BP&R April 2014

British Plastics

and Rubber

bp&r APRIL 2014

Temperature Control Perfect Technology Extrusion Machinery: Improvements and Efficiencies

Done and Dusted: Anti-Static Additives Driving Automotives

Temperature Control Tech Freezes Costs and Cycle Times

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bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk EDITORIAL Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com

SALES Group Advertising Manager: Lisa Montgomery T: +44(0)1244 680222 E: lisa@rapidnews.com

ART SAM HAMLYN T: +44(0)1244 680222 E: sam@rapidnews.com

Shale gas still splitting opinion

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non-fossil fuels were developed, as well arlier this month the triennial PVC as making the EU stronger. Peter Davis, conference took place, this year the Diretor-General of the BPF, who held on the sunny shores of chaired the session, backed Mottram’s Brighton. From sustainability and success sentiments wholeheartedly, stating he stories to studies and statistics, it was a well-attended event with some interesting “agreed entirely” with the need to utilise shale gas reserves. It insights. However, it would seem that once would seem that the argument over the use of “From sustainability and again, PVC has been drawn into battle, shale gas is still very success stories to much dividing opinion. In studies and statistics, it somewhat accidentally, between his keynote address, was a well-attended environmentalists and Jonathon Porritt, Founder event with some industry. What will happen of UK-based sustainable interesting insights.” in the long term remains development to be seen, but I for one organisation, Forum for will be interested to see the Future, outlined his visions for the PVC industry, suggesting to where the situation stands when I attend delegates that this should not be one that the next conference in 2017.

Speaking of industry events, this utilises fracking to tap into shale gas week saw the official registration for reserves in both the UK and Europe.

Interplas 2014 open. Anyone wishing to Porritt told the conference that the visit the show can now book their place use of shale gas would only provide a for free, giving access to not only 400 “quick fix” and that despite the obvious exhibitors, a three-day conference benefits being reaped in North America, programme and related technology these would only be short-lived. Instead, sessions, but also access to neighbouring he suggested that the UK would be better technology shows and the opportunity to off spending its resources on research network with some of the industry’s into the development of biotechnology leading lights. Head to and biofuels in order to ensure a www.interplasuk.com/register.html to sustainable future for the industry. This register and read more about the event view was later contested by Roger on page 43.

Mottram of Ineos ChlorVinyls, who made clear his opinion that utilising shale gas Enjoy the issue. reserves in both the UK and Europe Leanne Taylor, Editor would be a way of ensuring supply whilst

PUBLISHER Mark Blezard T: +44(0)1244 680222 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Unit 2, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (01244) 671074 © 2014 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.

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THE BIG STORY Adding the magic touch to modern temperature control

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anufacturer of temperature control units, Regloplas AG, says its latest range has the “magic formula” for the increasingly complex requirements of customers, in that it is energy efficient, universally compatible with a wide range of equipment and inherently user-friendly.

The Swiss-based company says its new generation of devices give manufacturers of injection moulded, extruded and die cast parts more scope for selectable options in units that are both small and compact enough to fit into the smallest of spaces.

Flow control: high-class quality with energy-saving potential Along with the classic energy consumers such as cooling units and electric heaters, pump technology is a significant factor in energy demand. This is where flow control comes in, as it optimises the energy balance in intelligent ways.

Regloplas says it is the first manufacturer to offer temperature control devices that regulate pump output and flow rate. The pump’s full power is only called upon during start-up; the controller automatically reduces the output to the minimum necessary during normal operation. This restriction of the pump speed, for example because less flow or pressure is required to maintain the set temperature, leads to a reduction in energy consumption. A reduction in pump speed of 20 percent reduces energy consumption by 50 percent. When the pump speed is halved, only 12.5 percent of the energy is consumed. vario system: high-class quality for application-specific uses Each manufacturing process requires specific temperature control solutions. The modular vario system enables a process-specific, cycle-dependant supply or removal of energy. The modular vario system from Regloplas is precisely matched to customer needs and processes. Cooling and heating control are perfectly combined, and even temperature shifts from 250 to 40°C are overcome within seconds, says the company. Production cycles are reduced by up to 50 percent and cost-effectiveness is improved long-term.

The modular combination of Regloplas standard temperature control equipment and the ‘Energy Battery’ technology, where surplus energy is stored in the battery and called upon when needed, optimises the energy balance. This can reduce the energy costs for heating and cooling the cavity during a cycle by up to 80 percent.

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High-class technology for standard applications The new 90smart and 150smart temperature control units in the Regloplas range have been designed especially for standard applications. Building on the proven mechanical basis, which has been significantly developed in certain key aspects, the temperature control units have modern control technology and comprehensive monitoring options. The new smart units set new standards in terms of equipment and convenience in this segment, says Regloplas.

The main feature of the smart units, explains the company, is the new RT70 control concept. This combines simple operation, the latest technology, convenient temperature regulation options and extensive safety features.

The 90smart unit from Regloplas designed for energy efficiency in standard applications

The RT70 control unit has a TFT colour display, which in terms of readability and conveying information is equivalent to the high-end RT100 control unit in the range. The functionality and user interface of the RT70, with clearly labelled selection buttons, enable intuitive operation anytime and anywhere, as well as quick access to all necessary parameters.

The smart line of units is said to be even more compact and slimmer than the existing Regloplas AG unit series. Shorter, narrower and lower, several units can be located in a very small space. The arrangement of all the controls on the front makes it easier for the user to set up and monitor parameters. Although the housings take up very little space, the smart line still has the latest technology and functionality.

In the smart units, Regloplas already uses high-quality solid-state relays (SSR). A technology that guarantees heating without wear and tear, which in turn significantly improves the service life of units and the production equipment they control.

The safety features of the RT70 also go far beyond the standard level of equipment, says the company. They include numerous automatic monitoring functions, wide-ranging alarm functions and safeguards to prevent unintentional or unauthorised changes. Settings can be downloaded and stored quickly and easily via the integrated USB port.

The range of Regloplas temperature control units are available in the UK and Ireland through Motan Colortronic. further information: www.motan-colortronic.co.uk

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on the cover

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bp&r BRITISH PLASTICS &RUBBER

contents april 2014

on the cover Adding the magic touch to modern temperature control Manufacturer of temperature control units, Regloplas AG, says its latest range has the “magic formula” for the increasingly complex requirements of customers, in that it is energy efficient, universally compatible with a wide range of equipment and inherently user-friendly.

See page 4

22-29 ]FEATURE temperature control Free cooling freezes energy costs by up to 70 percent

30-32 FEATURE

REGULARS INDUSTRY NEWS

08

Reclamation and Recycling

38

Materials

40

FROM THE FRONT LINE

42

SOFTWARE

43

BUYERS’ GUIDE

44

construction and infrastructure A fresh face for the construction industry

3 EDITOR’S LETTER Shale gas still splitting opinion

14-17 FEATURE

33 FEATURE PVC 2014 review On sustainability, shale gas and success so far

machinery Technology Days Review: Resurgence in automotive a driver for Arburg sales in UK

34-36 FEATURE

19-21 FEATURE

Simpler, more cost-effective extruder design launched

extrusion machinery

masterbatch and additives

35

Focus on flame-retardants and anti-static

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Industry News

a Budget to boost investment and productivity for plastics

D

irector-General of the British Plastics Federation (BPF), Peter Davis, has said the Chancellor’s Budget statement was “good for manufacturers” and should boost investment and productivity for the plastics industry.

Measures implemented by the Chancellor that were welcomed by UK After an overall positive manufacturers included response to the doubling the lending for Chancellor’s Budget export finance to Statement from UK £3 billion, cutting manufacturers, Peter interest rates by a third freezing the carbon Davis, Director-General and price floor. of the BPF and Nigel In February, the BPF Flowers, Chairman of the was one of a number of PMMDA, share their views associations that on how it might affect signed an open letter to the plastics industry. the Chancellor proposing a number of measures they felt would be beneficial to continued and sustainable economic recovery and growth, one of which was increasing the annual Investment Allowance.

“This is a good budget for manufacturing,” commented Davis. “In the BPF-led Seven Associations letter to the Chancellor in February we asked him to extend the £250k tax-free allowance to upgrade equipment and expand production. In fact, he has doubled it to £500k until December 2015. This will boost investment and productivity in the plastics industry.”

Nigel Flowers, Chairman of the PMMDA, added: “Following the recent budget announcements the good news is that the government is at last fully supporting manufacturing in the UK. Doubling the annual investment allowance encourages manufacturers to invest in new and efficient technology, enabling them to be more competitive. The OBR estimates up to £1billion of investment – great news for machinery and equipment suppliers alike.”

Davis praised the Chancellor’s doubling of UK Export Finance’s direct lending programme to £3bn and to be more proactive in stimulating export. “This will greatly help SME’s particularly to start exporting. Our trade deficit in goods was £106bn in 2012. We must reverse that,” he added.

On the extra £85 million for apprenticeship grants, both men agreed this would directly benefit the plastics industry.

Davis said it was a welcome initiative at a time there is a “growing skills shortage”, with Flowers adding “I welcome both the commitment to apprenticeships and the additional funding to support higher level apprenticeships right up to post graduate level. Coupled with the implementation of the Richards Report, this will help us to strengthen our manufacturing skills base.”

The Chancellor, as widely expected, capped the Carbon Price Support Rate from 2016-17 to 2019-20. “Capping the rate and extending the compensation scheme for energy intensive industries such as chemicals should benefit the plastics industry in stable or lower prices for the raw materials and additives they purchase,” continued Davis.

Despite the good news, however, Flowers did warn that there are some risks, with the laws of unintended consequences potentially coming into play. “Companies will respond positively to the Annual Investment changes, but this may simply bring forward decisions and lead to a gap further down the line, especially if companies are not confident that the incentive (or recovery) will last,” he said.

“Overall, I think we have an environment which is encouraging investment in manufacturing and skills – which can only be a good thing in both the short and long terms.

After all, to be successful we have to add value, and that means making things – lots of them.”

Finally, Davis had an innovative suggestion in response to the Chancellor’s plans to introduce a new £1 coin in order to combat the wide counterfeiting of the existing one. “ Why not [have] a plastics £1 coin, in which far more anti-counterfeiting devices are possible, as is the case with plastic bank notes?” further information: www.bpf.co.uk www.pmmda.org.uk

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Industry News

news Export Success: Meech’s sales growth is far from static Meech International has reported 11 percent increase in overall sales for its 2012-13 financial year, stating a consistently positive performance in China resulted in a rise in sales in the region of 45 percent, a solid increase on the previous year’s figure.

The company, which develops and manufactures electrostatic controls and related solutions for the plastics industry, says there has been steady growth in its exports sales, with these accounting for 81 percent of overall business.

“We are constantly looking to explore new markets abroad and not focus exclusively on business in the UK and mainland Europe,” commented Meech’s CEO, Chris Francis. “This year saw a lot of our growth come from China, but at the same time we also recognised Latin America as an emerging market worth investing in, and it has now been incorporated into our strategic growth plan.”

Meech says the latest sales figures indicate its static-control technology was of key importance. Having made significant investment in Q1 with the launch of its new Hyperion static range, further enhancements were made to the products in the initial part of 2013. In

What’s in your

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fordshire Meech HQ in Ox

addition, a particular focus was put on the launch of the CyClean non-contact webcleaner, which the company says has strengthened its web-cleaning product offering — allowing customers to choose from a complete range — and has been rapidly taken up in the market.

The company has also expanded and reorganised its production areas, leasing an additional building located close to its head office in Oxfordshire in September 2013. The 4000 sq.ft property is now the main production facility for web-cleaners, as well as its IonRinse and JetStream product ranges. The new building also houses research, development and engineering for all Meech product ranges, including the static control and Air Technology ranges. This has freed up additional space in the main building for increased production of other ranges.

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Nampak Plastic s in the UK is m ilking the succes lightweight plas s of its tic milk bottle, kn own as Infini. Si release in 2012 nce its , the company ha s sold over 500 bottles into maj million or retailers. Acco rding to the com Infini has reporte pany, dly saved 34,000 tonnes of carbon 16,000 tonnes of material per and year since its la www.infinibo unch. ttle.com

The reorganisation has also allowed the creation of a dedicated training and testing area.

The company has also increased its resources, employing a further four staff in the UK, ranging from positions such as Production Managers and Web Cleaning Specialists to roles across other departments, including sales, accounts and manufacturing. This takes the total number of full time staff to 62, which is expected to grow during 2014.

“In order to introduce new products to the market, we have invested heavily in our premises and our sales structure to ensure we have the right equipment and personnel to service our clients in the various industries we operate in,” added Francis. further information: www.meech.com

Prizes in Plastics: Is your design fit for the podium?

The Horners Award for Plastics Innovation and Design, as well as the Bottlemakers Award are now open for entries.

Any outstanding product, machine or process could be eligible to win the Horners Award. Entries are judged from the viewpoint of their significance in the UK through the imagination and appropriate use of plastics. Previous winners have included the ‘Airbus A350 XWB Composite Rear Spar’; ‘Birthing Baby’ and the ‘Cycloc’ storage system.

Entries for the Bottlemakers Award must be a plastic bottle, jar or hollow container, made by any process including extrusion blow, injection blow or injection stretch blow moulding, as well as injection moulding or vacuum forming. The 2014 competition is also accepting entries manufactured via rotational moulding for the first time.

