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PLASTICS PROVE CLARKSON’S GOT IT WRONG
BRITISH PLASTICS &RUBBER
www.britishplastics.co.uk EDITORIAL
group Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com
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duncan wood T: +44(0)1244 680222 E: duncan@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 rate: UK, Europe and rest of the world £249 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2017 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.
T
he importance of plastics in the future of the automotive industry shows no sign of waning. Quite the opposite in fact, if the materials innovations presented at the VDI Automotive Conference at the end of last month were anything to go by. Not only were there a number of newlydeveloped solutions presented for the ongoing light-weighting of vehicles, including thermoplastic composites used for the first time in structural components and engineering polymers for metal replacement in under-the-hood applications, but there was also a nod to the more futuristic, with plastics showing their importance when it comes to holographic lighting, intuitive dashboards and displays, and components for autonomous driving. Far from these latter developments being concepts that may never make the road, the use of plastics to enable technologies such as these to be used in mass-produced vehicles are the latest way of ensuring that driving is safer, more environmentally friendly and ultimately, more cost-efficient than ever before. So, despite disparaging comments made by Jeremy Clarkson in a
I am sure, like me, you’ll agree that plastics are actually valueadd, more advanced than ever and leaving their ‘cheap’ image in the dust
recent review for a driving website about the use of plastics in cars making them “crap”, after you read our VDI roundup starting on page 31, I am sure, like me, you’ll agree that plastics are actually value-add, more advanced than ever and leaving their ‘cheap’ image in the dust. Enjoy the issue.
Leanne Taylor, Group Editor
bp&r
THE BIG STORY DRIVING UP QUALITY
in automotive plastics recycling
C
ollecting and recycling plastics from an end-of-life vehicle represents a major challenge for the industry, depending on the application. Large plastic parts, for instance, are easy to dismantle and THE PLASTICS IN END- segregate. Bumpers OF-LIFE VEHICLES ARE OF (made from PP INCREASING IMPORTANCE or a PC / PBT TO RECYCLERS. THE blend), engine PURITY OF THE PLASTIC compartment WASTE, HOWEVER, IS panels, exterior and interior ULTIMATELY CRUCIAL TO components, THE EFFICIENCY OF THE and PP battery RECOVERY PROCESS. casings are just ETTLINGER’S ANDREAS a few examples. All other LIEBING EXPLAINS HOW THE COMPANY’S ERF HIGH plastic parts are shredded: PERFORMANCE MELT whatever still FILTERS ARE IDEALLY remains of SUITED FOR AUTOMOTIVE the end-ofRECYCLING APPLICATIONS life vehicle is AND PRODUCING A HIGHER mechanically QUALITY END PRODUCT. crushed to a size of <150 mm. Various shredder fractions are defined: the plastics are classed as SLF (shredder light fraction, also referred to as RESH (residue shredder), fluff, or ASR (auto shredder residue)). They add up to between 25 percent and 40 percent by weight. These mixtures of substances can be separated and sorted, e.g. into PP, PE-HD, ABS, and PS flake, in complex processes. The flake is then melted in an extruder, compounded and – ideally – converted into high quality recycled material which can be reused in demanding automotive applications.
high performance melt filter plays an important role. The central component is a slowly rotating, cylindrical filter screen which is driven by a servo motor. It has millions of conical holes and can be supplied with a variety of screen sizes. When the melt flows through the screen from the outside to the inside, contaminants are retained on the outside. These contaminants are wiped clean from the filter surface after each rotation of the screen, so that blockage of the holes is avoided. Thanks to this continuous cleaning principle, a constant pressure is maintained in the system and elastomers – which would otherwise be forced through the screen mesh as more and more pressure builds up – are now reliably removed from the rotating filter drum and discharged from the process. Whereas the cleaned melt is supplied to the downstream die via a system of flow channels, the particles that have been removed in this way are continuously fed to an exit screw, which is driven by a second servo motor. This principle ensures that almost all of the contaminants remaining in the flakes are efficiently removed, even if the level is as high as 18 percent, enabling high quality regrind to be produced.
Cost efficient, reliable and compact
In addition to the reliable and thorough separation of contaminants, the very low melt loss is another typical feature of all ERF filters that has gained them a reputation for cost efficiency. In automatic mode the contaminant level in the discharge can be as high as 70 percent.
Thorough filtration enables high quality regrind However, the sorted flakes generally also contain significant quantities of paint residues from bumpers and other exterior components as well as elastomer residues. These and similar contaminants must be removed in an efficient manner using a separate extrusion filtration process. This is where Ettlinger Kunststoffmaschinen GmbH’s specially-developed ERF
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The actual melt pressure at the inlet of the ERF filter is an important parameter for controlling the system. If it increases, for example because the contaminant level rises, the rotation speeds of the filter drum and the exit screw are automatically adapted. Each of these speeds can therefore be adjusted independently of the other. The rotary motion of the filter drum simultaneously supports the blending effect and ensures optimal homogeneity in the melt.
Tried and tested in ELV applications
The ERF melt filters have been tested on common plastic car components. For bumpers, where the biggest problem is the paint residues that remain on the flake in spite of the paint removal process, an ERF filter with a screen size as small as 80 µm can efficiently remove these unwanted particles allowing the final product to be used in injection moulding applications of automotive parts. The ERF filter is offered in three sizes (ERF200, ERF250, ERF500) and is suitable for maximum throughputs of 6000 kg/h depending on the material and the screen size. In the UK it is available through Chesterfield-based Motan Colortronic Ltd. WWW.MOTAN-COLORTRONIC.CO.UK WWW.ETTLINGER.COM
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contents
PLASTICS &RUBBER
APRIL 2017
on the cover DRIVING UP QUALITY IN AUTOMOTIVE PLASTICS RECYCLING The plastics in end-of-life vehicles are of increasing importance to recyclers. The purity of the plastic waste, however, is ultimately crucial to the efficiency of the recovery process. Ettlinger’s Andreas Liebing explains how the company’s ERF high performance melt filters are ideally suited for automotive recycling applications and producing a higher quality end product. SEE PAGE 4
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EDITOR’S LETTER PLASTICS PROVE CLARKSON’S GOT IT WRONG
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FEATURE PRODUCTIVITY IN PRACTICE: SMALL CHANGES FOR THE BIGGEST REWARD
Productivity, and ways for the UK manufacturing industry to increase its levels to remain competitive, is a topic of increasing importance. But how can the plastics industry benefit and can you increase productivity without major investment? Craig Forrester of Stäubli UK argues that in many cases, the maximum gain comes from the lowest investment.
29 REGULARS
FEATURE RECYCLING COLLECTION RATES ‘CLOUD’ THE NEED FOR INNOVATION
Innovation and development in technologies to increase recycling of household plastic packaging is being hampered by how we measure its collection, and a lack of economic drivers to encourage investment, argues Richard McKinlay, Head of Engineering and Research at UK-based resource recovery specialist, Axion Consulting.
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FEATURE AUTOMOTIVE PLASTICS: LIGHTWEIGHT, LIFESAVING, TRAILBLAZING
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Plastics in modern, and future, vehicles continue to increase in volume and importance. This was evident at the recent ‘Plastics in Automotives’ conference organised by the Association of German Engineers (VDI), where the very latest materials developments were unveiled.
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POLYMERMAN ON PRICES ARE INCREASING POLYMER PRICES MORE SUSTAINABLE THAN THE FEEDSTOCK PRICES THAT TYPICALLY HAVE INITIATED PRICE INFLATION?
In this edition of our latest feature looking at the key issues that influence polymer prices, Mike Boswell examines the sustainability of polymer price increases vs. feedstock.
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INDUSTRY NEWS 09 interplas 13 injection moulding 15 masterbatch and additives 23 Reclamation and Recycling 27 automotives 31 composites 38 extrusion machinery 40 materials 45 BUYERS’ GUIDE 47 SOFTWARE 49 NEWS FROM THE FRONTLINE 50
WWW.BRITISHPLASTICS.CO.UK
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INDUSTRY | NEWS PLASTICS COMPANIES IN UK AND GERMANY LAUNCH APPRENTICESHIP EXCHANGE PROGRAMME A new pilot programme designed to upskill apprentices across the continent has been launched in a collaborative programme between two plastics companies. Middlesex-based producer of plastic fittings, John Guest, has teamed up with German injection moulding machinery manufacturer, Arburg, for the scheme, which will see the two companies “trade” final-year apprentices for a four-week period. The UK apprentices will visit Arburg’s factory in Lossburg to learn how injection moulding machines are assembled, whilst the German exchange students will experience how Arburg’s machines are utilised for the manufacture of push-fit fittings at John Guest. “As well as technical knowledge, we believe the greatest gains for the apprentices will come from less obvious areas. They will be
lying is supp Genesis hinery’s c stic Ma la P y a B the UK range in
L-R Luke Perry (John Guest), Alex Jones (John Guest), Martin Schmid (Arburg) and Felix Schübel (Arburg)
working in a company and a country with different cultures, as part of different teams, which speak a different language,” commented Apprenticeships Co-ordinator at John Guest, Darryl Sheldon. It is hoped that this programme
will be successful, and become the first of many schemes that the two companies operate across the continent, helping to trade skills and experience.
GENESIS MARKS DECADE OF BUSINESS WITH NEW UK DISTRIBUTORSHIP
installed to most strand pelletisers, uses vacuum to immediately remove pellets from the cutting chamber. Bay Plastics Machinery manufactures three basic types of pelletiser – manual, automatic or water bath – and there are variations of each type, with options for customisation. This flexibility, says Phil Cameron, Sales Director of Genesis Process Solutions, is what has lead to BPM becoming one of the leading US manufacturers of pelletisers. “We believe that there is a strong market for the products from Bay Plastics Machinery and certainly the research that we have carried out has been very positive,” Cameron explained. “The whole range is competitively priced and extremely well engineered so it will be interesting to see how these products are accepted by the industry.”
Genesis Process Solutions is marking its 10th year of business with the announcement of a new UK distribution partnership with USbased Bay Plastics Machinery (BPM). Formed in 1961, Bay Plastics Machinery is a major manufacturer and supplier of plastics machinery in the United States but, until recently, has not had any representation in the UK. Cheshire-based Genesis is now introducing Bay’s range of strand pelletisers, conveyors and air knives to UK manufacturers, as well as the company’s latest patented system that is designed to eradicate ‘carryover’, a problem that commonly affects pelletisers when a small number of pellets are drawn back into the rotor during the cutting process and are cut multiple times. The BPM solution, which can be
WWW.BRITISHPLASTICS.CO.UK
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WWW.GENESISPS.CO.UK
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International Exhibition for Polyurethane Solutions
Discover the innovative capabilities of PU solutions – Applications for new markets! • Live presentations of machines and solutions • Feature areas for networking and knowledge exchange
27 – 29 June 2017
Organisers: Mack Brooks Exhibitions Ltd
MOC Munich, Germany • Raw materials • Materials/semi-finished products • PU products/systems • Processing machinery, systems & equipment • Services For various industries
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REVENUES RISE AFTER ONE51 PINS HOPES ON PLASTICS One51, the Irish environmental services and recycling company, continues to narrow its commercial focus to the plastics industry, selling off its metals recycling facilities. The company has announced an increase in its revenue of 18.3 percent over the last year, to €433 million (approx. £370 million GBP), after the acquisition of Encore Industries, an American plastic packaging maker, and selling off its British and Irish environmental services divisions. Alan Walsh, One51’s Group Chief Executive, said: “In a few short years One51 has evolved from being a diversified investment company to one focused solely on plastics. “Our latest results, which are ahead of expectations, support that strategy. Our challenge now is to continue to grow our plastics operations, both organically and through acquisition, while continuing to integrate our previous acquisitions.
