESPECTS, AN ENTIRELY UNREMARKABLE PART OF THE PLASTICS INDUSTRY.

An element of

he construction of VEKA Recycling Ltd’s new facility at Wellingborough, Northamptonshire, created for the unambiguous purpose of recycling up to 30,000 tonnes of PVC-U window and door frames and profiles annually, required a great deal of preparation, as all such projects do. However, in addition to the usual considerations of planning and permissions, site preparation, design and build, engineering calculations, specification and application, logistics and of course, installation, the company would also face the challenges of challenging perceptions of a sector that has a somewhat patchy reputation. The company’s commitment and faith are undeniable: against an original investment calculated at £12 million, funded by VEKA Recycling’s large and munificent parent VEKA AG, expenditure is now around the £15 million mark following the inclusion of additional refinements that will further increase the Wellingborough plant’s capabilities and capacities. The outline plan to create the third such facility under the German extrusion giant’s specialist recycling wing VEKA Umwelttechnik GmbH, based at Behringen, was well-founded even before the Brexit vote that came in June 2016, and was not diverted by Britain’s future withdrawal from the EU. In fact, if anything that decision was strengthened. For just as the UK has long been self-sufficient in its extrusion of profiles for the apparently insatiable window and door market – and especially so home improvements – then so too should be the recycling of end-of-life frames and virgin offcuts. The process would be entirely self-contained in both process and geographical terms and therefore studiously managed and documented throughout. And it is in this key aspect that lies VEKA Recycling’s core mission: to drive up the quality, and therefore perception of, the recycling processes for PVC-U profiles. And in doing so, help to reset the image of the sector.

This end game is crucial on a number of levels: for simple commercial considerations of course. But also, in the resolution of a conflict faced by producers of non-fenestration PVC-U products that are facing pressures to make their products more sustainable; but which have previously found the supply of recycled PVC-U pellet to be inconsistent in both its quality and security of supply. The UK window and door sector, does well to recycle its old frames, with an estimated 80 percent of those removed following an audited trail from removal to remanufacture as compound. This is particularly impressive bearing in mind that there is no regulated prevention of the material going to landfill, as there is in Germany for example. But around 20 percent of old frames therefore remain unaccounted for, which is a cause of some concern. As long as the material has a value, it is likely that somehow it remains in the system, but there is concern about what happens to associated materials that are not easily recyclable. Extraordinarily, against popular belief in some quarters the window and door sector as a whole does not absorb a great deal of the recycled material back into new frame profiles. VEKA Recycling’s Compounds sales division actually sells most of its pellet to extruders of a wide range of products, with one company, Verplas Ltd, providing an excellent example of how a high-end extruder resolved the challenge of obtaining a reliable source of high-quality PVC-U compounds with which to produce its premium ducting products, for which sustainability was a crucial USP. On paper, VEKA Compounds’ product specification reads well: the company’s most popular pellet is Grey white 9002.001, which shows Impurities of <0,02 percent; Colour L 89 (+1); and Apparent

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social climbing density of ≈0,85 g/cm3. But it is the consistency with which these standards are delivered that attracted the attention of Verplas Managing Director Derren Gittins, leading to his commitment late in 2020, to choosing VEKA as his sole supplier of recycled pellet for the production of the company’s high-end ventilation products. Gittins takes up the story: “We were determined that our range of self-seal ducting would be produced using sustainable PVC-U. We produce this product for the premium sector of the market, with a number of advantages that focus on speed and ease of fix, and which is self-sealing, all of which qualities are attractive to specifiers that also appreciate sustainability.”

At the core of our commitment is recognition of the need to professionalise the recycling of PVC-U and in doing so, to make it in most respects, an entirely unremarkable part of the plastics industry.

“Having committed to the use of sustainable, therefore recycled, pellet we were using three suppliers. But after accepting the invitation to tour the VEKA Recycling facility at Wellingborough late last year in between lockdowns, I was able to commit to VEKA as our sole supplier of sustainable PVC-U compounds,” said Gittins. “The Wellingborough site is impressive, in the way the site is run and also of course, in the processes by which it is able to guarantee the quality of product that we need and in the volumes required as our sales build for this particular product. I was able to make a final decision on the strength of that visit,” concluded Gittins. Simon Scholes, Managing Director of VEKA Recycling Ltd, says that Verplas epitomises the perfect end-game for his company: “High quality is crucial for the Verplas product for which Derren uses our material. In addition to the quality of the compound I believe that Derren also took into account that our material is processed entirely within our own facility within the UK, which further improves the sustainability credentials of the

material. A further key element is that we control the entire process ourselves which few companies within these shores are able to do. We can show a full audit trail.” However, says Scholes, he derives satisfaction from having achieved what might be described as an element of ‘social climbing’ with the completion of the new plant: “The reality is that the PVC-U recycling sector has not always enjoyed the best of reputations. At the core of our commitment is recognition of the need to professionalise the recycling of PVC-U and in doing so, to make it in most respects, an entirely unremarkable part of the plastics industry. And therefore, remove any doubts that may still linger about integrity. We believe we are achieving that.”

We were determined that our range of self-seal ducting would be produced using sustainable PVC-U.