“The Bottlemakers Award is a prestigious accolade with a number of valuable commercial benefits attached.

Last year we again saw a record number of entrants all demonstrating high levels of execution and exemplary creativity in design,” said Keith Pinker, the Master of the Horners Company.

Application forms are available to download from www.hornersaward.co.uk and entries for both awards must be received by the deadline of 25th July 2014.

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St David’s Audrey John (L) and Ann Griffiths (R) with Prime Minister, David Cameron

Prime Minister visits “Pembrokeshire success story” A Pembrokeshire-based manufacturer of precision plastic components recently played host to the Prime Minister, to demonstrate its manufacturing capabilities and reveal its ambitious plans for growth, despite being affected by the recent floods.

St Davids Assemblies Ltd, a supplier of components to the automotive and domestic appliance industries, says it experienced increased manufacturing activity during 2013 resulting in the employment of an extra 10 staff.

During the visit, David Cameron met with senior managers who outlined their plans for the business’ future, as well as speaking with employees, many of whom have been personally effected by the recent floods in the surrounding areas.

Also in attendance on the visit was local MP, Steven Crabb, who said St Davids Assemblies was a “Pembrokeshire success story” that signified the move towards economic recovery in Wales.

“Here we are in the far north of Pembrokeshire, who would have thought manufacturing would still exist in a place like this?” he added. further information: www.stdavidsassemblies.co.uk

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training & apprentices

news There’s Summit special at new training facility Ancillaries supplier, Summit Systems, is lending its support to what it describes as an “exciting” new UK training facility in order to help develop young talent within the industry.

The facility, at RPC Containers’ site in Oakham, has been set up following similar successful projects within the group’s European plants in order to address the growing skills deficit in its UK cluster as the average age of the engineering workforce increases.

So it can offer eight apprenticeship places per year, investment has been made in a custom-designed training centre, as well as staff, to provide a solid, structured programme utilising instructors who continue to work within the core business.

Within the new centre, Summit Systems has supplied ancillary equipment and visual training support aids, as well as making the extensive knowledge of its Technical Engineers available to RPC

The training facility at Oakham

Containers in order to broaden the knowledge of the trainees.

“Summit Systems appreciate only too well the importance of continuing to bring through new blood within the industry,” commented Mike Jordan, Managing Director of Summit Systems. “Our own experiences with apprenticeships have been very positive. This whole project is on another level and I applaud RPC Oakham for stepping up to the plate to address the issue.”

RPC says it has found that colleges are unable to offer the balance of practical skills, work readiness and added specialisms that it needs for new trainees

in order for the business to continue to grow.

Bruce Margetts, RPC UKIM Cluster Manager, said: “The support for our vision to kick-start serious apprenticeships relevant to the plastics processing industry has been gratifying. The opportunity to inject skills across our own workforce and benefit other local companies and industrial partners has to be a positive step.” further information: www.summitsystems.co.uk www.rpc-group.com

Students get to trial the new facilities

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Training academy aims to create skills pool Leicester-based engineering plastic solutions company, Nylacast, has recently opened an on-site Engineering Training Academy, which it hopes will help combat the UK skills shortage and create a resource pool of skilled engineers.

The company says opening a training academy was “the next progressive step” in plugging the engineering skills gap, however, it stressed the new facility will not only be utilised by students, but also to upscale the skills and knowledge of the current workforce as well as rewarding the loyalty of long-serving employees with structured training programs and opportunities to further their knowledge and gain qualifications.

“All of us at Nylacast are very excited and enthusiastic about the investment we have put into the Academy; there is a known skills shortage within Engineering which needs to be addressed,” said Mussa Mahomed, Group CEO. “Not only does the Academy provide us with a competitive edge in industry but also allows us to

focus our continuous investment in our most valued assets, our people and their dedication.”

The Engineering Training Academy features a number of dedicated teaching rooms for various training topics and methods, including a state-ofthe-art engineering simulator room, as well as a number of scaled down manual machines, which Nylacast says will provide the students with vital skills and experience on core engineering aspects.

With a dedicated facility now in place, Nylacast says it is looking forward to increasing the awareness of engineering within schools, colleges and communities. Ian Mallabone, Group HR & Training Manager said: “These are exciting times at Nylacast, not only will the Academy be used to house our current training and apprenticeship schemes, but importantly will allow us to expand on our learning and

development as a company, both internally and externally, to help bridge the engineering skills gap and help build the engineers of tomorrow.” further information: www.nylacast.com

Hydraulics Calibration & comprehensive seal replacement ensures leak free / trouble free operation.

Injection 15 point check – full report on all parameters, ‘zero tolerance’ replacement of worn components.

Safety Circuits Electrical & hydraulic safety circuits must be in full working order.

Clamp 12 point check; clamp force recorded; any worn components replaced; full service carried out.

Control Full test of all functions & non standard modifications removed.

Final test run with a mould .

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We run a 2500 cycle test to evaluate each machine before it’s refurbished. Then we clean and repaint the machine, and carry out over 100 checks, replacing any worn parts.

Finally, we run another 2500 cycles with a mould.

Fully documented refurb process

“After purchasing 15 machines over a 10 year period we still choose STV as a preferred supplier of top quality refurbished moulding machines.”

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So when that machine goes on sale. we can say, hand on heart, that it’s as close to new condition as practically p ully document Our customers have the peace-of-mind of a fully the extremely high cost of buying new. And to prove our point, buyers keep coming back for more!

Check out our website to see what some of them have said.

We refurbish all the leading brands of injection moulding machines, as well as all kinds of ancillaries from conveyors to recycling systems. And if you’re looking for a simple and transparent way to buy or sell used machinery, don’t forget STVconnect, our famous on-line brokerage service.

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Engineering Passion

news Poland one of “most important markets” for Wittmann Battenfeld Wittmann Battenfeld will present the latest in its portfolio of high-tech injection moulding equipment at the Plastpol trade fair in Poland next month, a market it says is “one of the most important in Europe” for the company.

The company says the Plastpol event, held in Kielce from 27-30 May, is a significant platform for the company to present its highlights in both machinery and process technology.

At this year’s event, Wittmann will exhibit an application from the field of multi-component technology with in-mould assembly. On an HM 180/525H/210S multi-component machine with ServoPower drive, an atomiser for the cosmetics industry will be manufactured

from PP and SEBS (TPE) with a 4+4+4 cavity mould. A process known as IMA (In-Mould Assembling) makes it possible to produce complex hollow parts in a single step. The two half-shells are brought into an overlapping position by means of an adaptive index platen drive, which cooperates with a Wittmann robot.

In this position, the parts are subsequently joined together and sealed by overmoulding. The Wittmann robot simultaneously handles the removal of finished parts and deposits them on a conveyor belt.

The second exhibit will be a machine from the all-electric EcoPower series. Screw-in dart tips weighing no more than 0.3g will be produced from POM on an EcoPower 180/750 with a

For injection mould tools, delivered on time and in budget, supported by expert advice, professional service and with agreed tool-life guarantees, contact Alliance Tooling.

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Atomiser for the cosmetics industry

smart plastic injection mould design and manufacture Alliance Tooling Our unique work SMART approach means we will not be beaten on lead times, offer value that is second to none and never compromise on quality to meet your specification. All of our injection mould tools are backed by genuine tool-life warranties. That is why clients who try our service come back time after time for all their injection mould tooling requirements.

32-cavity hot-runner mould, with narrow distances between cavities and a fully clean-room-compatible, electromagnetic needle drive.

Machinery supplier sees 50 percent increase in sales Premier Moulding Machinery (PMM) has announced a 50 percent increase on year-on-year sales, revealing it is taking on additional staff as well as moving to new premises.

The Buckinghamshire-based company, which is the UK supplier and service agent for Haitian and Zhafir injection moulding machinery, says the news comes ahead of the launch of an “innovative new product”, to be launched by Zhafir during Q3 of 2014.

“On the back of several successful years, in which we have seen a 50 percent year-on-year increase in sales, we welcome Rachael Bell to our team, as a Sales Support Administrator,” said Richard Hird, Sales Director. “We are also in the process of recruiting an additional sales person to support our current growth rate.”

The company has also revealed it is due to move to a new, purpose-built UK facility in early May. “This new unit will allow us to have a dedicated demonstration area and to be able to exhibit mouldshop best practice to those who visit our working showroom,” commented Paul Hulin, PMM’s Managing Director.

“All of this will take place against an innovative new product, to be launched by Zhafir during Q3, and the availability of the 550 – 950t two platen Jupiter II series from July 2014,” he concluded. further information: www.pmmuk.net

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mail: info@alliancetooling.co.uk tel: +44 (0) 1162 750584

PMM is the UK supplier of Zhafir and Haitian injection moulding machinery

e the Area Mike Madden has becom UK’s new el Eng Sales Manager for region ds lan Mid st We and Wales

www.kraussmaffei.com

Rapid growth sees new UK sales area for Engel Engel has added a new regional sales area and dedicated manager as a result of “rapidly growing” machinery sales in the UK. Mike Madden, who has been promoted to the position internally, will manage the new area in Wales and the West Midlands.

“With Engel UK winning an increasing share of the growing UK machinery market, it became clear to the management that in order to serve the market properly, it would be necessary to increase the size of the sales team,” commented Graeme Herlihy, Managing Director of Engel UK. “Mike has been with Engel UK for almost 20 years, and has been Training Manager for the last 13. With his vast experience gained in the training position, no one knows the product better than he does. This will bring tremendous benefit to his new role in the support of customer projects,” Herlihy continued.

The new Wales and West Midlands area extends up to Cheshire and Derbyshire in the North. The other three re-aligned territories within the sales team are: Ireland and South West England, South East and East Midlands and Scotland and Northern England, covered

by Steve Taylor, Bill Robbins and Robin Hornsby respectively. further information: www.engelglobal.com

The Romi machines are used in the manufacture of domestic ventilation products at Titon

Case Study: Energy saving is a breeze for Titon =Titon, a market leading manufacturer of domestic ventilation products and window and door hardware, says it has reduced its energy bill and improved efficiency with an investment in two new Romi Sandretto plastic injection moulding machines, an EN 150 and an EN 100.

Romi Sandretto measured the energy usage on the machines being replaced before demonstrating Titon-specific work on the EN technology in order to generate the cost savings.

“The EN 100 replaced a 75 tonne machine but despite the step-up in pressure capacity, the energy usage is down from nearly 70p/hour to 30p/hour.

The EN 150 replaced a 130 tonne machine but again, the electricity costs are down from 103p/hour to 34p/hour,” commented Lionel Holmes, Titon’s Operations Manager based at its Haverhill plant, which has 16 plastic injection moulding machines.

The ISO 14001-certified company is reportedly also showing a significant

reduction in carbon emissions as a result of the investment and an improvement in quality means that its previous four percent re-ground waste level is down to zero, further reducing energy consumption.

Titon, which says it is seeing a slight improvement in the economic climate post-recession, says productivity at its factory has increased, with a reported 25 percent improvement in set up times and a 30 percent reduction in cycle times. The combination of reduced energy saving and improved efficiency, including reduced running times and related labour costs as well as an uplift in work throughput, means that Titon predicts a return on investment within three years.

The machines handle a wide range of mid-size parts including airbricks as well as smaller mouldings for trickle ventilators. further information: www.sandretto.co.uk

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Engineering Passion machinery

The technology days attracted over 6,900 visitors

Resurgence in automotive a driver for Arburg sales in UK

H

elmut Heinson told press at Arburg’s Technology Days that the resurgence in the automotive market in the UK, as well as the trend of re-shoring is driving sales of injection moulding machines in the country.

Speaking at the company’s headquarters in Lossburg, Heinson said that they had seen significant pickup in the number of companies re-shoring in both the UK and the USA from lowcost Asian markets compared to three to four years ago.

During the event, the company showed several new innovative technologies and applications for the automotive sector, including long-fibre injection for the production of lightweight pedal levers produced on a 400 tonne servo-hydraulic Allrounder 820 S with intergrated automation technology.

It also demonstrated its proficiencies in the area of repeatability and efficiency with its concept of a ‘smart factory’, which includes the latest technology and software systems for traceability and quality control.

“We are taking the Technology Days as an opportunity to demonstrate that Arburg has already started the journey towards the smart factory. We can individualise every component and trace it at every point in its production. This ensures transparency,” said Michael Vieth, Group Manager, Technical Coordination at Arburg.

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Freeformer After it created a “sensation” when launched at K 2013, in October last year, Arburg revealed that the first models of its Freeformer will be piloted exclusively to selected German customers in 2014.

Managing Partner, Michael Hehl, revealed that the interest and demand around the machines is “overwhelming”, but made

Arburg displayed some of its earliest injection moulding machines at the Technology Days

clear the company is in no rush to launch the machines to the mass market before they are ready.

“When you have a highly innovative product, such as the Freeformer, you need to take time to get it right and that is why the Freeformer will not be available until the last two quarters of 2014,” Hehl said.

During the event, one and two-component parts were manufactured on the Freeformer, including an ABS connector housing as a spare part for an Allrounder injection moulding machine, and a housing for the main switch of the Freeformer itself.