We see the potential to make acquisitions in the retail packaging and bulk packaging sectors in both North America and Europe. Trading in 2017 to date has been solid and in line with expectations.” Earnings in 2016 increased by
WWW.ONE51.COM g its narrowin to the One51 is u c s rcial fo comme y s u ind tr plastics
SI PROTECH SET TO EXPAND FOLLOWING NATWEST INVESTMENT
SI Protech will use the half a million pounds worth of funding to expand its business
over half, 53 per cent, to €55.2 million (£47.8 million) and One51 has pledged to continue its efforts to buy plastics packaging and processing operations.
Littlehampton-based plastics design and manufacturing company, SI Protech, is set to invest £500,000 of NatWest and Lombard funding into automation and manufacturing improvements. The investment will enhance the design and implementation of the company’s products, leading to increased productivity. It will also support the introduction of operational improvements that will advance the company’s business procedures and help drive efficiencies. These refinements will lower SI Protech’s cost base and allow the business to hire high skilled employees through the expansion of its technical team. The firm currently employs over 25 local staff and is set to begin a moulding technician trainee scheme to help combat the technical and engineering skills shortage. The company was established in 1997 and focuses on plastic injection moulding, design and development,
WWW.BRITISHPLASTICS.CO.UK
building assemblies for the food, beverage, electronics and medical industries. It is the sole supplier of three major products to the breweries corporation, Heineken. Alan Edmonds, Managing Director of SI Protech, said: “This funding will be the key to ensuring that we remain at the cutting-edge of manufacturing and design technology. NatWest were able to provide us with flexible facilities and continual support throughout this process, and have been instrumental in the development of the business.” David Greenough, NatWest Relationship Manager, said: “SI Protech is a business that prioritises innovation. Their self-chilling ‘ChillCan’ that allows drinks to cool in under two minutes is just one example of how they are breaking the mould and delivering innovative design. We are confident that their hi-tech output will continue to contribute immensely to the local community, delivering jobs and significant economic benefits.” WWW.SIPROTECH.CO.UK
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PENTAGON PLASTICS WELCOMES STUDENTS FOR EDUCATION DAYS Plastic injection moulder and toolmaker, Pentagon Plastics, has welcomed design students from London South Bank University and separately, engineering students from the University of Brighton, to its manufacturing facilities. The visits are part of ‘education days’ conceived by Pentagon’s Managing Director, Paul Edwards, to give students hands-on experience, enhanced insight into design for manufacture and the opportunity to better understand the plastic injection moulding process. Whilst visiting the Sussex-based company, students were shown a presentation on all aspects of the business and asked questions to further enhance their understanding.
BANK OF ENGLAND CONSIDERS PALM OIL AS SUBSTRATE FOR POLYMER NOTES The Bank of England is considering palm oil as an alternative substrate material for the production of future polymer banknotes, following a backlash over the use of animalderived additives in the current notes. The current £5 and upcoming £10 polymer banknotes have so far been produced using a miniscule amount of animal tallow, bringing criticism from certain vegetarian and vegan, religious and environmental groups. Alongside a public consultation, the Bank has been researching alternative materials with the help of potential suppliers, Innovia Security and De La Rue, before it commences the printing of the £20 note, set to launch in 2020.
Pentagon has started Education Days for students studying design and engineering disciplines
A tour of the premises followed, including the newly acquired site of Phoenix Engineering. The final stage of the day involved visiting the postmoulding department, an expanding element of the business. Steven Smith, Tutor at the University of Brighton, said: “Visits to
So far, options such as palm oil or coconut oil have been mooted, although the conclusion is that palm-oil derived additives are the only practical alternative owing to a more mature supply chain. However, the Bank says it would have to mitigate any environmental impacts by ensuring its supply was from sustainable production sources. A substrate produced using palm oil must meet the technical and operational requirements to enable the manufacture of secure notes in high volume. The Bank says De La Rue and Innovia Security are “confident” that it should be technically possible to use palm oil. However, it must now reflect upon the various religious, ethical and environmental considerations of any replacement, alongside the responses to the public consultation. WWW.BANKOFENGLAND.CO.UK/ BANKNOTES/POLYMER
rrently k is cu The Ban palm oil as at looking native ial alter t n e t o a p olymer p s in it for use notes
companies like Pentagon Plastics are crucial to students’ understanding of industrial processes like injection moulding and tool making. In university lectures, we can describe the theory, but witnessing the operation in practice is an experience that will stay with them all their professional lives. And the better they understand the constraints (and opportunities) of these materials and processes, the more likely it is that they, and their ideas, will succeed.” Pentagon says the education days are a way of addressing the current skills gap that the industry faces, as well as helping inform the product designers and engineers of the future. In future it will open the opportunity to school age children with a keen interest in the industry. WWW.PENTAGONPLASTICS.CO.UK
TERRY SCUOLER, EEF CHIEF EXECUTIVE, TO STEP DOWN Terry Scuoler, the head of the manufacturers’ organisation EEF, is to step down as Chief Executive at the end of the year. Scuoler, 66, who is entering his eighth year as head of Britain’s leading manufacturing trade body, will continue to lead the group until the end of the year to allow time for a successor to be appointed. After being appointed Chief Executive of EEF in 2010, he has led the organisation through major changes, building the group’s representation work in Britain and Europe and significantly strengthening the business services provided by the group. Scuoler also led the sector’s response to recovering from the economic challenges following the financial crash of 2008, and, more recently, he represented manufacturing interests in the lead up to the EU referendum and subsequent Brexit debate. EEF Chair, Dame Judith Hackitt, said: “Terry will be an extremely difficult act to follow. His strong and successful leadership of EEF and the sector is widely recognised and appreciated and reflects his deep-seated commitment to British manufacturing.” WWW.EEF.ORG.UK
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WWW.BRITISHPLASTICS.CO.UK
PRE-SHOW NEWS
PMMDA looks forward to success at Interplas as UK moulding machinery figures increase
S
peaking to BP&R, Kevin Horne said recent statistics showed an increase in the value of moulding machines sold into the UK and Ireland, and, although the actual numbers were THE CHAIRMAN slightly down, turnover had increased OF THE PLASTICS by 15 percent. “This is impressive to say the least,” MACHINERY MOULDERS Horne said. “Having recently had a AND DISTRIBUTORS conversation with senior figures within ASSOCIATION (PMMDA) the BPF, they reported similar growth SAYS THAT THE patterns from their own membership, ORGANISATION IS which includes end users, LOOKING FORWARD manufacturers as well as machinery suppliers during 2016.” TO A SUCCESSFUL Horne said that the upcoming EXHIBITION AT Interplas exhibition in September, INTERPLAS THIS YEAR, which is the biggest plastics trade FOLLOWING ON FROM show in the UK, is the ideal forum for A POSITIVE 2016 FOR PMMDA members to showcase their machinery to an audience looking to ITS MEMBERS. compare and contrast a wide range of plastics manufacturing equipment. “We are looking forward to the show this year, which will give visitors an ideal opportunity to view working machinery, ask questions about their specific manufacturing needs and receive information and insight on updates that can help businesses remain competitive in a period of uncertainty as Brexit negotiations take place,” Horne commented. The PMMDA is exhibiting as part of the ‘Knowledge Pavilion’ at Interplas, which has been specifically designed to group together trade bodies, membership associations, consultants and service providers in order for visitors to easily find out information, solve problems or be signposted to the right area of expertise for their particular end sector.
“We are very much looking forward to some interesting and insightful conversations with visitors as part of the Knowledge Pavilion at Interplas,” Horne continued. “With the PMMDA’s presence as part of this, combined with our 24 members currently signed up to exhibit come September, we believe that the show this year is set to be terrific.” Interplas, which will take place from 26-28 September at Birmingham’s NEC, has recently expanded into an additional hall for the first time since 2005, following increased demand. There is currently 360 confirmed exhibitors, with over 85 percent of the total floor space sold with over five months still to go before the event takes place. “The endorsement of Interplas by the PMMDA once again in 2017 is testament to the strength of the show and our efforts to make it a success for the UK plastics industry and something that we can all be proud of, enjoy and benefit from,” commented Duncan Wood, COO, Rapid News Communications Group and Event Director for Interplas. “We look forward to a fruitful partnership in the run up to September and beyond.” WWW.PMMDA.ORG.UK
VISITORS - REGISTER NOW FOR FREE ENTRY TO INTERPLAS 2017 Visitor registration for Interplas in September is now open. The show, which is free to attend, will run from 26-28 September 2017 and will provide three full days of exhibitions, demonstrations, conference seminars and unmissable networking opportunities. To get your badge, as well as receive all the latest news relating to the show, head to the Interplas website: WWW.INTERPLASUK.COM/ REGISTER.HTML
WWW.BRITISHPLASTICS.CO.UK
Busy footfall seen at Interplas 2014
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INJECTION MOULDING | NEWS BOY OBTAINS PATENT FOR SMALL SCREW PLASTICISING UNIT BOY has been granted a new patent for its compact, 8mm reciprocating-screw plasticising unit. The technology was first premiered at Fakuma in 2015, where the company reported strong interest from moulders looking to produce small and micro parts. With its 8mm diameter and 1.9cm³ screw channel volume, BOY says the plasticising unit clearly provides a shorter residence time compared to larger screw diameters. This, the company adds, offers clear advantages when processing thermally sensitive materials that existing market solutions with predosing and an 8mm screw cannot achieve. For example, when producing medical micro-osteosynthesis plates from Polybutylene Terephthalate (PBT) with an injection volume of 0.06 cm³ and a part weight of 0.078g on a BOY XS, the material remains in the plasticising unit for approximately five minutes. Compared with a 12mm diameter
Micro-Osteosynthesis plate with a part weight of only 0.078 g
screw, BOY says the dwell time is reduced by more than 75 percent and in the case of a 14mm diameter screw by approximately 82 percent. The range of applications covered by the technology includes medical, automotive and electronics, as well as optics and microfluidics.
RGE GROUP INVESTS IN 1000TON BORSCHE MACHINE Cambridgeshire-based injection moulder, RGE Group, has invested in its first 1000-ton Borche machine to answer increasing demand from its domestic and international customers. The company has installed a new Borche BU1000 machine in its Whittlesey factory, where it will produce a range of large storage containers, up to 65 litres in size, in a range of colours and materials. The machine features a two platen locking design for a more compact footprint, together with additional mould height capacity. It employs the latest servo hydraulic systems for reduced power consumption and improved energy efficiency. The company serves a wide range of markets and blue chip names in sectors including white goods, office furniture, chair bases, material handling products, storage and
The new machine at RGE’s Whittlesey factory
The plasticising unit was introduced to the BOY product portfolio as a supplement to the BOY XXS and XS injection moulding machines. WWW.DR-BOY.DE/EN
technical mouldings, with an annual sales turnover exceeding £50 million. It has invested heavily recently in moulding machinery, robotics and automation equipment, materials handling systems and machine tools for its in-house tooling and mould making facility. Finally, changes have been made to logistics, infrastructure and health and safety procedures. “We have seen significant growth in our business and have steadily grown our capacity for larger mouldings. Having heard good things about Borche machines we were keen to measure its all round performance against our existing machinery types,” said Gordon Leach, RGE Group Managing Director. “We visited and inspected the machines in production at an existing Borche customer in the UK and decided to place our first order for our Whittlesey factory.” WWW.BORCHE.CO.UK
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INJECTION MOULDING PROCESS MONITORING SYSTEM REDUCES REJECTS TO LESS THAN THREE PERCENT Investment in a new process monitoring system has resulted in the reduction of rejects from 20 percent to less than three percent at a SouthWales based injection moulding manufacturer. Waldon Ltd installed the new ‘CoMoNeo’ process monitoring system from Kistler Instruments to enable cavity pressure-based analysis, optimisation, monitoring and documentation of the injection moulding process following on from the success of an earlier version of the technology in 2009. The new system builds on Kistler’s original cavity pressure monitoring system through increased ease of operation and user friendliness, as well as providing more detailed information on the production process. In particular, CoMoNeo identifies rejects more precisely, including notification of which cavity produced the reject, and delivers them automatically to a robotic handling system for recycling. At Waldon’s manufacturing site, the high level of process control and monitoring provided by the new system allows it to run its injection moulding machines ‘lights out’ for 24-hours a day, six days a week with any problems being advised to the duty maintenance engineer by mobile phone.