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how will gb reach impact polymer on polymer supply?

IN THIS EDITION OF HIS REGULAR COLUMN, OUR RESIDENT MATERIALS EXPERT, MIKE BOSWELL, LOOKS AT THE IMPLICATIONS THE GB REACH REGISTRATION HAS ON THE SUPPLY OF PLASTIC RAW MATERIALS TO UK PROCESSORS.

EACh stands for Registration, Evaluation, Authorisation and Restriction of Chemicals, and whilst originally conceived by the European Union, coming into legal effect from June 2007 this legislation has been adapted and incorporated into UK law with effect from January 1st 2021 as part Brexit and the end of the Transition Process. The purpose of the REACh regulation is to improve the protection of human health and the environment from the risks that can be posed by chemical substances. The regulations promote collaborative methods for the hazard assessment of substances in order to reduce testing on animals. Whilst polymers and articles manufactured from them are not subject to GB REACh, the monomers and in some circumstances any additives contained within plastic raw material are subject to the regulations. IT IS IMPORTANT TO NOTE THAT: With the departure of the UK from the EU, companies who were previously downstream users of EU27 suppliers, may now be regarded as importers and will therefore need to comply with GB REACh Importers must be authorised by a holder of GB REACh registration, or hold their own GB REACh registration, or have provided a DUIN (Downstream User Import Notification) by 27th October 2021 Any substance that did not have an existing EU REACh registration on 31.12.20 may not be imported until a GB REACh registration is obtained

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

ONCE A DUIN HAS BEEN SUBMITTED THE FOLLOWING REGISTRATION DEADLINES APPLY: 27/10/23 for substances manufactured or imported at >1,000 tonnes per annum plus substances in the highest hazard categories (SVHCs – Substances of Very High Concern) 27/10/25 for substances manufactured or imported at > 100 tonnes per annum 27/10/27 for substances manufactured or imported at > 1 tonnes per annum

Individual wRegistrant

Joint Registrant

1 – 10 tonnes per year

£1,518

£1,138

10 – 100 tonnes per year

£4,080

£3,061

100 – 1,000 tonnes per year

£10,913

£8,185

Above 1,000 tonnes per year

£29,419

£22,064

Volume Band

If an importer decides to proceed to full GB REACh registration the following fees will apply: The registrant will also be required to submit a technical dossier for the substance, the cost of which will vary, but could start at about £2,500 for a common substance such as Ethylene (C2). There will also be on-going expenses to maintain this information. SO, WHAT ARE THE IMPLICATIONS FOR THE SUPPLY OF PLASTIC RAW MATERIALS TO UK PROCESSORS? REACh regulations compromise cost and unregulated competition for enhanced safety. That cost, for those importers who choose to proceed with full GB REACh registration, is likely to be passed through the supply chain. Those importers who rely upon existing EU REACh registrations, through the DUIN process (Registration Deadline 27th October 2021) will face a diminishing capacity to import. The inevitable outcome will be higher prices resulting from a combination of higher cost and reduced competition. Finally, it should be noted that the HSE is likely to impose heavy fines in the event that GB REACh regulations are breached, and on that basis UK converters should undertake appropriate due diligence on their supply chains. NB Under the Norther Ireland Protocol imports into the province must comply with EU REACh, and exports of substances from the region to Great Britain will need to comply with GB REACh.

It should be noted that the HSE is likely to impose heavy fines in the event that GB REACh regulations are breached, and on that basis UK converters should undertake appropriate due diligence on their supply chains

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IMCD UK: The proud distributor of Asaclean Purging Compound Why Choose Asaclean? • Shortens time taken for colour/material changes • Suitable for high temperatures up to 420°c • Reduces scrap due to black specks • Can be used in hot runner systems • Allows for safe shutdowns and quick start-ups

Contact us for more information on how we can support you today. IMCD UK Advanced Materials Email: advmatuk@imcd.co.uk Tel: 020 8722 6975

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MATERIALS | NEWS World’s first biodegradable and recyclable plastic developed in the UK A startup based at Imperial College London’s White City Campus, Polymateria, has created plastic cling film that breaks down within a year. Polymateria’s thin, flexible plastic breaks down in 226 days but can also be recycled in UK facilities and turned into products like flowerpots or pallets, according to independent tests. It could also be used for food storage bags and packaging. The independent recyclability testing was conducted by the ISO-accredited Impact Solutions plastics experts

in the UK. This is the first time a polyethylene film has been independently proven both recyclable and truly biodegradable in the natural environment. Fashion brand Pour les Femmes, founded by House of Cards actress Robin Wright, will also be using the plastic in its clothing deliveries to customers and shops. The company has also developed rigid plastic material for products such as disposable drinks cups, which breaks down in the natural environment in less than a year and is in the final phases of testing for recyclability.