Hehl stressed that despite the flurry of interest around its newest technology, the development of the Freeformer does not mean it is “neglecting” the injection moulding sector.

“Quite the contrary,” he explained. “We will look to do much higher investments in the coming year with our new developments, in terms of both the machines and also in new production facilities and technologies for the growing markets.”

New Technology Some of these developments were brought to life in the HQ’s main hall, which was filled with machinery and processes demonstrating the company’s very latest production technology for a variety of sectors and applications.

www.kraussmaffei.com n at the event nered much attentio gar ill st r me or eef The Fr

This included the production of an over-moulded, thin wall optical lens for LEDs on an Allrounder 520A using Bayer’s Makrolon polycarbonate in a three-injection process, several highspeed packaging applications as well as cleanroom technology for the medical sector.

The company demonstrated its advances in fluid injection technology (FIT), where the weight of thick-walled components can be significantly reduced when gas (GIT) or water (WIT) is introduced into the cavity.

Using a plastic garden trowel as a sample part, the group demonstrated how significant material savings can be achieved by creating a hollow space in the handle using nitrogen. The

smaller wall thicknesses also result in shorter cooling times and therefore reduced cycle times. The 65g component was produced on an electric Allrounder 470 E with a clamping force of 1,000 kN in a cycle time of around 60 seconds.

Arburg also displayed a turnkey system for particle-foam composite injection moulding (PCIM), featuring a twocomponent Allrounder 470 S with a clamping force of 1,100 kN. Product handling was done by a mobile Agilus six-axis robotic system with Selogica user interface from Kuka, which was moving on a further linear axis allowing for fast entry into the mould and short cycle times.

History and Energy Efficiency During the technology days, which saw 6,900 visitors in attendance, the company charted the history and development of its technology, with a “museum” of its early models.

“The completely redesigned ‘Evolution’ exhibit allows visitors to experience the history of Arburg interactively,” explained Hehl during at the event. “The exhibit includes machines, innovations and plastic parts going back 90 years, as well as a wide range of multimedia content covering company and product development, the brand and trade fairs, as well as contemporary history and visions of the future.”

To coincide with the event, Arburg revealed the winner of its annual ‘Energy Efficiency’ Award, which was presented to Festo, a global supplier of technology for automation. The company won the award for its concept for energy-efficient plastic parts production as well as its co-operation on the testing and development of the Freeformer from a user’s perspective. further information: www.arburg.com

INTAREMA The new system generation from EREMA.

Efficiency at the fore.

High capacities have never been as easy to achieve as with the new INTAREMA®.

Counter Current technology makes it possible. Because the extruder handles more material in a shorter time. And this means for you: constant, top throughput within a considerably larger temperature range. For more productivity, flexibility and process stability.

CHOOSE THE NUMBER ONE.

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additives & masterbatch

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news Market report: Plastics light the touchpaper for flame retardant growth According to a recent study by research group, Ceresana, the market value of flame retardant additives for plastics will rise to approximately US$7.15 billion in 2021.

The study suggests more than two million tonnes of flame retardants were consumed in 2013, owing to the increased demand for plastics in the construction, automotive and electronics industries.

Demand in the construction sector is high, with the majority of flame retardants being used in pipes and cables made from plastic in residential buildings. However, the study finds that demand in the electronics sector is increasing even more dynamically, with manufacturers of smartphones and tablet computers consuming more and more flame retardant plastics. They also are increasingly concerned with environmental and health safety of the

The demand for flame retardants is growing worldwide, thanks to the increased use of plastics in markets such as construction, automotive and electronics

flame-retardants used, says Ceresana.

Halogenated flame retardants are increasingly losing market shares to products that are more environmentally friendly, according to the research.

Demand for flame retardants based on phosphor in particular is rising much more dynamically than was expected a few years ago.

“Sales volumes of organophosphorous products increase at an AAGR of five percent, which is the by far highest growth rate,” commented Oliver Kutsch, CEO of Ceresana. “The second largest growth market is antimony oxide. Aluminum trihydroxide, or, in short, ATH, remains the most important type of flame retardant nevertheless.” Regional differences are considerable: While halogenated flame retardants are still dominating the Chinese market, ATH compounds are accounting for about half of total market volume in Western Europe and North America.

Asia-Pacific is reportedly the largest worldwide sales market for flame retardants, with China single-handedly consuming almost one quarter of total production. North America still is the

second largest consumer, followed by Western Europe. Driven by China and India, Asia-Pacific is likely to gain market shares. The Middle East and South America are dynamic growth markets as well; absolute figures, however, still are comparatively low. further information: www.ceresana.com/en

nt etarda ed lame r eally suit f e h id T e r a es additiv port and iant ns s Clar a r t o t n, say io t c ru const

Clariant develops flame retardant additives for transport and construction Clariant has developed a new range of flame retardant additives that it says meet the strict requirements of the public transport and construction sectors.

The non-halongenated, phosphinatebased Exolit OP range and Exolit AP range of flame retardants are said to have been developed with a focus on sustainability, innovation, economy and performance.

Designed initially for the demanding and innovative applications of the electronic and electrical markets, Clariant says the Exolit OP range offers high thermal stability and excellent property profiles at comparably low dosage also for

challenging transport applications, such as railway rolling stock and airplanes.

“Clariant is committed to supporting the increasing need for safer fire protection based on more environmentallycompatible and sustainable solutions.

With our new Exolit products we make our best effort to capture these requirements in application-specific grades,” commented Adrian Beard, Head of Marketing for Flame Retardants at Clariant. “We see exciting potential for our Exolit product range within the transport and construction sectors, in addition to the E&E sector.”

AkzoNobel introduces version of antistatic additive for film and packaging Producer of polymer additives, AkzoNobel, has launched an easy-use, high concentrate version of its Armostat 1800 antistatic additive for plastics.

Armostat 1800-XP75 has reportedly been developed to address the need for a cost-effective, vegetable-based antistatic additive for PP film and rigid packaging applications.

Once added to the polymer during the extrusion process, the antistatic additives migrate to the surface giving the required effect. Armostat 1800-XP75 contains 75 percent Armostat 1800 when used on polypropylene.

“Armostat 1800-XP75 perfectly fits our portfolio of high performance concentrates and specialty additives,” commented Haimo Tonnaer, Business Development Manager for AkzoNobel’s Polymer Additives business. “This cost effective high concentrate allows for easy handling and dosing while offering all the advantages of pure Armostat 1800.” further information: www.akzonobel.com/ polymeradditives

further information: www.clariant.com

Armostat 1800-XP75 has been developed for PP film and rigid packaging applications

Tosaf presents a new range of FR masterbatches for corrugated pipes Tosaf has launched a new line of ‘green’ masterbatch products optimised for the production of corrugated pipes used as conductors for electrical cables in

construction. Such conductors have to meet the European Flame Retardant (FR) Standard IEC 61386-1.

The company says it has undergone intensive research into alternative products for use in this type of application, after REACH regulations banned the use

of short-chain chloroparaffins, previously the additive of choice for pipe manufacturers, as well as a number of producers wanting products to comply with the Low Smoke Zero Halogen regulation (LS0H; IEC 607541).

Tosaf says its new range of flame retardant masterbatches “represent the most advanced and cost-effective products on the market for this application.” They are said to use no chlorinated additives, meet the LS0H norm for standard pipes, are highly efficient in order to reduce dosing requirements and require no additional costs from the producer. further information: www.tosaf.com

19 Tosaf has introduced flame retardant masterbatches for pipe production that meet the REACH regulations and industry standards

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The aesthetical appearance of automotive interiors is highly important for manufacturers

Done and dusted: the antistatic developments driving automotives

M

ost plastics have a very low electrical conductivity, and therefore usually exhibit a strong tendency for charge accumulation on the surface, caused by contact with other materials. In many cases, the existence of surface charges leads to problematic effects, e.g. the coherence of plastic films or the adherence of dust due to electrostatic Dust and particle build-up on attraction. plastic surfaces can have a Furthermore, the detrimental effect on the resulting discharges aesthetics of a finished product, are a considerable from industries ranging from hazard, as they can automotive to packaging. Dust interfere with the accumulation can now be function of electronic prevented or delayed by means of equipment, as used in medical technology for specially developed static example. Also with inhibitors that are matched to the regards to explosion respective plastic. Here, Dr. Jan protection, electrostatic Stadermann, Head of R&D Projects discharges are highly at the Grafe Group, one of problematic. Similarly, Germany’s leading manufacturers dust accumulation on of masterbatches, explains more plastic components about the development of the due to electrostatic latest formulations. charges represents a problem in the packaging industry, as the impaired visual impression of the product can have a negative effect on the customer’s purchasing decision.

Also, the automotive industry is intensively engaged with this problem, as dust accumulation on plastic parts of a vehicle’s interior is highly undesirable. Based on the disadvantages mentioned above, there is a demand for antistatic properties of the plastic materials used.

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Taking type and surroundings into account In order to meet this demand, a range of substances can be used as additives. These so-called antistatic agents are divided into surface-active and volume-active substances. Surface-active antistatic agents are enriched at the surface by means of migration, whilst volume-active substances create a conductive network within the plastic matrix.

In the past, migrating antistatic agents were mainly used, as they produced the required effect already in low concentrations.

Water molecules accumulate on these surface-active substances, thereby forming a conductive film on the surface, which enables the electrostatic charge to be distributed and discharged evenly.

However, these systems do not provide a permanent protection against electrostatic charge build-up. Frequently, the active substances on the surface are sensitive to environmental influences, whereby they gradually lose their effect. What’s more, they can be removed from the surface by mechanical means.

Due to their action mechanisms, migrating antistatic agents require a minimum level of air humidity. The higher the air humidity, the better the antistatic effect. At lower humidity levels, the efficiency of these systems is significantly reduced, making them unsuitable for use in dry surroundings. The advantages of migrating antistatic agents are their low dosage, and a relatively low price.

Protection against charge build-up For applications in which the disadvantages of migrating antistatic agents cannot be accepted, non-migrating systems must be used, which are not affected by air humidity and provide permanent protection from charge build-up.

Graphite, carbon black and metal powder are typical nonmigrating conductive materials that can be used as volume-active antistatic agents. Similarly, the use of carbon nanotubes or graphenes is possible. Whilst carbon black or graphite can only be used for black plastic items, the use of metal powder is frequently not possible due to higher abrasiveness and difficult processing conditions.

Another class of volume-active conductive materials is formed by ion-conductive polymers, which are also suitable for use in coloured plastic products due to their low inherent colour. These also include polyether polymers, which create an ion-conductive network in the plastic matrix, providing an effective path to dissipate electric charges. These materials are the basis for numerous permanent antistatic agents on the market, which represent the current state-of-the art and are used in many applications.

However, compared with migrating antistatic agents, the high price and the comparatively high application concentrations are serious drawbacks, which is why many users are searching for more cost-effective alternatives for the established permanent systems.

Therefore, a lower dosage is usually needed for equal performance.

should not be higher than about 1011 ohms in order to counteract dust accumulation due to electrostatic charges.

Depending on the polymer to be processed, various kinds of antistatic properties can come into question, whereby the physical properties, e.g. melting point and melt viscosity, as well as the product’s chemical composition are decisive for the suitability and efficiency in the respective polymer. For automotive interiors, polypropylene (PP) is mainly used, as it features a very good price/performance ratio. Another frequently used material is (PC+ASA), a blend of polycarbonate and acrylonitrile styrene acrylate, which exhibits a high impact resistance and forms hard, scratch-resistant surfaces.

In cooperation with major German OEMs, the Grafe Group is currently working on new solutions for antistatic properties of corresponding plastics, with the focus on improved performance of both migrating as well as non-migrating systems.

The further development of migrating antistatic agents is aimed primarily at increasing the effective duration. For this, Grafe has introduced a new product for polyolefins – high-performance antistatic (HPAS) – which maintains its antistatic properties for more than four years, as demonstrated by long-term tests on PP components. At present, prototypes and pre-series components made of this product are undergoing final release tests. First results can be expected from two OEMs in the coming years, in combination with model changes and new vehicle types.

During development of permanently effective non-migrating systems, the focus lies on efficiency improvements. For use in PP and in (PC+ASA), new permanent antistatic agents have been developed and tested. Particularly low dosage levels of additives define these new products.

In addition, combination products have been developed for use in PP and in (PC+ASA), with which material colouring and permanent antistatic properties are achieved in a single dosing step.

additives & masterbatch

Developments for automobile interiors Depending on the application area of antistatic materials, additional product requirements often arise, which must be taken into account by new developments. Plastics that are used in automotive interiors must comply with corresponding automotive standards in which, for example, mechanical strength, light fastness or aging resistance are defined. Therefore, the influence of antistatic additives on the basic properties of the polymer mustn’t be too great.

Taking these criteria into account results in a very extensive profile of requirements for antistatic agents that are suitable for plastics in automotive interiors.

For evaluating a component’s antistatic properties, measurement of the charge dissipation in accordance with the automotive testing standard The team at Grafe has been working PV 3977 is highly with major automotive OEMs on significant. For this, the developing the antistatic technology component is charged for vehicles. Image: Grafe electrostatically, and the resulting surface resistance is recorded against time. The more effective the antistatic properties of the component are, the faster will the charge be dissipated. Measurement of the surface resistance is also an effective and very simple method for assessing antistatic properties. Depending on the application area, a specific antistatic region is required, which must be determined accordingly for every application. Project experience and correlative know-how gathered with PV 3977 shows that surface resistance

further information: www.grafe.com

When it comes to matching colour, no one gets closer.