MGS Technical Plastics has invested in new machinery and robots totalling £400,000
The CoMoNeo System in operation at Waldon
The precise control over the entire injection phase delivers a CPK, the measure of process capability, of better than 1.33 to be achieved consistently. In addition, reject parts have reduced from 20 percent to less than three percent, with a zero ppm forecast. The design of the software is predicated on operational simplicity by using advanced technology to minimising the need for manual input. “The user-friendliness of CoMoNeo means that the system’s benefits are achievable without heavy dependence on a senior, experienced engineer. In fact, they are now accessible to good semi-skilled technicians,” said Richard Kempa, Waldon’s Commercial Manager. In addition to making the initial
setup faster and more accurate, this approach ensures that the production process is continually monitored with high precision, false rejects reduced and faulty components eliminated from the production line. This improvement in reject detection is allowing Waldon to expand its marketing to high precision sectors such as medical products, where customers demand a guarantee that every moulding delivered is within specification. The use of the system has also led an existing customer to place orders for three new mission critical components of automobile sensing systems.
GROWING LANCASHIRE MOULDER INVESTS £400,000 TO SCALE UP DOMESTIC PRODUCTION
tonnage work and a D420, which gives the company greater capacity to undertake customers’ mid-range projects, came from a desire to improve shop floor and production efficiencies, as well as enabling it to meet increasing demand because of growth in reshoring of projects. “Acquiring these two new machines from Sumitomo (SHI) Demag means we are better equipped to meet customers’ requirements,” commented Neil Garrity, MGS’ Manufacturing Director. “Our recent expansion and this latest investment is testament that MGS is committed to growing our business. We are all really proud of what we are building here.”
Blackburn-based trade moulder, MGS Technical Plastics, has installed four new robots and two new injection moulding machines as part of a major investment programme to help it boost production and efficiencies. Fuelled by growth in the hygiene, pest control and automotive sectors, the company has purchased Sumitomo Demag injection moulding and robotic equipment totalling £400,000, in what it says is a “commitment to UK domestic manufacturing.” MGS says the decision to purchase the new Systec models, a D210 that increases capacity for lower WWW.BRITISHPLASTICS.CO.UK
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Engineering Passion Lenses are produced by UPT-Optik Wodak GmbH
OPTICAL MOULDER CHOOSES WITTMANN BATTENFELD HYBRID MACHINE FOR OPTIMUM PRECISION A German manufacturer of large, premium quality optical parts has invested in a hybrid injection moulding machine from Wittmann Battenfeld that it says is providing “excellent performance” in terms of quality and repeatability. UPT-Optik Wodak GmbH, based in Nuremberg, has been running a MacroPower E 850/5000 with 8,500 kN clamping force to produce large-sized, thick-walled optical parts since November 2016.
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The production of these parts, which includes light conductors for the automotive industry and illumination optics for the building industry, requires a machine that combines ultimate precision and repeatability and long holding pressure times without overloading the drive modules. The company chose the MacroPower E due to its combination of a servohydraulic clamping unit with a servoelectric injection unit, which makes it ideal for a highly accurate injection process. For the long cycle times of up to 25 minutes, the machine supplied to UPTOptik Wodak includes an active closing function for the check valve following dosing. Other optional systems on the machine include Wittmann Battenfeld’s high-precision coining system, known as ‘Expert-Coining’. This system can actuate each pressure box individually to regulate platen parallelism, and can therefore achieve even higher precision. Additionally, the ability to inject melt in several places during a single injection process enables UPT-Optik Wodak to put on an extra layer with a second set of injection parameters, or to inject melt into two cavities. Parts removal and depositing of parts on a conveyor belt is handled by a W843 pro robot from Wittmann. Thanks to its reinforced profiles, this robot comes with a high load capacity, which is required in this case in order to remove the parts safely from the mould with their very solid piece of sprue, as opposed to any particularly heavy weight. “The MacroPower E meets our stringent requirements in terms of precision and repeatability and shows excellent performance in handling the required holding times,” commented Horst Wodak, Owner-Manager of UPTOptik Wodak. Wodak added that the machine’s “low energy consumption, smooth, quiet running and compact design of this large machine as well as its easy, uncomplicated operation via the UNILOG B6 control system,” were distinct advantages.
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CASE STUDY: USE OF INJECTION MOULDING IS AN EASY ADJUSTMENT FOR UK SPECTACLES MANUFACTURER Eyejusters, a manufacturer of unique ‘adjustable’ spectacles based in Oxford, developed its unique product in response to a need for inexpensive visual aids for millions of people in the developing world that do not have access to optometrists to measure and provide prescription glasses. The company designed a concept where glasses could be tailored for the use of the individual wearer, with adjustable lenses enabling a standard pair of spectacles to be adapted for varying visual requirements. Crucial to this is the company’s pioneering ‘SlideLens’ technology, which features a lens with a special profile containing both positive and negative power areas. When two of these lenses are placed together, the positive and negative power areas cancel each other out. When one lens is then moved across the other, the amount by which they cancel each other out varies, changing the focus. A FOCUS ON MOULDING The company worked alongside injection moulding machinery manufacturer, Fanuc, with the objective of producing optically perfect lenses. For this, the partners focused on a design as thin as possible, so that the two lenses, plus the protective rear cover, remained aesthetically neat and compact. Eyejusters new adjustable glasses are a complex product to mould
The moulded lenses in thermoformed trays
Because the Eyejusters lens design has varying thickness profiles, it is almost impossible to mould the lens with conventional injection moulding techniques. This is because the injection melt front tends to move around the thicker sections before completing the fill at the thin sections, which, in this case, are located in the centre of the lens. Using conventional techniques, it is highly likely that problems with quality, such as hairline marks and air traps, would be present. To eliminate such problems, Fanuc ran a series of moulding development tests. At the same time, Eyejusters strove to perfect the tool design so that it could work in combination with the functions of Fanuc’s CNC Roboshot injection moulding machine, gradually calculating the workable boundaries to achieve the thinnest possible and highest quality lens product. The outcome of this process development exercise was a final production solution comprising a special patented mould design, combined with Roboshot’s precision ‘Pre Injection/compression’ function. First, the material was injected into the tool under reduced clamp force. At a precise injection point, full clamp force was then applied to compress the moulding as injection completed. The precision nature of the Roboshot CNC control meant selected positions to control the process were repeatable within 0.001mm. DEVELOPING THE SOLUTION With the lens moulding techniques and processes fully defined, the next stage was to consider the integration of the injection moulding process within a production cell. This would also need to contain the additional technologies and processes required to assemble and finish the lens modules. For WWW.BRITISHPLASTICS.CO.UK
this, the project partners sought the help of Hi-Tech Automation. As the Eyejusters ‘product’ was the only fully-defined element of this project, Hi-Tech’s initial task was to develop a working specification for each of the production processes and steps. The first step was to determine how best to remove the individual mouldings from the tool. In this instance, the team decided it would be beneficial to have the individual moulded parts attached to a runner/ sprue for handling and orientation purposes. This would allow the parts to be removed, transported and handled safely through subsequent processes, without the need to touch the critical optical surfaces. The robot gripper systems were therefore designed, manufactured and integrated into the robots. Secondly, the team turned its attention to the subsequent processes which needed to be considered, including lens coating, component de-gating, ultrasonic welding and final packing into thermoformed trays. As with any optical product, cleanliness was a key consideration, and the techniques used for degating and welding had to eliminate the potential for the contamination of the lens components by particulate matter. Hi-Tech selected laser degating and ultrasonic welding to perform these delicate operations. With the automation cell built and operational, a Class 5 Clean Room needed to be built around the cell before production level components could be produced. Hi-Tech specified a solution that met all cleanliness standards and incorporated full air handling through entry and exit air locks, allowing the cell to begin production. WWW.FANUC.EU WWW.HITECHAUTOMATION.NET WWW.EYEJUSTERS.COM 19
Engineering Passion
Productivity in Practice: Small changes for the biggest reward
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roductivity, namely what we produce for the amount of work it takes to do it, and solving the issue of it flatlining in the UK in recent years, is a hurdle the manufacturing PRODUCTIVITY, AND industry must jump in order to WAYS FOR THE UK remain competitive. Noise around MANUFACTURING overcoming the UK’s ‘productivity puzzle’ has been getting louder INDUSTRY TO INCREASE of late, with solutions pointing at ITS LEVELS TO REMAIN working smarter, not harder, with COMPETITIVE, IS A investment essential to secure TOPIC OF INCREASING future success. However, it is IMPORTANCE. BUT HOW possible for plastics manufacturers CAN THE PLASTICS to see huge returns from only a small investment. As a company, INDUSTRY BENEFIT AND we’ve seen how small changes and CAN YOU INCREASE integrating new technologies can PRODUCTIVITY WITHOUT make a big difference to not only MAJOR INVESTMENT? IN productivity, but also efficiency, THE FOLLOWING ARTICLE, safety and, ultimately, a company’s bottom line.
CRAIG FORRESTER OF STÄUBLI UK ARGUES THAT IN MANY CASES, THE MAXIMUM GAIN COMES FROM THE LOWEST INVESTMENT.
Connecting with connectors
A good example of such is connectors; the plastics market has been involved with, and has regularly been a pioneer of, new technologies such as ‘straight through’, restriction-free couplings, valved connectors for increased safety and multi connection systems either for single or multi media. The plastics industry is an ideal environment to realise the benefits of Quick Release Couplings, providing an important step in the relentless
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ongoing demand for faster and safer mould changes. The process of speeding up mould changes should ideally be approached methodically. Starting with the basics; significant benefits can be gained at very little expense, quick release couplings on a mould can often reduce tool change over from hours to just minutes. The next step is to consider the benefits of putting all connectors together by using one of a range of standard multi-couplings plates. This process often then leads on to a bespoke multi-coupling plate, specifically designed for a specific application, on which additional connectors and even electrical and signal circuits can be included. Consideration of mould clamping, mould transfer and loading should then follow. These are all tasks that need to be addressed to fully optimise productivity.