Haydale receives £1.1 million Innovate UK Loan Agreement Haydale has been awarded a £1.1 million loan facility by Innovate UK Loans Limited, a wholly owned subsidiary of UK Research and Innovation. Haydale, with the support of Innovate UK, is implementing its plan to expand its capacity to manufacture functionalised nanomaterials including Graphene to meet growing demand. The company will be investing in a HT1400 plasma reactor and ancillary equipment to provide a facility to be able to increase production volume by at least eight-fold once fully optimised. The reactor will increase production at the Ammanford facility to an industrial level with capacity to functionalise over 30 tonnes per annum of graphene and other

nanomaterials on a single shift pattern. Keith Broadbent, Chief Executive Officer of Haydale, said: “We are grateful to Innovate UK for their support of our strategy which will allow Haydale to deepen its roots in the UK industrial landscape, whilst supporting the UK’s high tech and advanced materials supply chain strategy.”

Avient expands reSound R TPE portfolio in Europe Avient has announced the global expansion of its reSound R recycledcontent thermoplastic elastomer (TPE) range. The launch includes new grades in Europe that contain over 80 percent recycled content, as well as versions in North America and Asia that are compatible with PC, ABS, and PC/ABS overmoulding. In Europe, new patent-pending grades are formulated using recovered materials such as recycled polypropylene, recycled

oil, and recycled glass filler. Utilising this combination of recovered materials, Avient is able to increase the overall percentage of recycled content in these grades to over 80 percent. These European grades include a blend of both post-industrial (PIR) and post-consumer recycled (PCR) content, and are available in 30, 50 and 70 Shore A hardness levels. Suitable for overmoulding onto polypropylene (PP), the new TPEs have comparable

performance to prime grades, and can replace them in typical applications for lawn and garden, outdoor high performance, personal care, footwear, office supplies,

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We are grateful to Innovate UK for their support of our strategy which will allow Haydale to deepen its roots in the UK industrial landscape, whilst supporting the UK’s high tech and advanced materials supply chain strategy.

houseware durables, and automotive industries. “With our global customers’ everincreasing focus on achieving a circular economy, we’ve responded by utilising innovative materials from local recycling streams,” said Matt Mitchell, Director, Global Marketing, Specialty Engineered Materials at Avient. “These developments are part of our ongoing commitment to expand our sustainability portfolio and help customers in all regions meet their sustainability goals.” 29

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COMPOSITES | NEWS UK consortium aims to accelerate sustainable composites development GKN Aerospace is leading a new UK industry consortium to develop more sustainable composite material for the UK aerospace and automotive industries. During a three-year period, the £39.6 million Aerospace and Automotive Supply Chain Enabled Development (ASCEND) consortium, funded by the UK Government and industry, will aim to increase the adoption of composite technologies, the industrialisation of new technologies, and aerospace production rates to meet future highvolume requirements. The collaboration aims to help develop technologies from across the UK supply chain to develop the advanced materials and automation equipment

required to manufacture lightweight structures for the sustainable air mobility, aerospace and automotive industries. GKN Aerospace is leading the consortium, with members including Assyst Bullmer, Airborne, Cobham Mission Systems Wimborne, Cygnet Texkimp, Des Composites, FAR-UK Ltd, Hexcel Composites, Hive Composites, LMAT, Loop Technology, McLaren Automotive, the National Composites Centre, Rafinex, Sigmatex (UK) and Solvay Composite Materials, with collaboration and investment support from Axillium Research. The consortium will be led from GKN Aerospace’s £32 million Global Technology Centre in Bristol and will support up to 130 jobs through 2023/24.

Composites manufacturer develops anti-viral composite solution

Exel Composites has launched its anti-viral Protector solution, which has been proven to reduce the viral load of strains of human Coronavirus. Results have demonstrated a 99.44 per cent reduction in viral load after one hour, and 99.99 per cent after 24 hours, compared to untreated composites. The solution consists of an anti-viral additive that is mixed into the composites’ resin during the manufacturing process of both Exel’s fiberglass and carbon fibre profiles. Ensuring consistent distribution throughout the resin, the additive permeates the composite to provide protection against viruses throughout the material’s lifecycle.

John Pritchard, President of the Civil Airframe Division at GKN Aerospace, said: “Accelerating the next generation of lightweight, cost-effective advanced composite technologies is critical for the aerospace and automotive industries and its move to more

energy-efficient aircraft and vehicles. Ensuring we can not only develop these technologies, but also manufacture them at a high rate across the UK supply chain, will maintain our position as an industry leader and underpin our commitment to sustainability.”

Accelerating the next generation of lightweight, advanced composite technologies is critical

Ricoh 3D launches powder-based 3D composite Richoh 3D has introduced carbon fibre composites to its line-up of highperformance materials through a partnership with composite-based manufacturer Impossible Objects. Ricoh 3D is one of the first AM service bureaus to make 3D printed Carbon Fibre PEEK and Carbon Fibre PA12 materials commercially available in Europe for functional prototypes and small batch production. The unique printing process leverages high-speed 2D graphics technology to create a high performance, reinforced composite part. The end result is extremely cost-effective parts with impressive

strength-to-weight ratios and a performance similar to that of metals. This is especially good news for aerospace and drone manufacturers, as fine features and flat parts were previously impossible with FDM and FFF technologies due to the short, chopped fibre formation and lamination between layers, causing parts to fall apart under

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force. Mark Dickin, Additive Manufacturing & Moulding Engineering Manager at Ricoh 3D, said: “Composites are set to be an area of huge growth in additive manufacturing in the coming years, so we are proud to be working with Impossible Objects to be at the forefront of the European movement.”