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Masters of colour

*iÀv À > ViÊ >ÃÌiÀL>ÌV ià Telephone: +44 (0)1495 310583 Email: customer.service@pmb.co.uk

21 ÜÜÜ°« L°V °Õ

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news Stäubli introduces temperature control manifold for injection moulding Stäubli has introduced a temperature control manifold for injection moulding applications in the plastics sector, which it says simplifies mould connections and brings added flexibility to temperature control circuits.

Stäubli’s fluid distribution manifold, the NCI 33, is part of its range of connectors for temperature control circuitry on injection moulding tools. The company says its modular design offers “several thousand” possible configurations to satisfy all applications.

Swivelling modules on the manifold permit rotation of each connector to the required angle and maintain a tight seal during adjustment, even under load.

A variety of connectors suitable for the specific fluid and temperatures being used can be incorporated into the manifold, from threaded plugs to quick release, anti-pollution flat face, full flow or shut-off couplings.

Stäubli says two types of inlet and outlet (axial or radial) allow multiple

connection possibilities along with a choice in quick release connector.

Coloured rings also provide simple and quick identification of the hot/cold fluid circuits. The manifold can be fitted with between two and 16 modules according to the number of circuits; sealing between modules is built into the design.

For temperature control, manifolds are used in pairs one at the inlet and the other at the outlet. Each manifold can be mounted either vertically or horizontally and can be stacked if required. 3D and 2D files of the manifold and fittings are

available to help with integration into existing installations.

Stäubli says the NCI 33 reflects the current trend in injection moulding to integrate different functions on the mould such as component ejection, sequential injection, as well as temperature control and provides a “simplified, ergonomically designed and reliable” manifold that can be readily adapted to all applications. further information: www.staubli.co.uk

Temperature control

www.quick-mould-change.com

The new NCI 33 manifold for temperature control in the injection moulding process

regloplas.com

PERFECT TECHNOLOGY

www.motan-colortronic.co.uk 23 bp&r

Temperature control

www.quick-mould-change.com

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news Cooling and heating units will raise the temperature at Interplas 2014 HC units that integrate both cooling and heating within a temperature range of +10°C up to +90°C in a single unit will be on display at Interplas 2014 from 30th September – 2nd October at the NEC, Birmingham.

The HC units, which are manufactured

by Frigosystem and supplied in the UK by InteliCare, are equipped with two fully independent user outlet circuits, with the option of a third circuit. While these units are produced as a standard assembly, they can be fully customised by way of pump pressure, pump flow and heating capacity.

The cooling phase is performed by a refrigeration system utilising ecological gas R407C with long life hermetically sealed compressors. These units are water-cooled with condenser cooling

Intelicare will be demonstrating HC units from the range on stand D17 at Interplas 2014

performed by an external water source i.e. a dry cooler or cooling tower, which could, weather conditions permitting, allow free cooling of the process. The fully insulated internal cold water storage tank is made from stainless steel, as is the plate type heat exchanger. The cooling circuit also features a centrifugal pump with by-pass circuit, automatic water filling and fully insulated stainless steel pipes.

Accurate temperature control of each user outlet is achieved by electronic

control and three-way modulating valves on each circuit. HC units are fully compatible, with many communication protocols allowing easy set up and monitoring by a number of systems or processing machines.

There are a number of models in the range with cooling capacities from 9.9 up to 110 kW and heating power from 6 + 6 up to 24 + 24 kW. further information: www.intelicare.co.uk

Tel: 01952 671918

Email: connectors.uk@staubli.com

“No frills chiller” to suit all budgets launched in UK Cooling and materials handling specialist, AB Systems, has launched a new, air-cooled chiller range to the UK market in response to what it says is market demand for a high quality, ‘no frills’ chiller.

The new EcoLight range, manufactured by chiller brand, Nova Frigo, is said to be cost-effective, reliable and technically sound, as well as being accessible within all budgets.

Despite being marketed as ‘basic’, the EcoLight is said to have a number of innovative features designed to optimise essential chiller functions. These include a Nova Frigo-designed multi-function microprocessor, which governs evaporating and condensing pressures and is said to accurately measure system parameters to ensure consistent, precise and efficient control of the chiller’s operation. For time saving and convenience, the units can also be ordered with an easy-to-use remote control panel that allows complete management of the chiller from a second location.

AB Systems says cooling plants with more than one chiller will also benefit from the EcoLight’s intelligent multichiller function, said to be an advanced piece of microprocessor technology that automatically adjusts the operation of each compressor in relation to thermal load. This reportedly not only achieves stable and exact process temperatures, but also avoids peaks in electrical usage caused by unnecessary starts, thereby minimising energy consumption.

The EcoLight is also said to be efficient — even in extreme ambient temperatures of up to 45oC — due to its intelligent microprocessor control and advanced evaporator and condenser design features, which are said to ensure very low power consumption.

Technical features include a pre-galvanised aluminium steel frame, gas condenser with a large exchange surface, plus copper piping and aluminium fins. The plate heat exchanger has stainless steel, copper braze welded plates and is placed inside a thermoinsulating material shell to optimise heat exchange efficiency.

New hot runner temperature control systems launched Athena Controls, Inc., a manufacturer of temperature/process controllers, hot runner controllers, temperature sensors and related accessories, has announced availability of two new hot runner temperature control systems.

The new RMB/6 and RMB/12 non-modular hot runner control systems are said to be ideally suited for six or 12 zones, offering integrated control in a compact package design. Each unit is equipped with a full-featured operator keypad/LCD display and discrete indicators of heat, boost, closed loop, open loop, idle and alarm for system status.

In addition, the company has also recently launched its Bedros and Bedros XL Hot Runner Controllers, said to be ideally suited for medium sized multizone runnerless control applications. Athena’s Bedros and Bedros XL offer from eight to 64 zones of control for a variety of applications. Used in injection moulding, thermoforming, extrusion and even heat trace operations, they are said to deliver functionality in a compact, easy to use design. Bedros is available in the UK through Hales Tool and Die and will be displayed at Interplas 2014. further information: www.halestooling.com

Suppliers to the TTooling ooling o & Plastic Industry Industr In y

further information: www.ab-ltd.co.uk

EcoLight chiller from AB Systems

Hales Tool Tool oo o and Die are the UK distributors of Athena Temperature Temperature empera e Controllers F For or more information on Athena products visit

www.hotrunnercontrol.com www.hotrunnercontrol.com

Internal view of the EcoLight Chiller

Hales Tool To & Die Limited Unit 10, Heybridge House Ind. Est. The Causeway,, Maldon, Essex. CM9 4XL 4XL. United Kingdom

Phone: 0800 634 8800 F Fax: ax: 0800 634 3800

www.halestooling.com www .halestooling.com

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www.quick-mould-change.com

Free Cooling freezes energy costs by up to 70 percent ‘Free cooling’ is a fast, effective and economic method of utilising low external air temperatures to assist in the cooling of water for industrial Now the clocks have gone temperature control forward, summertime has applications or in HVAC (heating, ventilation officially started in the UK, so and air conditioning) the annual hope for good systems. Within weather begins. However, one industrial temperature company that says Britain’s control applications, a traditional cooler climes can free cooler can be actually be more of a benefit installed in series with than a burden is ICS Cool Energy. a chiller system’s Here, the engineering team at ICS evaporator so in lower explains how the plastics ambient conditions, partial or 100 percent industry can utilise low ambient free cooling can be air temperatures to save energy achieved. and reduce cooling costs by as According to much as 70 percent. official Met Office statistics, the UK has experienced some of the lowest temperatures on record during the winter months in recent years, and free cooling could have saved many process or HVAC applications thousands of pounds in energy costs. When in low ambient conditions, free cooling methods remove the need to use a chiller’s compressors, utilising external cold air to cool water through a free cooling unit, which in turn can be used for a process or building’s cooling needs.

There are two main options available to achieve free cooling, firstly, a chiller working alongside an independent free cooler, and, secondly, a chiller with an integral free cooling coil.

achieved, and can result in massive energy savings. This method of operation utilises naturally low ambient temperatures, and in doing so, benefits from a reduction in energy costs which can reach as much as 70 percent.

By combining a class A energy-efficient scroll compressor chiller with an independent free cooler, maximum savings can be achieved when compared to a standard screw compressor chiller. As the ambient air temperature drops three to five degrees below the required process supply water temperature, 100 percent free cooling can be achieved, consequently providing an environmentally friendly and cost effective approach to process and HVAC cooling.

Free cooling can be applied to both new, and existing chiller systems through the use of free coolers, which are uniquely balanced to provide the greatest levels of efficiency at both full and partial loads.

Integral free cooling coils Where space is limited, free cooling can be achieved through integral free cooling coils. The units are designed to offer highenergy efficiency levels in all seasonal conditions and provide a more compact footprint.

Energy efficiency and savings Whichever avenue of free cooling is adopted, the benefits remain constant: increased reliability as each system monitors temperature and automatically switches from 100 percent compressor load to partial or total free cooling as climate conditions allow; use of ambient air temperature in place of compressors to facilitate free cooling and savings on running costs; and less wear and tear on chiller components and consequently a reduced life-cycle cost.

Independent free cooling A dedicated independent free cooler is designed to maximise the energy efficiency benefits of a circuit, and is not restricted by the size of a chiller. An independent free cooler has a greater capacity for heat exchange as it is sized to maximise efficiency, enabling a greater area for the transfer of thermal energy.

An independent free cooler is installed in series with the chiller system’s evaporator, so that in lower ambient temperatures, partial or 100 percent free cooling can be

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Case Study: A window of opportunity for free cooling within the plastics industry ICS Cool Energy recently supplied equipment to support free cooling technology to a manufacturer of plastic window profiles based in the Midlands in order to maximise efficiencies.

ICS implemented the free cooling technology and supplied a one-off Imperium 2197 CA chiller with screw compressors and twin R134a refrigeration circuits, to produce 580kW cooling capacity with a supply temperature of 13°C and a return of 18°C at 28 litres/second.

The units work with free cooling technology and can be used during spring, summer nights, autumn and winter months by using ambient air, helping to save up to 68 percent on the manufacturer’s annual energy bill.

After saving over £50,000 following use of the free cooling units, the company has since reinvested in a second machine in the bid to achieve even further savings.

further information: www.icstemp.com

Free cooling can cut energy costs by up to 70 percent

Email: connectors.uk@staubli.com

Case Study: Turbulent flow temperature control cuts cycle times Injection moulding specialist, Warden Plastics, says by fitting temperature control units on two of its highest output machines it has both stabilised its process and accrued “significant” financial savings by shaving 10 percent off cycle times.

The Luton-based company, which provides contract manufacturing of extruded and injection moulded parts and products to the automotive, electronics, medical, construction, point of sale and vending industries, also produces its own range of biological filter media. One of these products, the Biomarble, is a spherical polypropylene filter used in industrial and municipal wastewater treatment plants.

To keep pace with rising demand for these filters, Warden Plastics upgraded the moulding tool on its Sumitomo Systec 160-tonne machine from an eight-impression to a 16-impression tool in September 2013. The increase in cavities meant more heat was entering the tool, necessitating increased mould temperature control in order to maintain a stable process at high speed.

“As more heat was entering the process, we were unable to run the tooling for any length of time due to overheating. Because of the size of the tooling and the speed of the cycle we needed a temperature controller with more powerful flow and heat transfer capabilities,” commented Mark Barrett, Managing Director of Warden Plastics.

The company fitted two AEC TrueTemp TCU 300 9kW water temperature control units on the mould, which are designed to promote turbulent water flow to maximise heat transfer performance and are said to deliver more efficient and effective control than indirect cold water systems.

Since installing the units, Warden Plastics reports that it is able to run a stable process, producing a consistent, repeatable product with zero defects. In addition, the TCUs are said to have shaved a second off the cycle, reducing cycle time from 12 to 11 seconds.

“When calculated across 5,236 units per hour on a 24 hour operation, this represents a considerable cost saving. We expect the TCUs will pay for themselves within a year,” said Barrett.

“All injection moulding machines use some form of basic temperature control, but the advantages of optimising this operation are often overlooked. Anyone wanting to improve process control and reduce cycle can benefit from a TCU – whatever their product or industry,” explained Nick Smith, Processing and Training Manager at Sumitomo. further information: www.wardenbiomedia.com uk.sumitomo-shi-demag.eu

Stand-alone temperature control units can be fitted to any make or model of injection moulding machine to improve process control and reduce cycle - whatever their product or industry.

Temperature control

Tel: 01952 671918

The temperature control units have enabled Warden Plastics to cut the cycle time of its Biomarble biological filter production process by 10 percent

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Temperature control

www.quick-mould-change.com

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Cooling down in Saudi: IsoCool completes landmark installation for extruder

P

roving the value of UK manufacturing expertise in overseas emerging markets, IsoCool has completed its first major cooling system installation in the Gulf region – and immediately won another contract on the back of it.