Considering clamping
When it comes to consideration and evaluation of quick mould clamping, companies should consider the benefits of mechanical, hydraulic and magnetic systems; there will be an appropriate technique for any specific application. Mechanical systems are very often easy to install since they require no hydraulic or electrical connections. They can be readily fitted to most injection moulding machines below a maximum closing force of 300 tonnes. However, the selection of the mechanical system cannot be made on the size of the machine alone; the quantity of moulds deployed in the machine is also a very important economic factor. As a general rule the higher the quantity of moulds the more consideration should be given to magnetic clamping. In the case of larger machines, either hydraulic or magnetic systems will be necessary, the choice depending on the quantity and variation of moulds. Magnetic systems have the flexibility to clamp a wide range of mould sizes and normally require no modifications to the mould and no additional back plate, which represents a significant cost saving. Hydraulic systems require a standard back plate to be fitted to each mould which, dependant on the quantity of moulds, substantially increases the investment. Not to be forgotten when choosing between magnetic and hydraulic technologies is the increased safety and data storage capabilities of the magnetic systems. Software is available that provides a step-by-step guide to help evaluate the options and select the most suitable system. The choice for any given application is far from straight forward, and, the user should give really close consideration to both their current and, perhaps even more importantly, their future needs. Plastic moulders are increasingly insisting that injection moulding machine manufacturers incorporate clamping systems in their machines. This demonstrates that across the sector use and knowledge of the benefits of these types of systems is increasing, which in turn creates demand to retrofit systems to existing machines. Although it must be stressed that clamping is only a part of the quick mould change process, in the vast majority of applications, the most beneficial savings can come from reducing the time taken to disconnect and connect the thermal regulation lines. It is absolutely true that in many cases the maximum gain comes from the lowest investment.
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OVERLEAF | A good example of such is connectors; the plastics market has been involved with and have regularly been the pioneers of new technologies such as ‘straight through’, restriction-free couplings, valved connectors for increased safety and multi connection systems either for single or multi media. ABOVE | In the process of speeding up mould changes, mould transfer and loading can often be a neglected area, many even regarding it as a luxury, says Forrester.
Speeding up mould change
In the process of speeding up mould changes, mould transfer and loading can often be a neglected area, many even regarding it as a luxury. This is not always the case. Simple mould transfer and loading carts can be very economical, serving a range of machines and giving a payback on investment of just a few months. Handling moulds securely and preventing costly damage while improving operator safety are significant added benefits. Where restrictions on workshop height preclude the use of cranes, side loading of moulds using transfer systems often provide an attractive solution. For heavier moulds, systems right up to fully automated rail mounted carts are an option; individually designed to suit the specific application and user needs. Pre-heating stations can be included to ensure that the mould is at operating temperature ready for immediate use, again helping to minimise downtime. The selection of the correct technology and the correct processes are imperative to maximise return on investment. The aim should always be to chose the most suitable system, one capable of operating safely and securely over many years, meeting the financial and productivity goals established at the outset. That is the essence of productivity. WWW.STÄUBLI.COM/EN/CONNECTORS
Understanding productivity: Demonstrations at Interplas
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he demands of working smarter to increase productivity and capitalise upon the benefits for business is the theme of Stäubli’s presence at Interplas, the UK plastics industry show, taking place from 26-28 September at Birmingham’s NEC. On Stand E12 in Hall 4 there will be an interactive and operational injection moulding cell demonstrating Single Minute Exchange of Die (SMED), complete with mould connections, mould clamping, handling and loading as well as robotics. The robots will demonstrate their ability to work safely alongside operators within the production cell. On Stand L10 in Hall 4, several new products will be on show, including robust quick release connectors capable of working safely at the higher temperatures being used in injection moulding and secure reliable electrical multi connectors capable of handling all the electrical circuits on a moulding tool. Stäubli engineers will be on hand to discuss specific requirements and explain the technology behind these innovative developments. WWW.INTERPLASUK.COM
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MASTERBATCH & ADDITIVES | NEWS LUXUS ACQUIRES COLOUR TONE MASTERBATCH Technical plastics compounder, Luxus, has acquired Colour Tone Masterbatch, based in Bedwas, South Wales. Colour Tone Masterbatch currently employs 50 staff, with a turnover of £5m. The additive manufacturer focuses on the delivery of high quality service and bespoke colours, in universal, commodity and engineered polymers, as well as custom additive blends. The acquisition will enable a strategic realignment of the businesses allied with improvements in production capabilities at its site in Bedwas, Caerphilly. Tony Gaukroger remains as a non-stock holding Director and the company will continue to operate autonomously. “We are delighted that Colour Tone Masterbatch is now a part of Luxus,” said Peter Atterby, Managing Director, Luxus. “This strategic investment is a natural progression of our 20 year working relationship. It will enable us to significantly enhance our offering to deliver highly engineered coloured polymers that our global client base requires, providing the strongest possible market position.” In recent years, Colour Tone
NEW EFFECT MASTERBATCH SETS NEW STANDARDS IN METALLISATION SUBSTITUTION Masterbatch manufacturer, Gabriel-Chemie, and pigment specialist, Schlenk, have collaborated to launch a new range of metal-effect finishes for plastics. produced Metallic jar n between io at er op in co ie and em Ch Gabrielc ki ba er et di
Masterbatch was selected to support a WRAP funded project that aimed to develop the materials technology required to substitute carbon black pigment commonly used in black food packaging with infra-red reflection (IRR) black pigment, since recycling sorting systems are unable to detect black carbon as it reflects little or no light at all. This results in over one billion black plastic trays being sent to landfill or incinerated in the UK each year. Atterby added: “The project validated that IRR pigments could allow near infrared (NIR) spectroscopy to sort black plastic packaging waste. They reproduced as near as possible the shade and opacity of carbon black, instead of the less commercial ‘brown black’ achieved in previous trials proving that materials technology can deliver a solution to this serious landfill issue. “We have the opportunity to capitalise on the technological synergies in both companies. Since the original NIR project, a new masterbatch with the same IRR pigment has been devised for numerous applications including the prevention of heat build-up for example. This provides the
Designed to replace the need for metallisation in a number of different end-use applications, the new masterbatch series, known as ‘Flowing Metallics’, creates a silky, homogeneous surface on a plastic object thorugh mass colouration. The surface of an object produced using the masterbatch is free from visible glitter particles and characterised by an intense deep gloss, particularly when used for high-gloss surfaces. “This type of perfect surface can be cost-effectively achieved through mass colouration. We have adopted a unique position of quality in the metallisation substitution sector with our formulas and the high-grade effect pigments from Schlenk,” said Ulf Trabert, Product Manager for Branded Goods at Gabriel-Chemie. The masterbatch can be used with many polymers and has already been successfully tested in a wide range of manufacturing processes. It is also approved for contact with WWW.BRITISHPLASTICS.CO.UK
Peter Atterby (left) of Luxus and Tony Gaukroger of Colour Tone
opportunity to shape the technical properties of thermoplastics used for auto interior components including steering wheels, seats and instrument panels for example. “Since the masterbatch is NIR detectable too, another key advantage is that it can positively contribute to automakers’ ‘end of life’ requirements as the black plastic can be easily identified for sorting at a recycling facility. This means that in the future Luxus high performance engineered polymers such as the ‘next generation’ Hycolene thermoplastics range may be available in an NIR detectable version.” WWW.LUXUS.CO.UK WWW.COLOURTONE-MASTERBATCH.CO.UK
food. This alternative, says GabrielChemie, offers benefits in packaging processing for a number of end markets, particularly in the cosmetics industry, as additional logistical tasks and production steps can be omitted by eliminating the need for metallisation. All the benefits of plastic packaging are retained, including the higher breakage resistance compared to other materials. The masterbatch for all colours of the ‘Flowing Metallics’ series can also be used for food packaging, household products and in the sports industry for product differentiation. “The result of the cooperation with Gabriel-Chemie is setting new standards in the field of metallisation substitution, which we all can be very proud of,” said Dr. Frank J. Maile, Director of the Business Unit for Coatings and Plastics at Schlenk Metallic Pigments. WWW.GABRIEL-CHEMIE.COM 23
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ANTI-COUNTERFEIT ADDITIVE BLOWS THE WHISTLE ON FAKES
ACME has been providing professional whistles since 1860
Broadway Colours has provided a UK-based manufacturer of professional whistles with an anticounterfeit additive to help detect fake products. ACME Whistles, based in Birmingham, has been producing whistles since 1860. Founded by Joseph Hudson, ACME arms the referees of FIFA, the NFL and Hockey Canada with sports whistles, as well as suppling police forces across the world. ACME has made over a billion whistles in its 150-year history, and traditionally stamped them with its marque. Recently, however, an increase in fake ACME whistles has made a more innovative anticounterfeiting method necessary. The company is now using Suffolkbased Broadway Colours’ ‘Supra-Sure Anti-counterfeit’ additive, which consists of a unique combination of specialist pigments that
imperceptibly alter the light refraction of the surface of a moulding. The additive can be detected using two methods; firstly with a laser pen of specific wavelength, which shows a dot of light when the additive is present. If the product does not contain the additive the dot will not appear. The second method uses an acoustic detector to emit a sound and show a green light, when SupraSure is present. It stays silent and shows a blue light if there is no additive present. “It is important to us that we can ensure our products are safe for public use and are the genuine article. With such a large product range, across varying colours, rolling out an anti-counterfeit protection system was imperative,” commented Ben McFarlane, Sales Manager for ACME Whistles. WWW.BROADWAYCOLOURS.COM
SPECIAL EFFECT METALLIC MASTERBATCH GIVES PACKAGING DESIGNERS “NEW OPTIONS” A line of effect masterbatches that produce a highly reflective, metallic finish in PET packaging is giving designers greater choice in a competitive marketplace. According to Doug Brownfield, Strategic Business and Marketing Manager at Ampacet, the company behind the range of ‘Formula X LiquidMetal Colours’, the special effect colours are giving packaging designers new options when it comes to not only materials, but also overall cost, weight and aesthetics. “Our LiquidMetal Colours line is designed for use in high-energy packaging, including energy drinks and upscale cosmetic packaging, where highly reflective colours would play well,” said Brownfield. “By enhancing PET’s appearance with colours of great depth and intensity, LiquidMetal Colours creates packaging with strong shelf appeal. It also gives designers a new option in relation to metal. “For instance, anyone thinking of creating a polished aluminium package may want to evaluate a LiquidMetal Colours chrome PET package and compare the potential
cost savings and design flexibility.” Created for use with blow moulded and extruded PET, LiquidMetal Colours are designed to meet the demand for plastic packaging that replicates polished metal for use with cosmetics, health and beauty aids, speciality foods, beverages and carcare products. The special effect colours are built on Ampacet’s Formula X PET technology platform, which eliminates the need to pre-dry PET WWW.BRITISHPLASTICS.CO.UK
Ampacet’s Formula X LiquidMetal Colours line gives PET bottles the high-impact look of highlypolished metal
colours, and allows for feeding at the extruder throat. The company says this technology also reduces feedthroat clogging, screw slippage and improves colour dispersion. WWW.AMPACET.COM 25
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RECLAMATION & RECYCLING | NEWS NEXTEK AND VIRIDOR COLLABORATION FOR BLACK TRAY RECYCLING MARKS “MOMENTOUS” STEP FORWARD The collaboration between a technology innovator, recycler and retailer to overcome the problem of recycling black plastic trays has been described as a potential breakthrough by one of the project partners. Edward Kosior of packaging specialist, Nextek, said the new partnership between the company, leading recycler, Viridor, and the CoOp food group was “momentous”. “Bringing together all the main parties for the first time, from us as technology innovator, to the Co-Op as retailer, and Viridor as the recycler is momentous. I’m confident that together we have found a technology solution to end these trays filling up landfills. This is a technology that can work immediately in virtually all recycling facilities across UK, Europe and USA,” he explained. Nextek is behind the development of the new black pigment system that allows the use of black materials without using carbon black, allowing it to be sorted at source by existing