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Submissions open for Composites UK 2021 Industry Awards Composites UK has announced applications for its 2021 Industry Awards are now open. The annual award presentation celebrates the achievements of the UK composites industry, in categories covering company efforts and successes on an individual level. The categories will include innovation in composite design, manufacture and materials, as well as recognising start-up businesses, health and safety practices, sustainability projects, and investment in

employees. Exceptional employees and trainee/ apprentices will also be showcased. Entry into the awards is free-of-charge, however the shortlisted two companies/individuals in each category will be expected to attend the awards dinner, on Wednesday 3rd November at the National Motorcycle Museum in anticipation of a win. Claire Whysall, Composites UK Communications Manager, said; “We’re excited for the return of the awards dinner

in 2021, having had to postpone it due to COVID-19 last year. From speaking to our members, they are looking forward to catching up with their peers in the industry. “Entry into the awards is open to both members and non-members of the Association, with the deadline being 5pm on 30th July.”

We’re excited for the return of the awards dinner in 2021, having had to postpone it due to COVID-19 last year. From speaking to our members, they are looking forward to catching up with their peers in the industry.

Jaguar Land Rover announces groundbreaking advanced composite project Jaguar Land Rover has announced it is preparing for future electric vehicles with advanced lightweight composite research that will help deliver increased range, greater performance and a more dynamic drive. The Tucana project is a four year programme to make the UK a world leader in low-carbon technology, helping prevent 4.5 million tonnes of CO2 emissions between 2023 and 2032 by accelerating mainstream use of electric vehicles and making vehicles lighter to both decrease tailpipe emissions and reduce energy consumption of electrified powertrains. The company says the research will allow Jaguar Land Rover to develop lightweight vehicle and powertrain structures by replacing aluminium and steel with composites capable of handling the increased torque generated by high-performance

batteries, while improving efficiency and reducing CO2 impact. Jaguar Land Rover aims to increase vehicle stiffness by 30 per cent, cut weight by 35kg and further refine the crash safety structure through the strategic use of tailored composites, such as carbon fibre. Reducing the vehicle body weight will allow the fitting of larger batteries with increased range – without impacting CO2 emissions. By 2022, Jaguar Land Rover expects to have developed a fleet of prototype Tucana test vehicles. Led by Jaguar Land Rover, the consortium brings together world-leading academic and industry partners including the Warwick Manufacturing Group (WMG), Expert Tooling & Automation, Broetje-Automation UK, Toray International UK, CCP Gransden and The Centre for Modelling &

This project will allow the true environmental credentials of electric vehicles to be realised by enabling wider adoption of the technology and will propel Jaguar Land Rover and the UK supply chain into a world-leading position in low-carbon technology. Simulation (CFMS). Marcus Henry, Research Manager at Jaguar Land Rover, said: “The development of new lightweight body structures to complement the latest zero-emissions powertrains will be key as the electrification of our vehicle range continues. This project will allow the

true environmental credentials of electric vehicles to be realised by enabling wider adoption of the technology and will propel Jaguar Land Rover and the UK supply chain into a worldleading position in lowcarbon technology.” Ian Risk, Chief Technology Officer at CFMS, explained:

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“Tucana shows how new technology development can be optimised and accelerated with digital engineering. Using new digital design, development and manufacturing tools helps to deliver emissions reduction faster, so the UK economy can reach zero emissions quicker."

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EXTRUSION | NEWS Greiner Packaging invests over £3,700,000 in a new PET decontamination and extrusion line

Packaging’s factory in Dungannon, Northern Ireland, is a new worldclass decontamination unit which enables the removal of impurities and hence, creating a food-safe material. This is integrated with a greater material feed system which is directly linked to a new, state of the art extrusion line. This equipment and process arrangement gives complete flexibility with the capacity to utilise recycled input materials, virgin or a combination of both, giving total flexibility to meet

customer requirements. “Investing in these two new machines is the latest step in our continued commitment to innovate, increase capacity and reduce our carbon footprint,” says Greiner Packaging UK & Ireland Chief Executive Officer Philip Woolsey. “Since Greiner Packaging first introduced its K3 cardboard-plastic innovation in 2007, there has been continuous investment at our UK manufacturing facility. But alongside investing to create new packaging solutions, there has

been a constant focus on investing in improving our environmental sustainability performance and pursuing our goal to achieve a circular economy. We are working steadily towards the Dungannon plant becoming carbon-neutral by 2025.” He adds: “Installing the new equipment allows Greiner Packaging to integrate the supply chain, and it is planned to soon be able to include at least 30 per cent recycled content in all products. Rather than buying-in PET sheet and selling off any waste, we can now create recycled PET (r-PET) sheet onsite, and re-use excess material.” “Until now, we have only extruded polypropylene (PP) in Dungannon, but now we can extrude r-PET, and will soon also be trialling the extrusion of recycled polypropylene (r-PP).” “Currently, most of the recycled PET