The Essex-based process cooling specialist provided a turnkey solution to Neproplast, a plastic extrusion company that is part of the IKK Group, the largest construction group in the Middle East. The project involved a complete upgrade of the existing extrusion and mixing process cooling system at Neproplast’s Jeddah plant and used British and Italian manufactured equipment, as well as skilled labour from local engineers.

Neproplast is the Gulf’s market leader in PVC plastic pipes and fittings. Yet despite this established position, the company has experienced rapid growth over the past few years and is forecast to increase its material mixing and pipe production output from 70,000 to over 100,000 tonnes by 2015. The plant’s existing cooling system supported more than 31 extrusion lines.

“From a Neproplast perspective, it is vital that the plant continues to achieve the highest levels of performance and efficiency as it grows,” said Peter Fox, Maintenance Manager at Neproplast.

In order for the new cooling system to cater for Neproplast’s present and future needs, IsoCool’s solution included: five packaged air cooled water chillers (used in addition to the

The chillers once installed Neproplast aircooled chillers

existing chiller plant to provide a combined future cooling capacity of 5MW); a bespoke water recirculation and filtration system comprising plate heat exchanger skid, chiller circulation pump skid and process and hot water circulation pump skids (all manufactured by IsoCool in Essex); self-cleaning filtration systems and a system control panel.

IsoCool specified that the five new Eurochiller NAX V-A-920 air cooled water chillers were built with fin coil protection to counteract the corrosive effects of the coastal location and tropicalised to maintain performance in ambient temperatures of up to 50oC. Nigel Hallett, Managing Director of IsoCool, said: “It’s very important, in any installation, to use resources effectively. This is why local engineers were brought in to install the system under our supervision on this particular project — it ensures business continuity for Neproplast, especially in terms of maintaining system performance and efficiency.”

IsoCool will be contracted to perform full inspections of the cooling system periodically, however, this won’t be the only reason for IsoCool’s return to Jeddah – Neproplast has since awarded the process cooling specialist a second contract for its additional new 60,000 sq. metre injection and extrusion plant.

This project will involve IsoCool manufacturing a complete cooling plant system with cooling capacity of in excess of 8MW in Essex.

“We’re thoroughly impressed with IsoCool’s technical expertise, ability to understand and work with our unique requirements, and also to project manage a logistically-complex installation,” said Mr Fox. “IsoCool’s performance has given us complete confidence to move forward to the next project, and we’re looking forward to welcoming them back to Saudi in the near future.”

Tel: 01952 671918

Email: connectors.uk@staubli.com

Q&A: Exclusive BP&R caught up with Nigel Hallet to find out more about the installation, doing business in the MENA region, as well as advice for UK companies looking to export.

BP&R: In terms of export markets, how big an opportunity is the MENA region for IsoCool?

NH: It’s a massive opportunity for IsoCool! We’ve really only dipped our toe in the water so far and the response has been extremely positive. In fact, having just one customer in the Saudi region over the course of the past two years has meant a significant increase in our turnover.

BP&R: Why is this and have there been recent developments that have made the technology more appealing to companies operating within these countries?

NH: It’s not a technological issue.

There are already high expectations from the customer when it comes to technology, and in that way IsoCool is able to meet this demand with Eurochiller

products. It’s all about meeting the clients’ requirements in a technical and concise way.

What’s been missing in the region is a level of expertise that enables suppliers to identify exactly what clients need.

Previously, suppliers were more interested in selling a box than analysing the process in detail and providing a complete solution.

BP&R: When did IsoCool first become involved in doing business in the Middle East and what opportunities has it presented?

NH: IsoCool first became involved in 2012, with an installation in Saudi Arabia and since then opportunities have been opening up for us across the MENA region, including enquiries for very significant projects.

We have a great desire to open a wholly owned subsidiary in the region – something that will be coming very soon – working with agents and distributors in the short term. A permanent presence will enable us to provide

an even more exceptional level of service to our existing clients, and, of course, allow us to fulfill demand for IsoCool’s expertise more easily.

Another exciting development for IsoCool is the number of European-based companies — some of whom we’ve worked with previously — planning to move manufacturing to the MENA region, that have the trust and confidence to work with IsoCool as a partner in the Middle East.

BP&R: How easy has it been entering new markets in terms of culture, financing and regulation and what advice could you give other UK companies looking to export?

NH: I wouldn’t say it’s been an easy ride, but we got there! We’ve had the support of our bank and the client has been very honorable in meeting payment milestones. I’ve found it really easy to deal with the Saudi people, they are extremely hospitable and courteous and also very respectful in negotiations. Their business

principles are the same; they want value for money and quality and a product delivered on time and to specification.

To other UK companies looking to export, I would say that there is a lot of hard work involved, so be prepared. We’ve spent many years adhering to exceptionally high standards of customer care in order to provide industry-leading solutions, and this kind of reputation and credibility doesn’t go unnoticed in the Middle East. If you are able to build up an excellent reputation it will serve you well in the MENA region, where recommendation is everything.

You also have to be out there visiting clients on a very regular basis, and the costs of doing this are not inconsiderable. It’s also advisable to consult the DTI. In short, it is very hard work and requires massive investments in both time and money — but the rewards are worth it. further information: www.isocool.ltd.uk

Neproplast outdoor cooling system in the Middle East

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Providing plastics innovation to the construction industry

construction & infrastructure

The HDPE pipe system has been chosen for the new development in London

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news Polymer mix paves the way for new road surface A project being piloted in Spain is using waste rubber and plastic to create an asphalt mix to pave road surfaces.

The material has been developed jointly by AIMPLAS (Technological Institute of Plastics) along with Madrid-based construction firm, Acciona Infraestructuras, as the result of a project coordinated by Spain’s University of Cantabria.

The asphalt is made using end-of-use tyres, polypropylene caps, polyethylene packaging and polystyrene hangers. The mix has been used to pave a 2km long, M300 section road at access points to Alcalá de Henares, Madrid.

After studying the performance of the asphalted section of road over the last 18 months, the partners of the project, which has been named ‘Polymix’ have concluded that new asphalt mixes comply with the requirements established in the technical specifications to build roads. The findings also reportedly indicate that mixes that use polymer waste in their compositions are more resistant to plastic deformation than traditional mixes. This allows mixes

The mix has been trialed on roads in Madrid, Spain

to perform much better when cracks appear, especially with high temperatures and slow moving traffic.

According to AIMPLAS, increased rigidity without compromising the fatigue behavior of the mixes was another result of the trials. These mechanical properties convert Polymix mixes in a rolling layer, which carries a higher traffic load and is said to improve the structural capacity of a pavement.

AIMPLAS highlights that in the case of end-of-use tyres and polypropylene, the mixes can be manufactured with lower thicknesses due to their improved properties, lowering the cost of production. further information: www.aimplas.es

New “SUper-I nsulation” is a sharp bet Manufacturer of expanded polystyrene (EPS ) insulation material, Jablite , is in the runnin g for a £50million development gr ant to bring an insu lation product to market that it sa ys “will change the way we heat ou r homes.” This new ‘Super-Insulatio n’ product is reportedly mad e from a derivat ion of EPS and can be manufacture d to a 1mm or even lower thickness with a breaking strength 1000 times stronger than Clingfilm.

Jablite says it is planning a laun ch event that will in clude wrapping the outside of The Sh ard. www.jablite. co.uk

HPDE pipe system selected for luxury London residential development Polypipe, a UK plastic piping systems manufacturer, has had its Terrain Fuze pipe selected for use in a luxury residential development in central London.

The original plan for Goodman’s Fields, a mixed-use, seven-acre development in the heart of the City, called for a cast iron piping system, but after consultation with contractors, Fitzpatrick Mechanical Services, the Terrain Fuze plastic pipework was specified throughout the project.

Polypipe says Terrain Fuze is a high performance drainage system that has many advantages over cast iron and other traditional systems. Manufactured from high-density polyethylene (HDPE), it is said to provide a comprehensive, modern solution to above ground, non-pressure drainage requirements, providing specifiers and installers with maximum flexibility in the design process.

“Cast iron pipes can be cumbersome and unwieldy, making them far more time consuming and costly to transport to site and install,” commented Adam Turk, Polypipe Terrain’s Commercial Director.

“The lightweight nature of plastic products combined with the benefits of utilising a bespoke, prefabricated system made Fuze an obvious choice for this project.”

Lee Rouvray, Contracts Manager at Fitzpatrick Mechanical Services Ltd, explained the benefits of using the Fuze system: “It has enabled us to complete our installation in a quicker, safer and more cost effective manner, which is vital when undertaking any project due to the tight timescales we adhere to.” further information: www.polypipe.com

Tel: 0845 34 54 560

Email: sales@plastribution.co.uk

A fresh face for the construction industry A new company has been set up in the UK to meet a fast-growing demand for Belgian-manufactured plastic sandwich panels used for the construction and hygiene-related industries.

FRESH Plastics UK Ltd, based in Bury St. Edmunds in Suffolk, is the sole distributor of the Paneltim panels, which are said to be hugely successful in Europe and elsewhere in the world due to their strength and versatility.

The panels are made from polypropylene copolymer (PPCO) or highdensity polyethylene (HDPE) and are 51mm thick. They are said to be exceptionally strong due to their internal cell structure, with hollow chambers of 50/50mm or 50/100mm.

Due to this sandwich construction, fabrications made from Paneltim panels reportedly require considerably less reinforcement compared with those made from solid sheets. This, says FRESH, lowers the costs associated with steel or

FRESH Plastics are the sole UK distributor of the Paneltim Sandwich panels, used widely in the construction industry

ordinary plastic reinforcements used in constructions such as chemical tanks, fume scrubbers and clean rooms amongst others.

Produced using prime resin, with a UV additive, the panels are 100 percent recyclable and lightweight, varying from 10-13kg/m² and 11-14kg/m² for the polypropylene and polyethylene panels

Gelcoat gives good foundation for GRP parts Stormking Plastics Ltd, a UK manufacturer and trade supplier of high quality moulded GRP parts used nationally for residential building construction, has chosen a spray gelcoat to enhance the weatherability and durability of its products.

The company, which is spread across the three production sites in Tamworth, Staffordshire, specialises in producing highly visible, finished GRP parts for residential building construction, including entrance canopies and porticos, doors, bay window roofs, dummy chimney stacks, finials and gable ends.

Stormking says as part of an on-going product innovation and quality improvement programme, it specified the use of Crystic LS 96PA spray gelcoat from Scott Bader for all its glass reinforced plastic (GRP) residential products.

Crystic LS 96PA is a filled low styrene isophthalic spray gelcoat, which Scott Bader says has a proven track record in use for providing reliable long term performance for external and internal GRP parts used in building, transport and general industrial applications. The technical team at Stormking says it selected Crystic LS 96PA due to a combination of its good handling properties, being a robust, filled-spray gelcoat which can be evenly applied with an airless spray system, alongside its proven long-term weathering performance for UK building applications. further information: www.scottbader.com GRP parts on UK houses

www.plastribution.co.uk

respectively, depending upon the cell structure.

FRESH Plastics says it has invested in specialised equipment, including a wall saw and butt-welder, to allow panels to be cut and welded to bespoke requirements. further information: www.freshplastics.co.uk

• PPCO & HDPE sandwich construction panels • Internal cell structures 50/50mm & 50/100mm • Lightweight yet very strong • Used to fabricate: chemical tanks, air scrubbers, bunds and more.

• Anti slip & orange PP grids available for flooring • Cutting and welding service available for bespoke sizes

FRESH Plastics UK Ltd Tel: 01284 799 628 Email: info@freshplastics.co.uk Web: www.freshplastics.co.uk

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construction & infrastructure

Providing plastics innovation to the construction industry

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news Innovation drives technology to new pipeline markets Molecor says the growing popularity of PVC-O pipes used in construction and infrastructure is enabling it to expand into new sectors with a growing range of diameters and pressures, as well as new products.

The company, which specialises in both the development and production of PVC-O pipes, says that by subjecting an amorphous PVC-U structure to molecular orientation, a physical process that modifies the plastic’s molecular structure by reorganising it into a layered structure, gives pipes outstanding mechanical properties in regards to impact resistance, fatigue resistance and flexibility.

It is these properties, says Molecor, that make PVC-O pipes an increasingly popular choice for use in both water mains and in secondary feeders, in applications including water supply, irrigation, pressurised waste water collection, recycled water and other purposes such as urban supply, industrial or fire protection.

To accommodate the growing demand, Molecor has now increased its range to include sizes from DN 90- 800 mm for medium and high-pressure pipelines (PN 12.5 to 25 bars), development in PVC-O pipe seals and sockets as well as new products, such as PVC-O pipe fittings.

The system used to manufacture pipes up to 800 mm in diameter is the first of its kind in the world. Developed by Molecor, this system uses air-based technology for producing PVC-O pipes in a variety of diameters and is said to be highly stable

Amorphous PVC-U structure (lower section), subjected to Molecular Orientation adopts a layered structure

Main applications for PVC-O pipe include water supply, irrigation, pressured waste water collection and recycled water

as well as providing consistent raw material savings.