BPF RECYCLING GROUP WELCOMES CHINESE ACTION ON FOREIGN RECYCLATES An action plan announced by the Chinese ‘General Administration of Customs’ has been welcomed by the British Plastics Federation Recycling Group (BPFRG). The Chinese authority’s year-long ‘Bordergate Sword 2017’ (also known as ‘National Sword’) aims to crack down on the import of smuggled foreign waste, including plastics. This campaign will assess China’s processing methods, country of origin and end products to be made from plastic regrinds. The BPF believes the action will be of benefit to recycling processors, as current avenues for low quality sorted material through export prevents there from being a focus on driving up the quality of the material collected within the UK. This means
near infrared (NIR) technology. Trays made with this system have been trialled at Viridor’s specialist £15m plastics facility in Medway, Kent. Sarah Heald, Director of Corporate Affairs and Investor Relations at Viridor’s parent company, Pennon, said: “Working with Nextek has allowed us to test the potential for a new UK technology to transform the global problem of supermarket black plastic packaging into a new recycling stream. “We are committed to working with manufacturers, packaging designers and supermarkets to accelerate innovation – using less packaging, designing in recyclability then simplifying recycling systems so that everyone can do the right thing and put the right stuff in the right bin.” With recycling rates falling in England, down 0.7 percent in the last year to 43 percent, the innovation is badly needed. Surveys of consumers repeatedly highlight confusion as to what is eligible for recycling, with differentiation between local authorities, as well as On Pack Recycling Labels (OPRL) listed as common causes of uncertainty. The collaboration was recently
that UK recyclers have to spend resources sorting material, even if it has already been through a sorting process, before they can reprocess it. This in turn reduces their yield. Roger Baynham, Chairman of the Recycling Group, said: “A quality standard for all material going into the plastic recycling stream, whether it is recycled in the UK or exported, would ensure a level playing field and enable UK facilities to compete for material. This would also reduce any effects that an initiative such as ‘Bordergate Sword 2017’ might have upon the market. This standard needs to apply for all parts of the plastic recycling industry including packaging, waste electrical and electronic Equipment (WEEE), end-oflife vehicles and construction.” The BPF has iterated the Chinese Customs announcement also shows the importance of having sustainable markets for plastic recycling within the UK and not WWW.BRITISHPLASTICS.CO.UK
Black plastic trays could be widely recycled using exisiting sorting systems if the technology is adopted
highlighted on prime time BBC One television programme, the One Show, as well as reported in several mainstream newspapers and online media sites. WWW.VIRIDOR.CO.UK WWW.NEXTEK.ORG WWW.CO-OPERATIVE.COOP WWW.WRAP.ORG.UK
The BPF believes the action will be of benefit to recycling processors
relying on export. With a tightening of controls on imports into China and stricter regulation on facilities within the country, the market for UK plastic recycling within China is likely to reduce. Baynham added: “A sustainable market for plastic recycling within the UK would ensure this valuable material is available to UK-based manufacturers, which would help contribute towards a local circular economy. It would also help support UK jobs within these industries whilst securing resources for the country.” WWW.BPF.CO.UK 27
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Recycling collection rates ‘cloud’ the need for innovation
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here is a desire to increase recycling rates in the UK, but these rates are based on what is collected INNOVATION AND rather than DEVELOPMENT IN what is actually TECHNOLOGIES TO recycled. As INCREASE RECYCLING a rigorous Engineer in this OF HOUSEHOLD PLASTIC sector, I believe PACKAGING IS BEING this has a HAMPERED BY HOW WE negative impact MEASURE ITS COLLECTION, on innovation AND A LACK OF ECONOMIC and progress towards true DRIVERS TO ENCOURAGE recycling. INVESTMENT, ARGUES Increasing RICHARD MCKINLAY, HEAD the recycling OF ENGINEERING AND of household RESEARCH AT UK-BASED plastic RESOURCE RECOVERY packaging (bottles, pots, SPECIALIST, AXION tubs, trays and CONSULTING. films) is a key aim, enabling the conversion of this recycling stream into valuable materials and with the associated carbon benefits. More than 75 percent of all local authorities in the UK are now collecting pots, tubs and trays (PTTs), which are typically made from polystyrene (PS), polypropylene (PP) and PET. This is generating approximately 160,000 tonnes of material each year potentially for recycling. This mixed plastics pots, tubs and trays stream also includes a low level of PVC. McKinlay says innovation and development in recycling technology is being hampered by how we measure collection
A positive picture?
On the face of it this is a positive picture, and establishing a collection infrastructure is fundamental to setting up effective material recycling. However, on closer inspection, the difference between collection rates and material recycling rates for pots, tubs and trays is larger than is commonly believed. PS in PTTs is present in very small quantities and it rarely makes economic sense to recover this material. The PET is seen as a contaminant in the bottle recycling stream, and although a small volume is recycled with bottles, at levels greater than 10 percent it becomes problematic, and much of it cannot be economically recycled. With few end markets for recycled PET from PTTs, there are no economic drivers to process this material. Realistically only the polypropylene (PP) fraction has a chance of being recycled, so stating collection rates is, in my opinion, misleading. The PET used in PTTs is a lower grade of polymer than that used in PET bottles and so cannot enter the same recycling stream. Each time PET is thermally processed, through extrusion or moulding, it loses strength and becomes more brittle. PET can be reacted to build the strength back up, but this carries a high operating cost. It means that recycling bottles back into bottles is not currently economically desirable, due in part to the low virgin PET price. As a result, the bottle material is used in new PET trays, which uses a lower quality polymer as standard. This is common throughout Europe and it means there is no place in the market for a recycled PET from trays, aside from a relatively limited market in fibre. Again, the high operating cost of upgrading the polymer and limited end value restrict the viability of recycling the tray material and it is typically used for energy recovery across the continent. PET, although recyclable, is therefore currently in a rapid downward spiral with a maximum of three
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lifetimes, but more likely only one in the case of PET from PTTs.
Detrimental to innovation
The perception that more waste packaging is being recycled potentially damages innovation and development. With the introduction of a ‘widely recycled’ label on household pots, tubs and tray packaging, some parts of the supply chain may consider their job done when actually it is only the first step. We need to consider the packaging right through to end of life into use as a secondary raw material. It’s a block to innovation; packaging is a functional product that has the purpose of protecting food or goods to prevent the generation of waste. It is ideal if the packaging can be recycled, but we shouldn’t limit ourselves by simply accepting what is recyclable with today’s limited infrastructure. Instead we should focus on the value of recycling these materials and what could be possible though innovation and sensible economic drivers. Our recent research for WRAP into the recycling process for PET pots, tubs and trays demonstrated that it is technically viable, but it is economically challenging. Improving the quality of infeed materials is vital to achieving a better yield and a more financiallyviable process. This includes more targeted collection of PTTs by local authorities and improved sorting at MRFs, so that a PTT rich stream is sorted as target material. This will have an impact on MRFs as additional sorting capacity and equipment will be required. More work is also needed to identify and establish longer term and stable markets for PET flake and pellet produced from PTTs, including demonstration trials to build confidence with end users and markets. Ultimately, supply chain engagement and collaboration, and a realistic view on the current situation are essential if we are to recover and recycle these resources. Plus the allimportant economic pull/push factor. WWW.AXIONCONSULTING.CO.UK 29
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AUTOMOTIVES | NEWS LVS SMALL PLASTIC PARTS WINS MAJOR NEW AUTOMOTIVE CONTRACT IN RESHORING DEAL LVS Small Plastic Parts has started a production run of car boot storage containers and interior retention hooks as part of a newly-won contract that sees the reshoring of the components from Germany and Eastern Europe. The Telford-based company says the contract requires the production of around 300,000 components per month and winning the work will add around eight percent to its annual growth. The smaller components will be made in PC-ABS, with grained ‘A-Face’ finish. The larger 1+1 tools will run on a Negri Bossi hybrid 800-tonne machine with automation. The top frames for the containers are to be produced on a
TOYOTA’S INVESTMENT IN DERBY FACTORY “A SIGN OF CONFIDENCE” IN UK MANUFACTURING Toyota Motors Europe is to invest a further £240 million in its Toyota Manufacturing UK car plant in Burnaston, Derbyshire. The factory will be progressively upgraded with new equipment, technology and systems. This will enable production of vehicles on the Toyota New Global Architecture (TNGA) platform. Toyota is modifying its production system to bring in ‘Toyota New Global Architecture’, a standardisation of car components’ size and position on standard unitised car platforms. The investment aims to improve the Derby plant’s competitiveness, promoting UK supply chain efficiencies.
380-tonne machine using complex tooling with a total of 32 ‘up and aways’. LVS’ client is a German Tier One automotive company with worldwide operations. Its British assembly plant previously received all its plastic mouldings from Germany or Eastern Europe, requiring full loads to minimise transport costs. Simon Anderson, LVS’ Managing Director, said there was several reasons why the Tier One decided to bring the manufacturing of its products to the UK. “We will offer a stable cost (no exchange rate fluctuations), and we will use our fleet of vehicles to deliver product ‘line side’ twice daily on flow racks. As well as almost eliminating all stock holding for the client, product quality will improve. They previously had an ‘accepted’ level of
The investment also includes £21 million from the UK Government to support training, research and development and enhancements of the plant’s environmental performance. Johan van Zyl, President of Toyota Motor Europe, said: “We are very focused on securing the global competitiveness of our European plants. The roll-out of TNGA manufacturing capability is part of this plan. This upgrade of [Toyota Derby] is a sign of confidence in our employees and suppliers and their focus on superior quality and greater efficiency. We welcome the UK Government funding contribution for this activity. “Our investment demonstrates that, as a company, we are doing all we can to raise the competitiveness of our Burnaston plant in Derbyshire. Continued tariff-and-barrier free market access between the UK and Europe that is predictable and uncomplicated will be vital for future success.” WWW.TOYOTAUK.COM pe is to tors Euro Toyota Mo million 0 24 £ er h rt invest a fu turing c fa u an ta M in its Toyo ton, as t in Burn UK car plan Derbyshire. WWW.BRITISHPLASTICS.CO.UK
LVS Small Plastic Parts has started a production run of automotive components
fall out due to transportation and the very long storage times,” Anderson explained. “We secured this valuable business by delivering a cost saving per part, reduced inventory levels, improved quality of product and a speed to resolve engineering changes that couldn’t be previously achieved.” WWW.SMALL-PLASTIC-PARTS.CO.UK
BARTON FABRICATION INSTALLS THIRD GRANULES SILO AT SANKO GOSEI AUTOMOTIVE Sanko Gosei Automotive Systems has invested in a third polypropylene granules silo at its site in Lancashire, following the successful space saving and cost reductions it has seen from an initial pair installed last year. The company has installed a new 50-tonne silo from Barton Fabrications at its Skelmersdale site to store polypropylene plastic granules and enable bulk filling from tankers, avoiding the need for manual handling of sacks and bins of raw material. “The silos installed earlier in 2016 have exceeded our expectations and we were keen to gain additional savings by investing in a further silo,” commented James Bradley, Sanko Gosei’s Production Engineering Manager. “The latest installation has run smoothly and the silo will be used for a different grade of polypropylene used in the manufacture of windscreen related parts for many major global car manufacturers.” WWW.BARTONFABS.CO.UK 31
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Automotive plastics: Lightweight, life saving, trailblazing WORDS | Leanne Taylor
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he annual gathering of experts from both plastics and automotive industries at the VDI Conference in Germany is widely considered as an important platform for the exchange PLASTICS IN MODERN, AND of new ideas, the unveiling FUTURE, VEHICLES CONTINUE of new materials and TO INCREASE IN VOLUME information on new technology that is shaping AND IMPORTANCE. THIS WAS the future of vehicle design EVIDENT AT THE RECENT and production. This year’s ‘PLASTICS IN AUTOMOTIVES’ two-day conference, held CONFERENCE ORGANISED in Mannheim from 29-30 BY THE ASSOCIATION OF March, was no exception. The GERMAN ENGINEERS (VDI), focus on lightweight design concepts for exterior and WHERE THE VERY LATEST interior parts, development MATERIALS DEVELOPMENTS processes, sustainability and WERE UNVEILED. CO2 reduction brought raw materials producers, polymer processors and system suppliers together to participate in technical discussions about joined up thinking, future design and end-of-life options.