Virtual seminar to cover the basics of plastics extrusion

components, temperature control, control systems, maintenance practices, screw and die design, among others. All participants will see a virtual borescoping demonstration, as well as lab demonstrations, and receive a virtual tour of Davis-Standard’s manufacturing and technical facilities. “This seminar has been extremely beneficial to customers who seek to improve the knowledge base of their engineering and operational teams to strengthen overall productivity,” explained John Christiano,

Davis-Standard’s Vice President of technology. “Although the seminar will be in virtual format this year, it still contains the same amount of

Greiner Packaging UK & Ireland has invested over £3,700,000 in a new PET decontamination and extrusion line to enable the use of more recycled materials in its market leading pot and tub range as well as continuing innovation with more sustainable materials. Recycled flake is cleaned and washed, however still requires further decontamination. Installed at Greiner Below: Greiner Packaging UK & Ireland, CEO, Philip Woolsey

Davis-Standard is offering its “Basics of Plastics Extrusion” seminar, in virtual format, April 13–15, 2021. This 3-day interactive seminar will cover the fundamentals

Until now, we have only extruded polypropylene in Dungannon, but now we can extrude r-PET, and will soon also be trialling the extrusion of recycled polypropylene.

of plastics extrusion, composition and properties of various polymers, and the mechanics of essential downstream processes. Session topics include extruder

This seminar has been extremely beneficial to customers who seek to improve the knowledge base of their engineering and operational teams to strengthen overall productivity.

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supply available in the UK originates from plastic bottles, a very clean source. The new integrated line enables ‘tray-to-tray recycling’ – meaning that we can process material from a wider variety of sources and utilise a lighter grade of recyclate. This novel process and equipment arrangement will provide greater capability to control and enhance material characteristics to better meet customer’s product specifications. Using the new inhouse r-PET capability, a wide range of 100 per cent r-PET K3 products are now available. Greiner Packaging’s adaptable, popular and successful K3 cardboardplastic combination, reduces plastic consumption, while creating eye-catching packaging and it can be recycled efficiently, as the cardboard and plastic can be easily separated.

robust instruction and interaction with our engineering and technical teams. We look forward to an outstanding session.”

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FEATURE

“WE HAVE BUILT A SUPPLY CHAIN TO ENSURE MATERIALS ARE ALWAYS AVAILABLE”

W WITH THE PLASTIC PACKAGING TAX ON THE HORIZON, THE INTRODUCTION OF RECYCLED CONTENT CAN PRESENT NEW CHALLENGES IN EXTRUSION. HOW DO MANUFACTURERS MAINTAIN PRODUCTIVITY LEVELS USING RECYCLED CONTENT? CHASE PLASTICS GIVES BP&R READERS AN INSIGHT IN HOW TO DO JUST THIS.

he imminent UK Plastics Packaging Tax is designed to incentivise flexible packaging producers to introduce recycled materials into their packaging applications. Presently, such manufacturers typically use virgin materials that conform to a tight specification. As each delivery of virgin polymers is consistent with the previous one, they can manage their extrusion processes and quality procedures to optimise productivity and resource efficiency. However, the Plastic Packaging Tax means manufacturers will have to introduce at least 30 per cent recycled content to avoid the tax of £200 per tonne and so remain competitive. Designed to stimulate increased levels of plastic waste recycling – thereby diverting it from landfill or incineration - the tax provides an economic incentive for manufacturers to use recycled material in the production of plastic packaging. In an industry used to operating with tight margins, the introduction of recycled content presents new challenges for both process and quality control. Materials with inconsistent properties impact extrusion efficiency through necessitating frequent machinery adjustments or process modifications. So, how do manufacturers maintain productivity levels using recycled content? As with virgin polymers the answer is material consistency. To maintain manufacturing efficiency levels, it is imperative that the suppliers of recycled materials also recognise the critical nature of material consistency in the extrusion process and take the necessary actions to ensure that recyclates do not deviate from agreed specifications.

Until now, many plastic packaging manufacturers have been reluctant to use recycled content in their extrusion processes due to their concerns regarding inconsistent material and unreliable supply. While it is unrealistic to expect the recycled polymers supply chain to meet the exact same standards as virgin polymers, it is vital that recyclate manufacturers supply solutions that not only protect extrusion productivity levels but which also ensure the production of a high quality end product. Chase Plastics, a manufacturer of recycled polythene pellets, is a vocal advocate of material consistency in the production of recyclates. Their multi-stage recycling, blending and pelletising processes enables the production of consistent high quality recycled polythene pellets to an agreed specification. “Our success is down to our ability to consistently meet agreed product specifications.” remarks David Harris, CEO at Chase Plastics. “Our objective is to facilitate the ongoing operation of stable, consistent processes by our customers. Tight tolerances on product characteristics, feedstock origins and the recycling technologies we employ ensure the material consistency required is achieved again and again. Importantly, in the fastpaced extrusion industry where responsiveness is key, we also meet the challenge of confidence in supply and this challenge is greater with recycled materials. We have built a supply chain to ensure materials are always available.” Extrusion technologies continue to make impressive advances as does the technical expertise of UK manufacturers. The forthcoming Plastic Packaging Tax presents an opportunity to utilise both in the incorporation of recycled content to create a new generation of high performing plastic packaging that contributes to a circular economy.