Molecor has also developed additional technology to ensure pipe installation can be adapted to a number of different markets. The ISS+ (Integrated Seal System) is an evolving system to manufacture socketed biaxial oriented pipes with automated integration of the

gasket, retaining the orientation degree in the critical areas of the pipe. Moreover, Molecor says it is a pioneering process for forming the socket of the oriented pipe with integration of the gasket. further information: www.molecor.com

Email: sales@plastribution.co.uk

www.plastribution.co.uk

PVC 2014: On sustainability, shale gas and success so far

B

y 2050 the plastics industry will contribute massive economic and social benefits to society across the globe, as it will solve many of the issues surrounding sustainability, said Jonathon Porrit, Founder and Director of Forum for the Future, in his keynote address at the PVC 2014 conference in Brighton.

Presenting his views on the journey of the PVC industry, Porritt said it was “a fascinating one to follow from afar,” and that he deemed it a “yardstick material” to showcase sustainability.

“People may want to challenge that plastics and sustainability is an oxymoron, but they can absolutely co-exist, co-habit and co-create in the name of human good,” he commented.

Porritt’s vision for a plastics industry that has the “lowest possible dependency on carbon fuels possible” led to his suggestion that the development of industrial biotechnology would provide a more sustainable platform than fossil fuels for future production, making clear his opinion that the use of fracking to explore shale gas reserves would only provide a “quick fix”.

This opinion, however, was later challenged by Roger Mottram, Head of Environmental and Regulatory Affairs at Ineos ChlorVinyls, who acknowledged the need for non-fossil fuels, but suggested that utilising shale gas reserves in both the UK and Europe would be a way of ensuring supply in the interim whilst alternatives are developed.

“Regarding what Jonathon Porritt said, we do believe that the EU should go down the route of shale gas exploration,” said Mottram. “We would argue that using shale gas actually helps to reduce CO2 emissions as it burns more cleanly than some of the other fossil fuels. We would like to go for the bio-feedstocks in the long term, but it will take a lot of research and innovation in order for us to get there.”

During his presentation on critical success factors for the industry from the perspective of European PVC producers, Mottram made the case for de-regulation, less state intervention and lower regulatory compliance costs and also said despite clear progress in a number of areas, there is still no room for complacency.

Brigitte Dero, from the European Council of Vinyl Manufacturers (ECVM), highlighted some of these clear areas of progression, including the achievements

PVC 2014 REVIEW

Tel: 0845 34 54 560

m across the Over 300 delegates fro held in Brighton 14, 20 globe attended PVC Stuart Patrick, Chairman of the conference’s organising committee, opened the proceedings

of the Vinyl2010 programme, the voluntary commitment that saw the creation of both a new recycling industry and infrastructure, and also its successor, VinylPlus.

“VinylPlus was born out of Vinyl2010 as an ongoing commitment. It is more ambitious — aiming to address sustainability as a whole, to recycle 800,000 tonnes of PVC per year by 2020 and also to look at the sustainable use of additives and reductions in emissions,” Dero commented.

The challenges of the new VinylPlus programme were also discussed, including the 20 percent reduction in energy consumption targeted by resin producers, which Dero described as “vitally important in Europe, but not easy.”

“We are not yet sure that we will reach this target,” she said when questioned about the reality of reaching such an ambitious target. “We might get close, or we might achieve it, but even if we do not, we are still reducing energy consumption and learning in the process about how we do it.”

Dero also acknowledged the London 2012 Olympics as a “great achievement” in terms of the global platform the games gave to PVC in highlighting its use as a

sustainable material, saying that its postevent recycling and re-use in applications such as garden hoses and flooring for schools suggests the industry is “heading step-by-step towards a circular economy.”

“For many years as an industry we were quite shy. We were not used to sharing our achievements. However, now we have something to say. We want to share this experience and expertise with our partners and the PVC family all around the globe. We want to demonstrate that, dare I say it, this material can be green,” she commented.

Concluding and looking to the future in terms of sustainability, Dero said: “We are making progress in the PVC industry in Europe. We have achieved much, but we have not finished, certainly not. We are working on it, there is still a lot to do. We have to continue to work together.” further Information: www.pvc214.org

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EXTRUSION machinery

news New planetary cutter is the perfect prescription for medical tubing Conair has launched a new travelling planetary cutter (TPC) that it says will enable producers of small-diameter medical tubing to automate cut-to-length operations and increase productivity without worrying about cut-quality or particulate contamination.

Unlike a rotary fly-knife cutter, which chops through tubing in one quick slice, the planetary knife is said to rotate around the tubing, gradually penetrating the wall to yield a precise, square cut without the shattering, whitening or distortion that commonly occurs with other cutting methods.

“A rotary cutter can automate inline cutting of many resins,” explains Bob Bessemer, Conair Sales Manager, Medical Extrusion, “but for other more brittle materials like crystal polystyrene, highdensity polyethylene or highly-filled resins, processors concerned about getting a clean, square end cut had to resort to manual, off-line operations. The Conair TPC units change all that, now making it possible to automate the cutting process of even difficult resins for improved productivity and lower cost without sacrificing quality.”

Planetary cutting is not a new technology, but it has been used mainly in the manufacture of larger-diameter tubing

The new traveling planetary cutter

The new ModulPlus ncept compounding line co to offers simple access der ru ext rew sc the twinat ground-level

and pipe. Today, however, it is possible to handle tubing as small as 2.032 mm in diameter, while holding cut-to-length tolerances of ±0.381 mm.

In operation, the tubing exiting the extrusion puller moves through the cutter until it reaches the prescribed cutoff length. At that point, the servo-driven travelling table begins to move at the same speed as the tubing, which is clamped in place. The knife assembly begins to rotate and centrifugal force causes the knife blade to approach the tubing and make a lathe-like cut around the circumference of the tube. The cutter displaces material so cutting debris is essentially eliminated; distortion of the tube is avoided and a clean, square cut is created with no secondary trimming or deburring required. further information: www.conairgroup.com

Simpler, more cost-effective extruder design launched KraussMaffei Berstorff has added a variant to its ModulPlus compounding line platform, which it says is designed to be simpler and more cost-effective.

The group says that the time required to manufacture the line is now about two months shorter and the steel structure costs are reduced by up to 20 percent.

Four lines in the new configuration have already been sold to customers in Denmark and China.

The new design is reportedly simpler than previous lines, though metering, material handling, pelletising and control modules are almost unchanged. The real difference, says the company, is that the extruder is no longer integrated in a steel module, enabling simple access to the extruder at ground level.

“Thanks to this innovative solution, we save up to 20 percent in steel structure costs and reduce the manufacturing time by about two months,” said Thorsten Schroer, Assistant Head of Plant Engineering at KraussMaffei Berstorff.

ModulPlus has been designed with standardisation in mind, says the company, which also saves on build time.

KraussMaffei Berstorff says that the key benefits of the new design are rapid start-up without any interface problems, easy disassembly and re-installation in case there is a need to re-locate, and a low total investment cost as a simple production area is usually sufficient and there is no need for sophisticated steel structures. further information: www.kraussmaffeigroup.com

electricity SStatic tatic elec tricity ccontrol ontrol ttechnology echnology ffor or use in industrial both industr ial and cleanroom cleanroom areas areas

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Call Call +44(0)1993 706700 or visit w www.meech.com ww.meech.com

h a processing unit that Main extruder (front) wit ruder with a planetary roller ext combines a single screw ti nna nci -ci from battenfeld section and co-extruder

PET sheet capacity increased with high-tech, multi-layer co-extrusion line Germany-based packaging manufacturer, Paccor International, which is now a member of the Coveris group, has expanded its production capacity for PET sheet with the purchase of a complete three-layer co-extrusion line, including an in-line lamination station, for its Polish factory in Skierniewice.

The new battenfeld-cincinnati line, which has been in operation since August 2013, has an output of 1.1 tonnes per hour with thicknesses ranging from 200Âľm to 1.2mm. Due to the inclusion of an in-line lamination station, multi-layer sheet can reportedly be produced as easily as barrier sheet. “We are absolutely satisfied with the energy-efficient operation and the options of manufacturing a variety of different sheet products with one extrusion line only,â€? commented Marcin Antos, Managing Director of Coveris in Skierniewice. “The high output of 1.1 tonnes per hour with a net sheet width of 900mm enables us to optimally cater to the growth market of food packaging.â€?

The complete line includes components ranging from material dosing through to the sheet winder and lamination unit.

The co-extrusion line is capable of producing three-layer PET sheet in thicknesses ranging from 200Âľm to 1.2mm. With an optional rotating infrared tube (or heater) for pre-crystallisation of the material, regrind can also be used for the middle layer.

Also included is the lamination unit, which means that barrier layer can be incorporated to extend shelf life of the packaging, or with a PE sealing layer for subsequent peelability and/or weldability.

The extruder used for the system is a BC 1-120-40 D WT 170, equipped with a processing unit in which a single screw is combined with a planetary roller extruder section. The machine’s design is similar to that of a standard single screw extruder, but equipped with a planetary roller zone in the degassing area. The operating principle in this area causes the melt to be spread out in very thin layers. In this way, an extremely large surface is generated, which produces excellent degassing results, says battenfeld-cincinnati. This can allow for the use of undried regrind material and also offers a boost to efficiency. further information: www.battenfeld-cincinnati.com Coveris produces product packaging for the food industry. Photo: Coveris

Greenpak enters Chinese barrier market Chinese company, Greenpak, has installed a seven-layer ‘Evolution’ blown film line from Reifenhäuser Kiefel Extrusion into operation to become to be the first producer of barrier film in the greater Shanghai area.

Since the line came on stream in March 2013, Greenpak has been producing symmetric and asymmetric barrier films for end products in the rapidly growing food and packaging industries.

The seven-layer Evolution line features components that meet the requirements of the demanding packaging market, says Reifenhäuser, including the ability to process a broad range of raw materials across all layers. The W-P winder installed allows change between contact, centre and gap winding, making the winder suitable for both sensitive and demanding films. further information: www.reifenhauser.com Greenpak has installed a seven-layer Evolution blown film line from Reifenhäuser

Kongskilde your conveying specialist

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EXTRUSION machinery

news

m is used to produce Macro’s cast barrier film co-extrusion syste up to three metres wide and rs 11-laye multilayer film structures up to

technology, the cast barrier film lines can now be used for applications including thermoformed trays, insulation pouches, value-added lamination materials and stiffer, glossy films for on-shelf appeal.

Individual layer foaming is achieved with nitrogen gas injection through a feedblock that distributes each layer of the melt flow.

The feedblock’s design alleviates the need for a multi-manifold system that can add significant cost to the system, claims Macro Engineering.

The line can operate with or without foam injection, giving the filmmaker the option to switch between conventional multilayer films and foamed films without

Tuning insert for Ultraflow I Feedblock

Macro adds gas foaming to cast film co-extrusion lines Film and sheet extrusion systems supplier, Macro Engineering, has added the option of including gas foaming into any layer of the multilayer film structures produced on its cast film co-extrusion line.

Macro’s cast barrier film co-extrusion system is used to produce multilayer film structures of up to 11-layers and up to three metres wide using a variety of materials including PA, EVOH and PVdC. The films produced are most typically used in food and medical packaging applications.

“The addition of individual layer foaming broadens the possibilities of end-use applications,” said Andrew Erskine, Macro’s Marketing Manager. “Not only can foaming reduce weight and lead to raw material savings, but it can also create favourable properties in the film. By foaming one or more layers embedded in the co-extruded film, thermal and sound insulation can be improved, flexibility and conformability can be enhanced and opacity can be obtained without using fillers.”

With the addition of the foaming

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Extrusion feedblocks bring speed and precision Nordson Extrusion Dies Industries has developed feedblock-tuning inserts that it says bring speed and precision to profiling of layers in flat-die film and sheet coextrusion.

Tuning inserts for the Ultraflow I feedblock that can be adjusted during coextrusion enable manufacturers of film and sheet to reduce downtime and

material waste while permanent flow inserts are prepared, as well as achieving greater precision in the ultimate thickness profiles of each layer across the width of the die, says the company.

The feedblock shapes molten polymers from two or more extruders into layers in a sandwich structure that is subsequently distributed to full endproduct width inside a flat die. In feedblocks such as the Ultraflow I, a specially machined flow insert yields a target cross-direction thickness profile for each layer and any job change involving

changing machinery configuration.

“Versatility is a driving motivation for us,” Erskine continued. “Supplying systems with inherent flexibility helps our customers adapt to changing market demands. It also helps mitigate risk on their capital investment”.

Macro recently installed a seven-layer cast co-extrusion line in Europe that produces high barrier films with layer foaming in two of the seven layers and inline embossing to create an optimised product for the user’s end application. further information: www.macroeng.com

significantly different layer ratios or polymer flow properties makes it necessary to design and machine different inserts. The tuning inserts for Ultraflow I feedblocks enable processors to maintain production while being adjusted until the target profile is achieved and a matching permanent insert can be built.

“The new tuning inserts help processors to maximise run time and minimise waste during the week or more that is required to design and machine permanent inserts,” said Sam G. Iuliano, Chief Technologist at Nordson EDI. “Because the tuning inserts can be finetuned ‘on the fly,’ it is possible to do several iterations, making small additional changes in very little time and refining the geometry with great precision before machining a permanent insert. This process eliminates the need to do several ‘re-cuts’ of the permanent insert before arriving at the target layer profile.”