LANXESS: COMPOSITES AND PA 6/66 FOR SAFETY AND WEIGHT REDUCTION Lanxess exhibited its latest materials solutions for the automotive industry with a focus on lightweight design with added value. This included the first all-plastic break pedal in series production made from its ‘Tepex’-branded continuous-fibre-reinforced thermoplastic composites. So far, this component has been fitted in the Porsche Panamera and the Bentley Continental GT. It is manufactured by using a one-shot hybrid moulding process with short cycle times. The process integrates the shaping of a Tepex blank into the injection moulding process. “This safety component is only about half the weight of a comparable steel structure, and meets the high load requirements thanks to the innovative Lanxess displayed an all-plastic brake pedal which weighs about half as much as a comparable steel structure. Photo: BOGE Elastmetall GmbH
multi-axial fibre layer construction of the Tepex blank,” explained Henrik Plaggenborg, Head of Technical Marketing and Business Development, Tepex Automotive. In addition to the brake pedal, Lanxess demonstrated how its Tepex-based hybrid moulding process could be used to produce a module carrier for the Mercedes Benz S Class convertible that is just one millimetre thick. “The component is a prime example of how Tepex can be used to produce large structural components that are particularly thin and thus lightweight. They can also be fitted with numerous functions at the same time,” Plaggenborg continued. Aside from its composites offerings, Lanxess also highlighted its use of polyamide 6 to replace aluminum in the design of engine oil pans. Produced using its ‘Durethan’ material, an oil pan module for the new six-cylinder boxer engines of the Porsche 911 Carrera was on display. This exhibit, according to Tim Arping, Head of Application Development for the EMEA (Europe, Middle East, Africa) region at Lanxess’ High Performance Materials (HPM) business unit, underlines how the more cost-efficient polyamide 6 is, at the very least, just as suitable as polyamide 66 for replacing aluminium in the manufacture of engine oil pans. The component satisfies all the specific requirements imposed on the new-generation engine in terms of weight reduction, functional integration and cost-efficient production. “The weight of the oil pan could be reduced by more than two kilograms compared to the previous aluminium model,” Arping said. Not forgetting the commercial vehicle sector, Lanxess demonstrated the lightweighting potential of polyamide 66 used for the production of two air filter mounts that have been fitted in Mercedes Benz Actros since the start of the year. These filters are made of Durethan AKV 50 H2.0.
INEOS STYROLUTION: NEW ABS COPOLYMERS FOR LIGHT WEIGHT AND STRENGTH INEOS Styrolution, also chose VDI as a platform for its recent material developments. This included a new grade of its ‘Novodur’ range of speciality ABS copolymers for automotive interiors, Ultra 4255, which is a version of its established Novodur HH-112 grade that has been optimised for laser welding. The new Novodur Ultra 4255 grade features high impact strength at room temperature as well as at low temperatures, 100 per cent ductility at -30°C, high heat resistance and superior flow. As it is optimised for laser welding, it offers improved adhesion to other materials, such as PMMA, for high aesthetic requirements. Additonally, INEOS Styrolution said this tailored Novodur HH-112 is also reducing production costs, where it can provide a perfect surface when it comes to bonding two different materials. Christophe Ginss, INEOS Styrolution Automotive Sales Director, said: “We expect the new Novodur Ultra 4255 to become a material of choice for car interiors, especially for applications like door panels, lower seat trims, centre and overhead consoles or glove box doors and frames.” Along with the new Novodur Ultra grade, the company
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INEOS Styrolution demonstrated the use of Novodur HH-112 with a rear lamp housing
We provide lightness!
also highlighted the benefits of its thermoplastic composite, StyLight, at the conference. This, says INEOS Styrolution, is a response to the industry’s increasing demand for lightweight parts, without compromising on aesthetics, safety and performance, as the new composite boasts properties that not only reduce weight, but also structural and dimensional stiffness and impact strength. The production process for StyLight is said to ensure highest quality and low cycle times, as complex parts can be produced in a hybrid production process; the thermoplastic composite sheets made from StyLight can be thermoformed, back-injection-moulded and decorated in one processing step. At the same time, INEOS Styrolution says the lower shrinkage during the consolidation step of the styrenic copolymer matrix, based on a modified SAN, reduces the surface roughness or ‘waviness’ significantly, and offers a “superior” surface quality. Possible applications include body panels, brake pedals, electronic device carriers, gear sticks, instrument panels, spoilers and sun roofs.
COVESTRO: NEW PC GLAZING AND HOLOGRAPHIC FILMS FOR FUTURISTIC DRIVING Covestro’s exhibit at VDI was central to demonstrating its commitment to “pushing technical boundaries” with its materials. This was represented in the form of a new concept in electric car design, a vehicle ‘wrapped’ in polycarbonate glazing. “Based on pioneering plastics technologies, the concept incorporates current trends in automotive design,” explained Project Manager, Jochen Hardt. “It enables us to give vehicle designers new possibilities for designing comfortable, functional and energy-efficient cars.” Designed with automotive supplier, HELLA, and the Umeå Institute of Design in Sweden, the concept car is the first vehicle with wrap-around glazing made of transparent polycarbonate. The glazing is lightweight and aerodynamic, two features that reduce energy consumption. The designers also implemented entirely new styling options that they say “would not have been feasible in glass”. This includes the design of transparent A-pillars, where wrap-around glazing rewards passengers with a panorama view, and enhances pedestrian safety because it almost entirely eliminates blind spots. The glazing, says Covestro, meets all the requirements of the new UN Regulation R43. The vehicle also features a novel new concept for
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Covestro is presented a new concept in electric car design at this year’s VDI Plastics in Automotive Engineering conference.
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lighting, where illuminated surfaces with integrated LED ‘spots’ can display messages, which Covestro and HELLA say provides automotive designers with “fascinating possibilities” for enhancing safety, energy efficiency and functionality. Looking to the future, the partners say holography will likely prove to be a top technology in automotive lighting. They have developed an innovative solution based on holographic films from Covestro’s ‘Bayfol HX’ range. This enables various lighting functions to be integrated into body components, requiring little space and opening up entirely new possibilities for using light as a design element. It also featured technologies to enable autonomous driving, such as new polycarbonate materials to enable good transmission of LiDAR signals and the homogeneous integration of sensors, i.e. the ‘eyes’ of an autonomous vehicle, to enhance the safety of passengers and pedestrians. Another one of Covestro’s highlights at the VDI congress was various film solutions for interior automotive display applications. The focus was on displays and operating panels that are protected by scratch-resistant, glare-free films. They support new lighting effects and the integration of functions into the instrument panel.
BOREALIS: NEW PP GRADES FOR CONTINUED WEIGHT REDUCTION Borealis and Borouge launched new ranges of
Fibremod GB416LF is said to fulfil both emission requirements and mechanical performance criteria. It has good surface aesthetics, meaning the grade can be used for visible parts. Its sustainability is enhanced not only by its lighter weight, but by eliminating the need for one or more paint layers, or additional aesthetic parts. The second new grade, Fibremod GD577SF, is a new short glass fibre (SGF) grade with 50 percent filler. In addition to what Borealis describes as “outstanding” mechanical performance – even at higher temperatures – the grade is also said to offer pleasing surface qualities for visible structural parts. As a potential replacement solution for demanding metal and polyamide (PA) applications, GD577SF is suited for a diverse range of exterior, interior and UTB applications, including full plastic front end modules, clutch and gas pedals, external mirror structures, and more. Finally, the product launched in Borealis’ Daplen family is ‘Daplen EE001AI’, a new material generation designed to serve as a “drop-in” solution. A highly pure grade, it is said to boast “excellent” mechanical properties and minimal filler content. With the similar shrinkage characteristics typical of grades with higher filler content (such as PP-T15), the new Daplen EE001AI can be used in existing tool geometries. The new material is easily processable and robust in large-scale series production and, whilst a lightweight grade, can be used to to achieve class-A surfaces free of tiger stripes and any other visible flaws typically affecting injection-moulded parts. Borealis says it is “highly suitable” for a wide range of injection configurations and tool layouts.
CLARIANT: NEW STABILISER FOR INTERIOR APPLICATIONS
polypropylene compounds in the Daplen family of PP thermoplastic olefins (TPO), and the Fibremod range of polypropylene fibrereinforced compounds. Borealis aims to use the new compounds to improve lightweighting in cars for interior, exterior, and under-the-bonnet (UTB) parts. Additionally, the grades are particularly suited for electric or hybrid vehicles, which will become more viable with lighter component materials. “As we explore the new frontier of electric vehicles together with leading OEMs and their Tier One partners, we are committed to developing value-creating polyolefins that enable our customers to think about the material science of cars in a different way,” explained Nicholas Kolesch, Head of Automotive Marketing at Borealis. “But even more, we can see the potential for fundamentally rethinking automotive design, thanks to the wealth of PP-based solutions available today, and on the immediate horizon.” The new grades launched at VDI include Fibremod GB416LF, a long glass fibre (LGF) reinforced polypropylene, which is a high-flow material with a 40 percent filler content, making it a new, lighter weight solution for a full polyolefin tailgate module as a lowerdensity replacement solution for conventional metal or engineering polymers.
Automotive lightweight design solutions from Borealis were highlighted through its range of new materials
Clariant chose VDI to introduce its new stabiliser for filled polypropylene (TPO) compounds used in interior applications. New AddWorks ATR 146 is a heat and light shield that aims to create longer-lasting aesthetics and a healthier environment inside future vehicles due to reduced Volatile Organic Compounds (VOC). AddWorks ATR 146 is proven to deliver exceptional heat stability to TPO compounds, with no surface cracking reported after 700 hours and beyond at 150°C when dosed as low as 0.3 percent. This performance level largely exceeds the standard requirements in the industry for such applications and outperforms the heat stability of currently available alternatives. Clariant has introduced Moreover, it displays a new stabiliser for excellent light stability interior applications performance that protects long term against discoloration. The outstanding UV and heat protection, plus high resistance to extraction media like water or detergents, enable typical TPO-based parts such as dashboards, instrument panels, door panels, and pillars to maintain their aesthetics for longer than with traditional stabilisers. In addition, AddWorks ATR 146 has high compatibility with the PP polymer and high intrinsic stability that contribute to reduce blooming and VOC emissions from an injected part. “Today, over 50 percent of plastics in vehicle interiors are made of polypropylene. With AddWorks ATR 146, we are excited to offer Tier Ones
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and OEMs the opportunity to go beyond the most stringent requirements for heat stability, light stability and VOC emissions with a low dosage solution,” said Emilie Meddah, Global Segment Leader for Automotive Applications at Clariant. “Such advanced performance responds precisely to the emerging trend in the segment for durability and lower VOC environments, setting the new benchmark for the next generation of automotive interiors.”