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MACHINERY | NEWS Dugard Offers Blueprint for Success Machfab Engineering has invested in 3D printing and CNC machine tools from Dugard. Ian Hazlehurst, Machfab Engineering Ltd Director, said: “Two years ago, we had the idea to diversify the company, we have always predominantly been a conventional machine shop and we wanted to get into CNC machining - but we wanted to do something different to everybody else. So, we went down the 3D

printing route to get into additive manufacturing. We worked with the Liverpool Innovation Fund and we managed to get funding from them to purchase our first 3D printer.” The company bought a Stratasys Fortus 380mc. Explaining the reason for buying the machine, Hazlehurst continues: “We bought this machine to get into additive manufacturing and primarily prototyping for R&D work. If we can

get a project where we get a final part, we would never be able to offer the service to manufacture that part. So, this is why we invested in CNC machining to offer customers the full package.” Another reason the company opted to invest in CNC machine tools was that it was not always competitive on batch work or small production runs of components. Alluding to this, Hazlehurst adds: “We weren’t competitive on volume work as everyone has CNC machines and we had conventional machines, which meant our production times were a lot longer. So, we decided as part of the project with the 3D printer to invest in two Dugard machining centres.” The subcontract manufacturer simultaneously purchased a 3-axis Dugard 1100 machining centre with a rotary table as well as a Dugard

1000E machining centre. He continues: “The story behind the Dugard 1000E machine is that Dugard actually gave us the machine as a ‘test machine’ as we had initially decided to buy the larger Dugard 1100. The Dugard 1000E machine was installed for our guys to learn on - and we liked the machine so much, we bought it as well as the larger Dugard 1100

machine.” For a company that had not yet stepped into the realms of CNC machining and had a history steeped in conventional machining, the initial loan of a CNC machining centre to prepare the North West Company for CNC production goes a long way to demonstrate the service provided by Brighton based Dugard Machine Tools.

there will always be the occasional issue, which is where this level of rapid support becomes invaluable.” “Through FAR, our service engineers and

technicians will be able to consult with one another, in order to analyse issues together and reach an outcome more quickly. It’s a fantastic example of how the latest in augmented reality technology can allow us to help our customers keep their production lines running.” A key part of the software’s development has been a focus on ensuring it works in environments with low data transmission. This is combined with an intuitive user interface, which means it will be a viable option for most, if not all, users of FANUC machinery.

FANUC launches assisted reality service in Europe FAUNC has launched its new digital service FAR (FANUC Assisted Reality) in the UK, which provides quicker response times for maintenance issues on FANUC products. FAR is an app that uses augmented reality to facilitate remote support for FANUC customers. It allows service engineers to identify problems via real-time video and overlaid digital content, which ensures the correct spare parts and tools can be determined during the initial call. Despite already

boasting an unrivalled 28-hour average response time from initial call to machine repair, the introduction of FAR is anticipated to bring this down to less than 24-hours. It forms part of FANUC’s commitment to providing ‘lifetime maintenance’, whereby customers can continue to receive support for as long as they are using the product. Tom Bouchier, Managing Director at FANUC UK, said: “We’re thrilled to be launching FAR in the UK, particularly at

a time when social distancing measures and travel restrictions are putting extra strain on manufacturers. While all of our machines are built to minimise downtime,

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WIP X GRIPS RESOUNDING SUCCESS

O OUR ‘WOMEN LEADING IN SUSTAINABILITY IN THE PLASTICS INDUSTRY’ SESSION HELD ONLINE AS PART OF THE GLOBAL RESEARCH IN PLASTICS SUSTAINABLY CONFERENCE (GRIPS) ON 17TH MARCH 2021, WAS A GREAT SUCCESS.

The panel discussion saw our four guest speakers, Dr Sally Beken, Katherine White, Kirsty Wood and Dr Anthea Blackburn, discuss the different sustainability routes into their careers and how their companies are leading the way. The last part of the online conference was dedicated to an insightful Q&A session. What was clear from our panel is that visibility of role models to encourage more women into the sector is vital and the benefits of mentoring will promote greater confidence in young women. OUR SPEAKERS Dr Sally Beken wears many hats! She is a Knowledge Transfer Manager in the Materials team at KTN, networking with individuals and organisations to make them aware of the opportunities and activities that are underway or upcoming in the UK. In addition, at the KTN she is also the Network Manager for the UK Circular Plastics Network. Her second hat is as an Innovation Lead at Innovate UK for the Sustainable Smart Plastic Packaging Challenge. Sally has also been a freelance polymer consultant focussing on polymer technology and worked in the medical sector developing elastomeric seal formulations patented for use in asthma inhalers. Katherine White, Commercial Director at Plastribution, was appointed to the company’s board of directors in 2011, making her the first female to have ever done so.

side of the business, from catalyst discovery and process development to new polymer product evaluation. Kirsty Wood has worked in the TPE industry for 9 years and is based in Manchester, UK. In her role as Development Technologist & Sustainability Lead for HEXPOL TPE she works on the development of progressive TPE compounds that meet new and emerging market demands and leads the team efforts in working sustainably. Commenting on the success of the online event, Grace Nolan, Content, Partnerships and Digital Lead, said: “It was great to host our first online session. We need to make diversity and inclusion more relatable, by ensuring there are visible role models at all levels. There needs to be transparency in progression, by listening and acting upon feedback, and starting early via school outreach initiatives.”