Typically about 10 cm wide and machined from hardened stainless steel, a flow insert is specially designed to generate a corrective layer profile for a polymer with specific flow properties. further information: www.nordson.com

Injection Moulding Rotational Moulding Extrusion Blow Moulding Thermoforming Vacuum Forming Film Extrusion Recycling Materials Design

ER T S I REG ...

N OW

30 September-2 October 2014

NEC, BIRMINGHAM, UK

www.interplasuk.com

reclamation & recycling

news recycling venture scores at the Emirates stadium Closed Loop Environmental Solutions (CLES) and packaging manufacturer, Coveris, have won a major contract with foodservice company, Delaware North, to establish closed loop recycling programmes for plastic cups at the Emirates Stadium, home of Arsenal Football Club.

An initial 750,000 plastic cups made using a minimum 50 percent recycled PET from CLES’s sister company, Closed Loop Recycling, will be supplied by Coveris to Delaware North, with the volume expected to ultimately rise to in excess of two million per year. After use, the cups, which are all compatible with a closed loop programme, will be collected to be recycled again at Closed Loop Recycling’s Dagenham plant.

Plastic recycling guidance inadequate, finds Recoup A consumer perceptions study has indicated that consumers are “most uncertain” about recycling plastics ahead of any other material, with mixed messaging from councils leading to increased confusion amongst householders.

The study, which was led by Recoup and supported with funding from DEFRA and Kent Resource Partnership (KRP) amongst others, aims to deliver an alignment of information that will help to minimise confusion and contradictory messaging,

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L-R: David Peskett, Delaware North Companies UK; Peter Goodwin, Closed Loop Environmental Solutions, Michael Lloyd, Arsenal FC and Mark Durston, Coveris

Graham Barton, Coveris UK Rigid Managing Director said: “The leisure industry offers a huge opportunity for packaging companies and we see this agreement as the first of many in this

maximise the potential for the right actions being taken by consumers and, ultimately, lead to more plastics collected for recycling.

“Consumer education is a key driver for behavioral change and to increasing plastic recycling rates,” said Cllr Barrington-King, KRP Chair.

When asked about the recycling of various materials, plastic was the material consumers were most uncertain about (63 percent). There was also a wide range of responses from consumers when asked to give their council a score out for ten relating to how clear the instructions on plastics recycling are, including over 40 percent giving a score of six or less.

sector, allowing us to close the loop on packaging.” further information: www.closedloop.com

The desire for more information about recycling was clear with three quarters of respondents stating that they are “very” or “fairly” interested to find out more about what happens to their plastics.

When asked about the acceptability of different disposal options for plastics, households indicated near-universal acceptability for recycling, and, in contrast, the vast majority considered sending plastics to landfill unacceptable. Over 70 percent of respondents also considered burning plastics as a form of energy from waste acceptable, more acceptable than sending plastics to other countries to be recycled.

Stuart Foster, Recoup CEO, said the plastic recycling consumer survey was “one of the largest and most insightful ever undertaken,” which gives “a fantastic platform” to develop a communications initiative which can achieve maximum impact based on the feedback received.

Consumer “The steering group will education is use the information imperative when it from the consumer comes to plastics insight work to recycling, says continue to develop Recoup plans which will culminate in a Summer 2014 initiative launch,” he added. further information: www.recoup.org

“The plastics industry does not litter beaches or dump waste at sea. We don’t want used plastics littered or landfilled, we want it back for recycling. There should be zero tolerance towards littering behaviour. Fines should be enforced and more litter bins provided,” Peter Davis

“The plastics industry does not litter beaches or dump waste at sea,” says BPF In response to the publication of the Marine Conservation Society’s report on a 2013 beach clean and survey, the British Plastics Federation has reinforced the message that the industry fully supports fining individuals who litter the marine environment.

The report found that that the number of litter items per kilometre of beach has increased, with plastic pieces strongly in evidence. However, less plastic bottles, crisp bags and sweet wrappers were found.

“My colleagues and I have taken part in MCS Beach cleans and surveys and seen for ourselves the extent of the problem,” said Peter Davis, DirectorGeneral of the British Plastics Federation.

“The plastics industry does not litter beaches or dump waste at sea. We don’t want used plastics littered or landfilled, we want it back for recycling. There should be zero tolerance towards littering behaviour.

Fines should be enforced and more litter bins provided.”

Davis is the spokesperson for the ‘Plastics 2020 Challenge’, an initiative launched in the UK in 2009 designed to challenge industry, consumers and Government to prevent the landfilling and littering of plastics by 2020.

“We want to work with all stakeholders to prevent plastics entering the marine environment. We strongly support the Marine Conservation Society’s Marine Litter Action Network being launched in June and intend to play a full part, finding ways to reduce marine litter,” Davis added.

He outlined current activities undertaken by the plastics industry to prevent plastics in marine litter, including ‘Operation Clean Sweep’, a pledge by major UK plastics companies to prevent plastic pellets and powder being lost into the environment, as well as international action by the BPF, which has seen the association sign a ‘Declaration for Solutions on Marine Litter”, which outlines a six-point strategy for industry action. further information: www.bpf.co.uk

Right to Left at the 26th April 2013 Kent beach clean, organised by the MCS: Philip Watkins past BPF President; Dick Searle, Chief Executive the Packaging Federation; Peter Davis, DirectorGeneral the British Plastics Federation

39 bp&r

engineering materials

news Bayer was responsible for the design of the complete cockpit shell, amongst other things. Image: Copyright Solar Impulse 2014

The second-generation aircraft will attempt to fly around the world without fuel in 2015.

Image: Copyright Solar Impulse 2014

40 bp&r

Plastics take flight in new super-light aircraft Innovative plastics from Bayer MaterialScience have been used to construct parts of a futuristic aircraft that is aiming to be the first to complete a round-the-world flight without fuel in 2015.

The new, second-generation Solar Impulse aircraft is an advancement of the first prototype, which in 2010 demonstrated the feasibility to fly day and night using only solar energy. Since then it has successfully completed numerous flights, most recently a coast-to-coast journey across the United States.

On board are numerous products and solutions from Bayer MaterialScience that make the plane especially lightweight and energy efficient, including Baytherm Microcell, an efficient insulating material used for the cockpit.

The insulating performance of Baytherm Microcell is said to be as much

as 10 percent greater than the current standard. Highly efficient insulation is particularly important for the aircraft because it must withstand temperature fluctuations between minus 40°C at night and plus 40°C degrees during the day.

Baytherm Microcell is used for the aircraft door, while the rest of the cockpit shell is made of a different type of rigid polyurethane foam from Bayer. The company also supplies a polyurethane/carbon fibre composite material for the door locks, and thin sheets of transparent, high-performance polycarbonate for the window. Although the cockpit is larger overall than in the first prototype, it is only minimally heavier.

Outside the cockpit, rigid polyurethane foam is used to insulate the batteries.

Bayer also provides the raw materials for the silvery coating covering large portions of the aircraft and the adhesives that hold the textile fabric in place underneath the wings.

“The Solar Impulse initiative is both scientific and innovative. It is also

philosophical, by its goal of raising awareness in society about the need to save our planet’s energy resources,” commented Bertrand Piccard, one of the solar Impulse project’s founders. “Without Bayer and its mission of conducting ‘Science For A Better Life’ this solar airplane would never have been light and efficient enough to be able to fly night and day without fuel.”

On its historic journey around the world, the plane is to be powered solely by the sun. The energy will be generated by roughly 17,200 solar cells on the wings, which at 72 metres have a span equal to that of the largest passenger airliners. The entire aircraft, however, only weighs 2.3 tonnes.

The second model will undertake a number of test flights this year prior to setting off on its main mission in March 2015. further information: www.bayer.com www.solarimpulse.com

// Materials Technical //

Blog In association with Hardie Polymers – www.hardiepolymers.com This month, polymer expert and technical blog author, Dr Charlie Geddes, wonders where industry demand for increasingly versatile applications might take polymer blends.

Where are Engineering Thermoplastics Blends going?

The timeline of appearance of materials for the plastics industry can be viewed as several overlapping phases. The industry started with natural materials such as horn and bone, which can be thermoformed. Next came chemical modification of natural polymers, producing cellulose nitrate and cellulose acetate from cotton and wood fibre. The 20th century saw the appearance of wholly synthetic polymers (PVC, polystyrene, polyethylene etc). The era of seeking monomers to convert into useful polymers was followed by a period of creating copolymers to extend the choice of thermoplastics and the range of properties. This quest for new polymers and copolymers became curtailed because of the massive capital investment required.

The less expensive route of blending two existing polymers has become an attractive method of widening the properties profiles to satisfy diverse applications. Some polymers mix well with each other (miscible or compatible blends) but most pairs result in blends that literally fall apart or delaminate. The addition of a few percent of special polymers (compatibilisers) can encourage the two engineering thermoplastics to stick together and generate some interesting blends, which bring out the best properties of the two components in a synergistic way.

In PC/ABS, the most common blend, the polycarbonate adds fire performance to the properties of ABS and, in return, ABS contributes processability. Acrylonitrilestyrene-acrylic (ASA) and polymethylmethacylate (PMMA) improve weathering resistance in blends with polycarbonate or polyesters, while polycarbonate adds dimensional stability and flame resistance in blends with polyesters. Some blends, such as polypropylene/polyamide, give good mould detail for matt, scratch resistant finishes, obviating the cost of painting, while acrylics in blends with polycarbonate can achieve high quality, gloss, piano black finishes.

What will be the next development in thermoplastic blends in providing designers with broader palettes in matching thermoplastics with design requirements?

Got a view on the above? Blog posts will also be published on the BP&R website at www.britishplastics.co.uk - feel free to leave your comments.

Plastics take to th

e podiu

m at Sochi The medals awarded to winners at the recent Soc hi Winter Olympics were made using a combinatio n of metal and durable pol ycarbonate (PC) sheet from Sabic's Innovative Pla stics business. Lexan Ma rgard sheet was used in the centre of the medal s so a representation of the landscape of Sochi could be engraved. www.sabic.com

41 bp&r

News from the Front Line

A

recent seminar organised by the BPF for the UK’s rotational moulding industry provided a microcosm of the value This month, Philip Law, provided by Director General Designate the at the British Plastics Federation.

Federation, talks Held at rotational moulding, Worcester packaging progress and Racecourse health and safety. on 8th April, the event attracted 103 delegates from some 50 companies and proved to be a veritable ‘Who’s Who’ in rotational moulding – a manufacturing practice once regarded as a ‘cinderella’ process, but now at the cutting edge of materialising innovative design in plastics.

The UK’s rotational moulding sector is one of the largest in the world with an estimated 70 companies. The BPF’s Rotational Moulders Group is also one of the most venerable, with its origins dating back to 1978 when a hardcore of companies came together under the auspices of the BPF to draft a code of practice for the safeguarding of rotational moulding machines. From those modest origins the Group, now under the Chairmanship of Karen Drinkwater of JSC Rotational, has grown to 24 companies

and will next year host the prestigious ARMO Conference at the Nottingham Centre on September 13th - 15th. This will be the second time in recent years the BPF has taken responsibility for organising the annual forum of the Affiliation of Rotational Moulding Organisations (the first was at Belfast in 2008) and the vibrancy of the sector here is certainly helping the UK establish itself as a real nerve centre of the worldwide rotational moulding industry.

BPF activity is richly varied and a current point of emphasis is plastics packaging, long the Aunt Sally of NGOs and, indeed, Governments. Not so long ago the BPF published ‘Plastics Packaging - The Progressive Packaging Medium’. I rate this, even in spite of its short and pithy eleven pages, as the most comprehensive statement of the benefits of plastics packaging ever to be produced.

“Impossible” some may respond, “Haven’t there been lots of brochures about plastics packaging?” “Well,” I would reiterate, quoting Evelyn Waugh’s ‘Scoop’, “only up to a point, Lord Copper”. The uniqueness of the BPF document is that it tells the reader that the plastics packaging industry in this country is a national economic strength based on the UK’s historic status as a trading entrepôt and

one which is arguably the most innovative in the world, supporting one of the most sophisticated retailing systems on the planet and enabling supermarkets to offer UK consumers unrivalled choice and quality.

Health and Safety is so crucial to the reputation of the plastics industry and a topic, thanks to the BPF’s Health and Safety Committee, under the Chairmanship of Mike Jones (Distrupol), in which the Federation is very active. This diligence is now bearing fruit. As the BPF’s ‘Annual Accident Survey’ revealed, there is a general downward trend in accidents in the sector.

To help members secure further improvements in their health and safety record the BPF has launched a safety audit tool as part of its contribution to the SIMPL initiative, the Safety In Manufacturing Plastics Campaign, in which BPF is a key partner, alongside the HSE. The audit tool aims to help small and medium sized operations in assessing the risks of their manufacturing environments and in taking corrective action. further information: www.bpf.co.uk

Don’t watch your profits go up in smoke

C

onstruction and infrastructure sectors have proved their significance over the years with the building of roads, homes, work and commercial This month, Steve Shaw, spaces and the Executive Director at overall RAPRA, explains how infrastructure of investing in R&D can our society using prove crucial when historically choosing the right traditional material and additives materials and, for new applications in more recently, the building and plastics and construction industries. rubbers.

The art and science of finding new, better, more cost effective materials requires innovative research that throws up new challenges and problems to solve. Current and future legislation affects the tried and tested chemical additives that industry is allowed to use. Advances in 3D printing and prototyping challenge the way the building environment is designed and constructed.