TRINSEO: INVESTING IN ABS FOR THE AUTOMOTIVE INDUSTRY Underscoring its commitment to producing premium ABS products for the global automotive industry, Trinseo announced the start of production of its ‘Magnum’ ABS resins in Zhangjiagang, China. Making the announcement at VDI, the company said the move was a “key development” in terms of reinforcing its position as a sustainable partner for global product supply and consistency. Trinseo’s Magnum ABS resins have a successful history in automotive exterior and interior applications for OEMs in North America and Europe. Now the same product range will be produced in China. “This growth strengthens our existing collaborative relationships with our customers, delivering on our commitment to provide premium ABS products worldwide,” commented Thomas Mettler, Trinseo’s Global Product Director, Performance Plastics. Trinseo says its Magnum ABS resins portfolio differentiates itself from competition due to proprietary mass polymerisation technology, which provides a number of functional qualities tailored to the automotive industry, including low gloss, low odour and excellent consistent material quality. This versatility, it says, means that Magnum ABS can cater to the individual needs of Tier suppliers and OEMs, and enable significant cost savings on colouring without a loss of quality. The portfolio is available globally for use in a wide variety of interior automotive applications, and is increasingly being used for exterior applications. Trinseo Magnum ABS resin is being used for a variety of both interior and exterior automotive applications
RADICI GROUP: ADVANCED METHOD FOR STRUCTURAL CALCULATION OF PLASTIC COMPONENTS In partnership with Politecnico di Milano, at VDI RadiciGroup Performance Plastics presented an advanced method for the structural calculation of components made from plastic combined with fibres or other substances, which it says is potentially “very precise” compared to the traditional method. This new approach aims to make structural calculation more reliable when replacing increasingly critical components which must be sized accurately. “The world of automotive needs to find increasingly innovative, high performance and low cost solutions to achieve the objectives of reducing environmental
impact, improving safety, aesthetics and comfort. In recent years, the innovative polymers offered by RadiciGroup Performance Plastics for the automotive sector are undoubtedly heading in this direction,” commented Andrea Bernasconi, Professor Erico Spini of RadiciGroup Performance of the Mechanics Department Plastics. of the Politecnico di Milano, “Nowadays however, along with suitable left, with Erico Spini, polymers, it is necessary to provide European Marketing Director of RadiciGroup Performance designers with a more reliable calculation Plastics, at VDI approach and characterisation of the materials compared to the past. In using advanced calculation instruments it is necessary to always focus on the correspondence of the results achieved with the experimental data. For this reason we collaborate with Politecnico di Milano, so that everyone, in their responsibility and role, can give the best contribution to the development of calculation instruments and approaches that are better suited to the requirements of our partners.”
SABIC: LIGHTWEIGHT PP AND PLASTIC-METAL HYBRID SOLUTIONS SABIC’s showing at VDI centered around reducing emissions and increasing fuel efficiency, with a range of solutions that crossed a range of application segments. This included plastic-metal hybrid (PMH) structural reinforcements for a vehicle’s body-in-white (BIW). A PMH floor rocker reinforcement, says SABIC, can help reduce weight by up to 45 percent vs. an all-steel alternative. In the component, Noryl GTX resin (MPPE/PA) from SABIC was combined with steel to form a very efficient energy-absorption crash box structure. This saves one kilogram (kg) in weight and maintains the required level of crashworthiness. The component is an industry-first use of plastic in a BIW reinforcement without the use of structural adhesives or foams. Use of the Noryl GTX resin allows the part to go through the automaker’s e-coat process with the rest of the BIW. Additional opportunities across the BIW means that a manufacturer could save up to 8 kg of weight with these hybrid solutions vs. all-metal reinforcements. SABIC also featured an injection-moulded, foamed instrument panel carrier. The part uses the company’s Stamax resin (LGFPP; 60YK270E grade) with SABIC PP resin (612MK10EE grade) in a structural foaming process. In this approach, the manufacturer injects the material into the mould with a foaming agent. Immediately afterwards, the mould is opened a few millimeters (mm), controlling the final density of the part. During the process, the foaming agent produces CO2 bubbles that create a foamed core. The final produced part is both light and stiff. SABIC says the solution is emission-optimised and meets the VDA278 industry standard. Other potential benefits from this foamed Stamax resin solution include the need for less material during processing, shorter cycle times, and a better balance of impact and stiffness.
At this year’s VDI Congress in Mannheim, Germany, Sabic displayed an injectionmoulded foamed instrument panel carrier
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COMPOSITES | NEWS KRAUSSMAFFEI TECHNOLOGY ENHANCES HYBRID FIBREREINFORCED PLASTICS FOR CAR MATERIALS Researchers at the Dresden University of Technology are using a system developed by KraussMaffei to pioneer hybrid fibre-reinforced plastics for automotive lightweighting applications. KraussMaffei has provided a new laboratory test system as part of a research project, ‘Leichtbau in Karosseriebauteilen’ (LEIKA), which aims to reduce structural mass in electric vehicles by using hybrid materials that could have large-scale series production. “The new lab system at the Institute for Lightweight Engineering and Polymer Technology allows us to form and back-inject FRP-metal hybrid materials in one step. The resulting process and structure quality, together with the achieved cycle times of significantly less than two minutes, supports the potential of such hybridisation on both the material and production end,” explained Martin Würtele, KraussMaffei Director of Injection Moulding Technology Development. Designing floor structures for electric vehicles, the researchers used hybrid plastic/ metals to make metallic outer layers of steel with a core of CFRP for the centre tunnel. “The first test results are excellent,” continued Würtele. “The mass is reduced by 25 percent compared to an all-metal lightweight construction solution. Simultaneously, it was possible to demonstrate comparable performance under the most important load conditions regarding
The new lab system at the Institute for Lightweight Engineering and Polymer Technology at Dresden University of Technology allows forming and back injection of the FRP-metal hybrid materials in one step
stiffness and crash situations for components with significantly lower mass.” KraussMaffei has provided systems and aided project engineering from the start of the LEIKA project. The new lab system is suited both for the manufacturing of components by injection moulding and for the back injection of semifinished products. Additionally, plastics can be used for compression in the mould or for reinforcement for local areas in the component. This process sequence is applied through the integration of a flat sheet die as well as a conveyor belt with an insertion robot.
Michael Krahl, LEIKA Project Manager, said: “The new test system lets us project a large number of incredibly varied processes on a single system. This lets us offer significant added value to our partners from the automotive industry.” The system in use within the laboratory is also capable of combining injection moulding and extrusion technology, with an integrated, reduced height bolt-on unit used for the production line, including a press, infrared oven, robot and conveyor belt. WWW.KRAUSSMAFFEI.COM
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EVONIK INTRODUCES NEW TECH FOR MASS PRODUCTION OF COMPLEX COMPOSITE PARTS Materials specialist, Evonik, is pioneering a new, hybrid production system that it says will produce complex composite parts in high volumes. Evonik says its new ‘PulPress’ method could ensure cost savings of up to 60 percent over previous lightweight construction methods. Conventional composite moulding is expensive and complex, but Evonik believes its PulPress system can shift complex moulding from the luxury end of the market to large-scale production at reasonable prices. The PulPress method combines compression moulding and pultrusion to make continuous composite parts. Evonik’s key material in the method is Rohacell, a lightweight, rigid foam core that retains shape well and is temperature resistant. Evonik says highlights of the new manufacturing process include its design flexibility and cost efficiency, as well as the crash behaviour
of the resulting composite parts, which are around 75 percent lighter than traditional steel structures. Additionally, the PulPress method also reduces costs by up to 60 percent compared to composite parts manufactured using established methods such as resin injection. Dr Sivakumara Krishnamoorthy, Manager for New Applications in Evonik’s Resource Efficiency Segment, said: “These advantages have already won over many customers in the European automotive industry. Moulded parts made using PulPress will soon be going into mass production.” Evonik is touting Pulpress for transferring composite moulds from luxury to mid-range cars. As well as the auto industry, it expects aeronautical engineers could find it a cost-effective method for producing large numbers of carry-over aeroplane parts. Another application will be making lightweight sandwich cores in sports equipment. WWW.EVONIK.COM
A composite part made by the PulPress method from a structural foam core of Rohacell woven around with fibers is about 75 percent lighter than traditional steel structures.
Covestro has developed the new Desmocomp polyurethane matrix for composites with very good UV, weathering and chemical resistance. It is ideally suited to outdoor applications
COVESTRO WINS JEC INNOVATION AWARD FOR WEATHER RESISTANT MATERIAL Covestro has been awarded the JEC Innovation Award in the Raw Materials category for a new polyurethane matrix for composites with high UV, weathering and chemical resistance. On display at the JEC event in Paris this week, new Desmocomp is formulated from aliphatic isocyanates and is ideally suited to outdoor applications, as it eliminates the need for any additional surface protection, such as coatings, UV absorbers and UV-stable mats or films. Covestro says the new matrix material can be processed extremely cost-efficiently, thanks to its long pot life and rapid curing. Like other polyurethane materials, Desmocomp also displays high reactivity, variable viscosity and good bonding strength. It wets a composite’s glass fibres very effectively, lending it high and lasting strength. The anti-graffiti properties and good flame retardance of the composites round out the profile. Following the award win, Paul Heinz, Senior Project Manager, Fibre Reinforced Polymers at Covestro, said: “Desmocomp is an outstanding material. It is the first time a polyurethane has been used without any coatings or auxiliary materials in outdoor applications. This is the reason the JEC Group recognised the potential of the material.” WWW.COVESTRO.COM
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EXTRUSION MACHINERY THE FACTORY AUTOMATION COMPANY
Superior unmanned moulding. With FANUC it’s easy.
Scan the QR code to watch the video about FANUC ROBOSHOT
MISTER BLISTER INVESTS IN BANDERA RIGID FILM EXTRUSION LINE Manchester-based producer of thermoformed blister packaging, Mister Blister, has invested in a new multi-layer PET rigid film extrusion line from Bandera. The new line was supplied by Bandera’s UK distributor, UK Extrusion Ltd, following a steady increase in product manufacturers worldwide choosing the Mister Blister patented range of tamper-proof packaging. Commenting on the capacity of the new line, Mister Blister’s Managing Director, Gary Briscoe, said: “We will be working on an average output in the region of 660 kg/hr and expect to produce 2000 tonnes of material per annum. The majority of this material will be for our own production, but we will be selling small orders of several popular widths and microns of sheet from stock.” Steve Trainor of UK Extrusion Ltd added that Bandera’s rigid film lines were a good choice for thermoformed packaging, owing to their flexibility in processing a variety of raw materials. “We find them robust and well-engineered,” said Trainor
of the range. “They [Bandera] provide single screw extruders and/or HVTSE co-rotating twin screw extruders, with no requirement for drying of raw materials and the option of the inclusion of mineral fillers.” In addition, Trainor said packaging manufacturers can select single or multi-manifold flat extrusion die with internal deckling systems. They are also able to specify from a wide range of winding systems, with varying degrees of automation. Mister Blister says the purchase of this new rigid film extrusion line is an example of the company’s commitment to invest in the latest machinery to provide its customers with high quality products. “I carried out in-depth research before selecting the Bandera line. People within the industry, whose opinions I value, all recommended the Italian manufacturer,” Briscoe added. “I was further convinced by the fact that there are already 12 lines operating within UK manufacturing and an established support network. This is particularly important in a project of this magnitude.” WWW.LUIGIBANDERA.COM
Mister Blister in Manchester has recently invested in a new multi-layer PET extrusion line from Bandera
FANUC ROBOSHOT HIGH PRECISION ELECTRIC INJECTION MOULDING
Roboshot was designed for maximum precision, convenience and performance. Thanks to FANUC’s common control platform it’s also easy to automate with robots. Adding these not only enables seamless tending but also gives you the flexibility to produce sophisticated parts that require inserts. That way you have the best of everything: excellent cycle times, low costs per part and the ability to mould almost anything.