Katherine has a BSc in polymer science from Coventry University and has been involved with the woman-in-plastics initiative since 2019, being proactive in its support since.

We hope you enjoyed the session as much as us and don’t forget you have up to 90 days to catch up on the GRIPS Hub.

Dr Anthea Blackburn is a Team Leader at Econic Technologies, a UK-based company who offer an innovative catalyst technology that allows for the tailored incorporation of carbon dioxide in polymer manufacture, replacing up to 50 per cent of traditional oil-based raw materials, for application in the plastics industry. Upon completing her PhD in Chemistry at Northwestern University in the US, Anthea moved to the UK and has spent the past five years at Econic. During this time she has worked across and led multiple areas of the technical

Date for your diary 28th-30th September 2021

Following on from previous success with both networking events and seminars, Women in Plastics is set to hold its biggest event yet in 2021. At Interplas visitors will be able to network with the founders of Women in Plastics to find out more about the benefits of joining and opportunities available. There will also be information about how to support the initiative and promote gender equality in business, as well as information on how to recruit new talent and make a company attractive to all.

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PLANTMASTER BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com www.visionbms.com/plastics

RJG TECHNOLOGIES LTD Moulding Technology

INTOUCH 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.

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

Cycle time reduction Reduced scrap rates Improved process capability Higher yield and OEE

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

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

Kistler Instruments Ltd

Zero Defect Moulding – What’s your target? • • • •

Branson Ultrasonics

QUALITY MONITORING CONTROL

T: +44 (0)1733 232211 E info@rjginc.co.uk

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

VIBRATION WELDING

CONTROL SYSTEMS AND EQUIPMENT

PROCESS OPTIMISATION SOFTWARE

MONITORING

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

MACHINERY & EQUIPMENT

SILICONE MOULDINGS Technical Mouldings in

Silicone, FKM, EPDM, Neoprene, NBR Contact

WWW.MEADEX.CO.UK

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 www.britishPLASTICS.co.uk

BP&R BUYER’S GUIDE MACHINERY & EQUIPMENT Super Bluish Titanium Dioxide

HOT RUNNER SYSTEMS

CONTROL SYSTEMS AND EQUIPMENT QUALITY MONITORING CONTROL Kistler Instruments Ltd

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

METAL DETECTION

INJECTION MOULDING

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

and dosing

MOULD CHANGE

HEATING EQUIPMENT Metal Detection

Magnetic Separation

INDUCTION HEATING FOR PLATENS AND TOOLS MF Induction Heating

MASTERMAGNETS.COM

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

Permanent Electrostatic Magnets Separation BOOK YOUR FREE SITE VISIT TODAY

+44(0)1527 65858

Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 E: sales@mfinduction.com W: www.mfinduction.com

www.quick-mould-change.com

TO ADVERTISE HERE CONTACT MANDY O’BRIEN ON 01244 952519 RUBBER

SCREWS & BARRELS

DRYERS

Wanted

www.magog.co.uk

Rubber Manufacturing Company

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

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

In the first instance email us on rubberukp3@rubber.today

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

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

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

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

FILTRATION ALUMINIUM MATERIAL STORAGE BINS

Die-Sep mould separators & tippers improve tool room efficiency because they:

Off the shelf or made to order with very competitive pricing!

• Eliminate the need for pry bars and

hammers to open and close moulds • Eliminate jamming of leader pins and bushings • Eliminate damage to parting line and mold • Eliminate repetitive injury to wrists, elbows, shoulders and back • Increase safety, efficiency and morale!

Standard sizes available: 80l, 200l, 420l, 830l. Contact us today on 01827 265800 or visit www.summitsystems.co.uk Prices start from £428 10% reduction with offer code:

BPR18

Exhibiting at Interplas on stand DD10 Hall 3A

T: 01.262.767.9751 E: sales@diesep.com www.diesep.com

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

www.britishPLASTICS.co.uk

SECONDHAND AND RECONDITIONED Cooper Plastics Machinery

8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 719850 E: Cooperplastics@gmail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, fly knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.

DTL Machinery UK

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

TransXL International Ltd

Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

BP&R BUYER’S GUIDE MACHINERY & EQUIPMENT second hand & re-conditioned

BUSINESS FOR SALE

TESTING EQUIPMENT Gammadot Rheology Testing & Consultancy Services

Selling the Business?

Refurbished machines with fault and leak free guarantee. We buy & sell all manner of plasscs equipment.