All these challenges affect the way industry works and the products they bp&r produce and use.

42

From the very beginning of the plastics industry, additives have been introduced to promote new operational effects on plastic compounds. They have helped chemical processing and mitigate undesirable properties such as thermal degradation into volatile and potentially fatal compounds as a byproduct of fire.

RAPRA has Flame retardants represent an area of access to a research that is constantly in demand as wide network of the need for ever safer materials and the companies changes in legislation and law move the that have goal posts in terms of chemicals that are specialist allowed, and the effect that removing current chemicals has on the materials in knowledge in a variety of use at the present time. fields No one wants to see their brand new building go up in flames because the plastics used didn’t have adequate flame incredibly niche. We encourage retardant properties. But with so many investment in R&D for new applications in different flame-retardants available, how do you know which is the best one for your order to ensure they conform to all relevant regulations and criterion, as well job? as being the most suitable for the task in This is where effective research and hand. development can prove crucial. RAPRA offers access to a network of ‘preferred further information: providers’ that have expertise in a range www.rapralimited.org of fields – from the very general to the

events

BP&R takes a look ahead at some of the upcoming conferences, trade shows and industry events of 2014.

2014

software directory manufacturing management directory ENTERPRISE RESOURCE PLANNING Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com

SEPT

30

OCT

2 And they’re off! Starting gun sounds for Interplas visitor registration In keeping with the theme of some notable equestrian events of late, the starting gun has sounded, meaning the gates are open for visitors to register their attendance at Interplas 2014.

As we gallop (excuse the pun) towards the opening day of the show on 30th September, visitors who register from now will guarantee themselves free entry into Interplas, the ‘must attend’ plastics event of the year in the UK. Organised by Rapid News Communications Group, the triennial event is set to play host to more than 400 exhibitors. With so many plastics giants booked to attend, Interplas is set to be the place to do business in the plastics industry in 2014. A full list of confirmed exhibitors can be found at www.interplasuk.com.

The exhibition floor, which is over 80 percent sold, will be complemented by an exceptional speaker line-up, which will see top-flight innovators and leaders of the industry take to the stage to deliver thought-provoking and engaging speeches. Moreover, there will be a range of superb technology sessions for attendees from every corner of the market and of every experience level, to enlighten, educate and expand on the hottest topics facing the industry.

Interplas will once again take place at the NEC, Birmingham, UK, running from September 30th to October 2nd with more than 12,000 visitors set to pour through the doors. The show will be colocating with corresponding design and manufacturing shows including TCT Show + Personalize, Sensing & Instrumentation, Micro Nano Mems and the PPMA Show. Visitors will have access to every event on one ticket.

Duncan Wood, COO and Event Director at Rapid News Communications Group, commented: “We are extremely excited about the forthcoming show. On the back of a hugely successful event in 2011 the expanded exhibition floor is on track to be a sell out with almost 400 exhibitors taking their place in the hall. Anyone involved in designing and manufacturing plastic parts will find a wealth of new products, innovations and intelligence across the three-day event. It is clearly the biggest and most important event for the UK plastics industry and we look forward to welcoming thousands of visitors to the NEC in September.”

Interplas 2014 takes place at the NEC, Birmingham, UK on September 30th-October 2nd 2014. Visitors can register for free at www.interplasuk.com/register.html.

Epicor’s ERP (on-site, hosted & SAAS) manufacturing software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution.

It seamlessly integrates with Epicor Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING Epicor Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com Modules: Production Monitoring, Process Monitoring, “Drag and Drop” Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts’ Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/ Public Address System Alerts, Stand-alone “Drag and Drop” Scheduler, Stand-alone SPC “Machine Analyzer”, Machine Energy Monitoring, KPI Dashboards, Visual Manufacturing (Large LED Displays), Automatic Data Import/Export Functions (For Integration with Epicor ERP & Other Manufacturing Systems/Software Packages).

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ 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.

ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Standalone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages).

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

Affordable and flexible MES system for the plastics/rubber industry.

Real-time production monitoring features wireless data units and OPC Ethernet machine connections.

“Drag & 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.

Easy to use systems from a €600m company with over 30 years experience.

SYSCON-PlantStar MTec Services Ltd T: 0114 2476267 F: 0114 2476267 E: mt@mtec-services.co.uk W: www.mtec-services.co.uk W: www.syscon-intl.com PlantStar systems provide customised, scalable applications that deliver real-time plant floor data from any machine, shift, and plant anywhere in your business.

Affordable systems available for all size of processor.

Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed.

Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.

A listing in the Software Directory costs £140 per programme per year. Call Lisa on 01244 680222 for details.

43 bp&r

buyers’ guide

materials

colour masterbatch

mould release

FOR SALE

Reheat Stretch Blow Moulding Machine (PET) Make: Sidel, France Type: SBO 24/24 Year: 1994 - Preform Tipper, Hopper / Elevator, Infeed Rail - Oven & Heating Wheel - Electrical Cabinet (Siemens S5) - Operating manuals

For further details: 01925 596170 – 07838138342 Email: douglastrading@gmail.com

assembly hot plate welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu Machine Techniques Ltd Units 3-5, Sutton Court, Bath Street, Market Harborough, Leicestershire LE16 9EW T: 01858 434059 F: 01858 433638 E: davidchatterton@ymail.com W: www.mactec.co.uk

pulse staking H.T.E Engineering Ltd

equipment Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service.

1 mm Easysperse MicroPellets to 4 mm MaxiPellets.

Standards second to none.

control systems and equipment quality monitoring control Kistler Instruments Ltd

Unit 9, St Ives Enterprise Centre, St Ives, Huntingdon Cambridgeshire, UK, PE27 3NP T: +44 (0) 1480 467321 M: +44 (0) 7435 967632 E: john@hte.ie W: www.pulsestaker.com

ultrasonic welding

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.

Dosing equipment material handlinG masterbatch

InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 816507 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

polymer distributors

Telsonic UK Ltd

ancillary

FLEXIBLE POLYMERS RIGID POLYMERS ADDITIVES PURGING SOLUTIONS

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

C.J.P. Sales Ltd, 8 Heol West Plas, Litchard, Bridgend CF31 1PA

Tel: 01656 644907 Fax: 01656 662 397 Email: sales@cjpsales.co.uk Web: www.cjpsales.co.uk

conductive plastics and coatings TBA Electro Conductive Products Ltd Unit 3 Transpennine Trading Estate Gorrells Way, Rochdale, OL11 2PX T: 01706 647718 F: 01706 646170 E: info@tbaecp.co.uk W: www.tbaecp.co.uk

To advertise in this space

44 bp&r

12a - 15 Birch Copse, Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: info@uk.telsonic.com W: www.telsonic.co.uk Blog:www.telsonicuk.wordpress.com

contact lisa montgomery 01244 680222

chillers/temperature controllers

Energy Saving Dryers

ROTOR WHEEL DRYERS The New Industry Standard Up to 70% Energy Saving Low regeneration No Chilled Water No Compressed Air Temp. range 55-180˚C 5 Year Warranty E info@summitsystems.co.uk W www.summitsystems.co.uk T 01827 265 800

extrusion systems

Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

thermocouples Elmatic (Cardiff) Ltd Wentloog Road, Rumney, Cardiff CF3 1XH T: 029 20 778727 F: 029 20 792297 E: sales@elmatic.co.uk W: www.elmatic.co.uk

extruders and downstream equipment Cooper Plastics Machinery Unit 12, Harmill Industrial Estate, Grovebury Road, Leighton Buzzard, Bedfordshire LU7 4FF T: 01525 850610 F: 01525 218008 E: cooperplastics@googlemail.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.

granulators

dryers/dehumidifiers

hopper loaders

Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

Motan Colortronic Ltd

hot runner systems

screws and barrels

DTL Machinery UK We Buy / Sell all Makes, Age and Sizes of Injection Moulding Machines & Ancillaries Tool room machines and also complete factories / plants Factory Clearance Services Dismantling / Removal of obsolete plant and machinery T: 01925 596170 M: 07838138342 E: douglastrading@gmail.com

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

hot runner controllers

secondhand and reconditioned Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com

Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

Rawmec (EEC) Ltd Rawmec Industrial Park, Plumpton Road, Hoddesdon, Herts EN11 0EE T: 01992 471796 F: 01992 471797 E: rawmec@btconnect.com W: www.rawmec.com

mixing, feeding, drying

heating equipment infra red systems

Motan Colortronic Ltd

TransXL International Ltd Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

metal detection & separation equipment

static control Arrowquint Ltd Unit 5 Sanders Close, Finedon Road Industrial Estate, Wellingborough, Northamptonshire NN8 4HQ T: 08450 655455 F: 08450 655456 E: sales@arrowquint.co.uk W: www.arrowquint.co.uk Static control solutions, equipment sales and rental, repairs and on-site servicing. UK/Eire agent for Eltex – market leaders in static control systems.

Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

nozzles & nozzle tips Injection Moulding

testing equipment

secondhand and reconditioned ANGLO PLASTICS LTD

induction heating for platens and tools MF Induction Heating Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 F: 01543 574460 E: sales@mfinduction.com W: www.mfinduction.com BS EN ISO9001: 2000 registered.

BS EN ISO9001:2008

LABORATORY machines

printing machines materials handling and storage

Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com

pad Ray Ran Test Equipment Ltd

gravimetric/volumetric blending

Buy and Sell Cable and Plastics Machinery

Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan colortronic.co.uk W: www.motan-colortronic.co.uk

Presently Available:

Floatair tumble mixer 250kg capacity

Kelsey Close, Attleborough Fields Industrial Estate, Nuneaton, Warwickshire, CV11 6RS T: 024 763 42002 F: 024 766 41670 E: Polytest@ray-ran.com W: www.ray-ran.com

50mm x 24:1 Boston Matthews extruder 90mm x 24:1 Francis Shaw extruder

hopper dryers

Rapid Granulator type 4535/KV Please Contact:

T: +44 (0)1204 534414 E: sales@goodwinmachinery.co.uk W: www.goodwinmachinery.co.uk

screen changers Industrial Plastics Ltd Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk

DM Machinery Ltd Used Injection Moulding Machine Stockists 40 Thorne Lane, Wakefield West Yorkshire, WF1 5RR T: 01924 290206 E: sales@dmmachinery.co.uk W: www.dmmachinery.co.uk

hardness - IRHD and shore MAPRA Technik Co — BAREISS 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

To advertise in this space contact lisa montgomery 01244 680222

45 bp&r

buyers’ guide To advertise in this space

services mouldflow analysis

contact lisa montgomery 01244 680222

World leader in Materials Testing Instrumentation

parts & services

EXTRUSION Extrusion and Plastics Services Extrusion, Compounding, Wash Plant Installation, Maintenance, Removal New Factory Setups / Single Machine CAD work / Tooling Mods / Trials Product Development / Line Trials Downstream Equipment Repairs Chillers, Pumps, Pipework, Air etc Punching / Drilling / Foiling / Wrap Filtration / Settlement Systems Process Improvement / Training

EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H. Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at

07930 150120 extrusionandplastics@hotmail.co.uk

Tensile|Fatigue| Impact Compression|Melt Flow

CHOOSE THE NUMBER ONE.

printers

Coronation Road, High Wycombe, Bucks HP12 3SY, UK

EXTRUSION FLOW ANAYLYSIS

Tel: +44 1494 464646

printers of plastic mouldings

FLEMING Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in the flow simulation of: Extruder screws & spiral mandrel,flat spiral,profile, coathanger & coex dies Compuplast distributor Stop guessing start simulating Tel: +44 (0)1299 253300 www.flemingptc.co.uk

www.instron.com inspection & measurement 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

Contract cleaning

WANTED injection moulding

RIDAT COMPANY

Injection Moulding Extrusion

SUPERIOR PERFORMANCE. COMPETITIVE PRICE.

• • • • • • UK manufacturer of Thermoforming & Pressure Forming Equipment, including Blister & Skin Packaging machines For more information or to order our sales brochure please contact us:

T: 0845 050 6525 or E: info@ridat.com www.ridat.com

RECYCLING systems

Hot Runners Nozzles Moulds Dies Filters Screws Cleaning service for processors Remove all polymers Tel:- +44 121 511 1203 Fax:- +44 121 511 1192 Email:- LesH@claytonholdings.com Web:- www.claytonholdings.com

testing/consultancy FLEMING

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

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

Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in: Capillary rheometry FTIR DSC/TGA MFR/MVR Extrusion Pilot-scale blown film Line Instrumented impact Flow simulation Tel: +44 (0)1299 253300 www.flemingptc.co.uk

Gammadot Rheology Testing & Consultancy Services 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 lisa montgomery 01244 680222

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GLOBAL PLASTICS INDUSTRY

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Overproportional throughput combined with perfect product quality 41D single-screw extruder for highperformance extrusion The real processing length of the 41 L/D offers top performances in pipe extrusion in PE and PP processing. The 41D line – equipped with the new C6 line control system – offers you a wide range of benefits: – Patented screw concept guarantees material-friendly plasticization – Perfect wear-resistance though bi-metal barrels – Flexible control, intuitive and fast operation thanks to the C6 line control system – Maximum reliability through individual and continuous process control

Engineering Value

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