Kingswood Business Sales are your industry experts with a proven track record of successfully selling companies like yours. Avoid the pitfalls - contact Paul Holohan in complete confidence on 07798 530684

Visit our workshop in Wellingborough, Northants. 01933 272747

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

kingswoodbusinesssales.co.uk

‘USED INJECTION MOULDING MACHINERY DEALERS’

Single Machines to whole plants purchased Tel: David 07540 633552 info@plasticinvestments.co.uk www.plasticinvestments.co.uk

Ultrasonic Plastic Welders New & Used

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

Tel; 01258 459257 Tel; 07730 413197

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

MAPRA Technik Co — BAREISS

INSPECTION & MEASUREMENT

Wanted

Branson - Mecasonic - Telsonic

HARDNESS - IRHD AND SHORE For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

new & used

For Sale &

Unit 5C, Leaton Industrial Estate, Bomere Heath, Shrewsbury, Shropshire, SY4 3AP T: 01939 291677 E: enquiries@gammadot.com W: www.gammadot.com Providing independant testing solutions to all your quality control, failure analysis & flow simulation data needs

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

MAPRA Technik Co – DOSS

MARCEL AUBERT – KAFER

For DOSS visual solution of Italy –Inspection & sorting machines for O’rings, Seals, Gaskets. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

SERVICES TESTING/CONSULTANCY

TRAINING

PRINTERS PRINTERS OF PLASTIC MOULDINGS Total Print Ltd

Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry

COMPONENT PRINTERS MONITORING

MOULDFLOW ANALYSIS

SOFTWARE

Improve OEE Reduce downtime Increase throughput Reduce scrap

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

60 Day Free Trial www.intouchmonitoring.com

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 www.britishPLASTICS.co.uk

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NEWS FROM THE FRONTLINE

IN THE LATEST INSTALMENT OF HIS EXCLUSIVE COLUMN FOR BP&R, DIRECTORGENERAL OF THE BPF, PHILIP LAW FOCUSES ON THE OPPORTUNITY THE INDUSTRY HAS TO JOIN OPERATION CLEAN SWEEP, THE PELLET LOSS MITIGATION PROGRAMME OPERATED IN THE UK BY THE BPF SINCE 2009.

his month I am going to focus on just one topic and that is the opportunity the industry has to join Operation Clean Sweep. This is an opportunity for the entire sweep of the plastics supply chain from raw material production all the way through to recyclers. It is suitable for any company which is handling pellets in any quantities from thousands of tonnes per annum down to just a few kilos. It is very relevant for logistics companies, port authorities and shipping companies. It’s not just a scheme for the UK, it’s international and started off in the Unites States with the old Society of the Plastics Industry (now the Plastics Industry Association). The BPF was the first organisation to pick this up outside of the USA. We now have some 235 companies (who represent an estimated 60 per cent of all plastic pellets handled in the UK) currently signed up which makes the UK a global leader in terms of industry commitment. What do you have to do? Your company signs a commitment to implement basic housekeeping measures which prevent pellets escaping from your plant and ending up in the riverine and marine environments. Our long coastline and intensive river and canal network have given the issue, rightly or wrongly, a particularly high profile. We provide a Guidance Manual, written housekeeping procedures to aid implementation and stage regular seminars/ webinars to update adherents on the best tools and methods used to retain pellets on the factory site. All companies signing up are listed on our website.

This is an opportunity for the entire sweep of the plastics supply chain from raw material production all the way through to recyclers.

If you are not already signed up I personally urge you to consider joining Operation Clean Sweep. Your company can sign up on www. operationcleansweep.co.uk and join the growing list of adherents. WHY JOIN THIS MOMENTUM? • Operation Clean Sweep shows that the plastics industry is setting a positive environmental agenda and has demonstrated to government, NGOs and customers that the industry is a problem solver. • Not only does it increase your company’s sustainable use of materials by preventing leakage of pellets it improves your company’s image as a progressive operator and an industry leader promoting best practice. • Operation Clean Sweep is increasingly on the radar screen of customers and other downstream users and your participation can be used as a selling point. • Signing up to Operation Clean Sweep is a simple process, and a variety of resources will be provided to you to help your company prevent plastic pellet loss and implement best practice. Building on the success of the scheme, the BPF has worked in collaboration with the British Standards Institution (BSI) and a wide group of governmental and non-governmental stakeholders to create the first international standard on pellet loss prevention. PAS 510 is expected to be finalised later this year and can be used to verify implementation of the procedures laid out in the Operation Clean Sweep programme. It is addressed to any organisation in the supply chain which uses or transports plastic pellets. Operation Clean Sweep has won great acclaim. It shows that the plastics industry is taking strong action to address a public concern and increased numbers of firms signing up to it will certainly help the BPF demonstrate that voluntary action from the industry is an effective and credible way to prevent pellet loss to the environment. Should you require further information please contact my expert colleague, the BPf’s Senior Sustainability Issues Executive, Adela Putinelu, on aputinelu@bpf.co.uk

www.britishPLASTICS.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

OMOTIV UT

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SECOMID RANGE PA6 & PA66 compounds from the recycling of plastics

STARFLAM & STARAMIDE RANGE PA6 & PA66 ﬂame retardant

Snetor UK Limited I www.snetor.com snetor.uk@snetor.com 180E Park Drive Milton Park Abingdon, Oxon, OX14 4SE – UK I T: +44 (0) 1235 432610