Find out more about FANUC ROBOSHOT fanuc.co/roboshot-en marketing@fanuc.co.uk | ref. PRW1116
40 MAD-02237-RS Cross Selling Roboshot_86x265mm.indd 1
W W W .04/04/2017 B R I T I S09:56:09 HPLASTICS.CO.UK
| NEWS TRANSAM EXTRUSIONS INVESTS IN ADDITIONAL DAVISSTANDARD MACHINERY A UK manufacturer of tubing and profiles has invested in its sixth Davis-Standard extruder as a result of significant growth and an ongoing reinvestment programme. Transam Extrusions, based in Barton-Le-Clay, Bedfordshire, produces a wide range of both flexible and rigid plastic pipes and profiles up to 180mm wide. The past decade has seen major growth at the company, which has resulted in investment in extruders, screw technology and other downstream equipment. The latest addition to its manufacturing facility is a new DavisStandard EB50 EuroBlue extruder with associated downstream. The
PROFILE PRODUCER INTEGRATES NEW EXTRUDER TO BRING 10-YEAR-OLD TECHNOLOGY UP TO DATE A window profile extrusion company based in Weißenfels, Germany, has made its 10-year-old machine ‘state of the art’, thanks to integration with a co-extrusion combination and process control software. Schüco Polymer Technologies KG is commissioning a twin-strand coextrusion combination from KraussMaffei Berstorff, which integrates the company’s KMD 114-32/P twin-screw extruder, which has been running for more than ten years, into a new co-ex combination, which is equipped with two KMD 63 K/P conical machines. “With our concept of twin-strand coextrusion, we have met a special requirement from Schüco,” explained Marc Stramm, Sales Representative for Germany at KraussMaffei Berstorff. “The machine, which has been in operation as a single extruder for more than ten years, has been integrated into the new, efficient and high-performance twin-strand extrusion machine that produces coextruded window profiles with a high output of 700 – 800 kg/h,” Stramm continued. The main
machine was ordered and delivered within five days, resulting in minimal production delays for Transam’s clients. In addition, Transam purchased a custom-built DavisStandard water-bath specifically designed for the company’s unique business requirements. “Davis-Standard’s expertise, dedication and responsiveness to their customers goes beyond all expectations,” said Russell Brazier, Managing Director, Transam. “Their equipment is extremely reliable, screw technology second to none and we’ve been delighted with the technical staff that support and help us to concentrate on our growing business in the United Kingdom.”
ard -Stand w Davis extruder e n e h T e uroBlu EB50 E
WWW.DAVIS-STANDARD.COM
extruder prepares the material with a higher proportion of recycled or filler content for the inner layer. The two coextruders (executed as a piggyback model) deliver the outer layer in a twin strand with performance of up to 200 kg/h per strand. The machine is equipped with KraussMaffei Group’s C6 control system, meaning the machine is state-of-the-art in terms of control and monitoring. It also guarantees reliable production, especially regarding extruders produced in cooperation and downstream units.
“We have been using twin-screw extruders from KraussMaffei Berstorff for profile extrusion for many years,” said Joachim Papenheim, Supply Chain Manager at Schüco Polymer Technologies KG. “The machines are highly compact and robust and we are confident that the revised configuration will continue to manufacture in such a reliable, hassle-free and, above all, substantially higher-performance fashion.” WWW.KRAUSSMAFFEIBERSTORFF.COM
Twin-screw extruder KMD 11432/P in mono extrusion before and after the upgrade with two conical coextruders – twin-strand – and C6 control System
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The Plastics Industry Exhibition in France www.f-i-p.com
The new Super-G high speed extruder
PTI LAUNCHES NEW SUPER-G HIGH-SPEED EXTRUDERS Processing Technologies International (PTi), a manufacturer of sheet extrusion machinery, has launched a new range of high-speed extruders for the packaging market. New ‘Super-G’ high-speed extruders have been developed to process polypropylene (PP) and high-impact polystyrene (HIPS). The Super-G SGHS3000, which comes in two models, is said to deliver “significant performance advantages” and overcomes the limitations of competitive products. “Our new high-speed extruder technology sets a new industry standard because of its innovative and unique design and performance,” said Dana Hanson, President of PTi. “This technology offers our customer base a highspeed solution that delivers improved melt quality as a result of our Super-G Lobe screw technology and is offered integrated with all of our advanced G-Series Configurable roll stand configurations.” The Super-G SGHS3000-36D is equipped with a 500hp motor and runs at a maximum speed of 1000rpm, while the Super-G SGHS3000-42D has a 600hp motor and runs at a maximum speed of 1200rpm. Each is capable of faster speeds, however, PTi establishes the maximum rated speed based on an upper motor load threshold of 85 percent. For processing of PP, the Super-G SGHS3000-36D has a
BOSTON MATTHEWS BOOSTS TEAM AND TECHNOLOGY FOLLOWING INCREASING DEMAND Extrusion machinery manufacturer, Boston Matthews, has expanded its engineering department in the UK, with investments in both technology and new staff. The investment at its Worcester headquarters comes as a result of growing worldwide demand across a wide range of industries. The company has recruited new mechanical and electrical design engineers to work on both the Boston Matthews extrusion machinery and Munchy recycling product ranges. It has also invested in high precision machine component manufacturing equipment and digital
production output of approximately 3,000 lb/hr (1361 kg/hr). In addition to delivering excellent melt quality, PTi’s high-speed extruders feature carbide-lined barrels and Colmonoy hard-faced feed screws versus case-hardened screws as featured on competitive models. The Super-G high speed extruders have an oversized feed section which promotes higher regrind feed rates (up to +70 percent), along with a streamlined feed hopper with
support, delivery chute and tramp metal protection. Other key features include feed screw removal from the back of the unit, an easy cleanout vent chamber and linear bearing barrel glide support. Special aircooled heater and blower assemblies limit the exterior heater temperature for safety and efficiency purposes (< 43°C) versus competitive models which can be as high as 260°C. WWW.PTIEXTRUDERS.COM
measurement equipment. This, says Simon Brookes, Boston Matthews’ Managing Director, will help the company efficiently manufacture complex die heads, tooling and other precision component parts. “The decision to take on more design engineers is a big investment. Technological innovation and the constant drive for product improvement is at the heart of Boston Matthews and Munchy, and it is imperative we have the experience and skills to accomplish this,” Brookes explained. “We are experiencing a high level of demand for our products because of our ability to work with customers and take them to the next level, which is fantastic, but it does place demands on engineering.
The new [staff] additions have been very carefully selected to add to our already highly experienced and skilled design team.” In addition, investment has also been made into new electrical design software packages, which Brookes says will allow engineers to produce accurate electrical schematics for individual machines and complete turnkey installations. “We try and keep as much manufacturing in-house as possible to enable us to incorporate any design improvement as quickly as possible. It also greatly improves our R & D capabilities,” Brookes concluded.
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WWW.BOSTONMATTHEWS.CO.UK
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NEC BIRMINGHAM, UK | 26-28 SEPTEMBER 2017
INJECTION MOULDING
EXTRUSION
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DO YOU HAVE EXPERIENCE IN THE SUPPLY OF RUBBER PRODUCTS?
Adwan Marketing Company, www.adwanmarketing.com, a leading electrical materials distributor in Saudi Arabia, is planning to expand its services to include distribution of rubber products for industrial, construction and consumer applications. Adwan Marketing plans to engage consultants/advisors with long experience in rubber products distribution/supply to help in this expansion. Please send your resume to : khaled@adwanmarketing.com Mobile : +966505466331
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WWW.BRITISHPLASTICS.CO.UK
MATERIALS | NEWS ALBIS TO EXPAND PURELL PRODUCT RANGE WITH NEW COLOURING LICENSE Albis Plastic and LyondellBasell have signed a licensing agreement for colouring of Purell materials. The new agreement allows Albis to expand the product range for use in medical devices, laboratory and diagnostic areas as well as pharmaceutical packaging. With the agreement to globally offer Purell polyolefin materials coloured to customer requirements, the two companies say they have set a further milestone in their partnership. The Purell range of polyolefins (polypropylene as well as high density and low density polyethylene grades) addresses the specific requirements of healthcare applications through a strict commitment of a consistent formulation, change management procedures for unavoidable formulation changes and compliance with biocompatibility requirements in Europe and the United States. Mike Freudenstein, Director of Marketing Healthcare at Albis Plastic, said: “We are looking
adquarters Repsol’s he
forward to LyondellBasell being our further licensing partner for the development and production of coloured healthcare materials, and to expanding our range of licensed colouring. The new agreement gives us the opportunity to better serve the continuing trend toward pre-coloured materials. For our customers, this step means a reduction in complexity.” With Purell, Albis will develop tailor-made colours without changing the fundamental properties of the
healthcare materials. “Components for medical products and pharmaceutical packaging that are made from our compounds not only impress with their functionality, but also their attractive appearance and safety-related properties. This includes, for example, the important colour distinctions of operating parts or connections on medical devices or infusion aids in hospitals”, added Freudenstein. WWW.ALBIS.COM
w offer Albis will no es of ad gr ed colour Purell l’s el LyondellBas products
REPSOL DEVELOPS NEW POLYMERIC POLYOL GRADE FOR FURNITURE MARKETS Repsol, the Spanish oil company, has launched a new polyol grade designed to meet the requirements WWW.BRITISHPLASTICS.CO.UK
of the bedding and furniture industries. Its new Alcupol P-3091 grade has a very low total of volatile organic compounds (VOCs), meaning product manufacturers can adhere to stringent European certifications such as ‘CertiPur’ and ‘OEKO-TEX’. To meet these requirements of the polyurethane industry, Repsol has implemented improvements in its processes that have made possible to achieve a specification of styrenefree content in Alcupol P-3091, of less than 5ppm, and a reduction of total volatile organic compounds in 75 per cent, compared to a standard polymer polyol. The improvement extends the range of Repsol’s polymer polyols for flexible slabstock. With the launch of the new grade, Repsol says it is reinforcing its strategy towards differentiation in the quality of its products. WWW.REPSOL.COM
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@POLYMERMAN ON PRICES Are increasing polymer prices more sustainable than the feedstock prices that typically have initiated price inflation? IN THIS EDITION OF OUR LATEST FEATURE LOOKING AT THE KEY ISSUES THAT INFLUENCE POLYMER PRICES, MIKE BOSWELL EXAMINES THE SUSTAINABILITY OF POLYMER PRICE INCREASES VS. FEEDSTOCK.
T
he dependence, or perhaps the interdependence or independence of plastics from their input costs is, and is likely to remain, a hot topic of debate. In the case of polyolefins the graph to the right, which is an index of a polyolefin price basket compared to brent crude, depicts a close correlation until about August 2014. Thereafter there appears to have been a paradigm shift with polyolefins becoming relatively much more expensive over a significant period of time. Not withstanding the question of how polyethylene pricing may be affected by the start-up of a swathe of new capacity in the USA, where the economics of shale gas feedstocks will give plenty of opportunity for price competition, perhaps the more pertinent questions relate to the future pricing of styrenic and engineering polymers. In the case of styrenic polymers, the meteoric rise in prices, particularly affecting polystyrene, was entirely based around short supply of styrene monomer in the North America region due to planned plant maintenance. Availability and lead-times were scarcely impacted and now that styrene monomer production has returned to more normal levels, there is clear downward pressure on styrene-based polymers; this looks like a trend that may be set to continue through into the quieter summer months. However, the case of engineering polymers is potentially quite different. Although initially benzene was the driver for many cost increases, the situation for a wide range engineering polymers is now one of short supply and extended lead times and, on this basis, the independence of the supplydemand balance for the polymer rather than the price of feedstock has become the determinant of price. In fact, although benzene prices have now started to reduce
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significantly, it is likely that the producers will resolutely defend price increases on the basis that they have bulging order books. For methanol-derived polymers, including POM and PMMA, it appears that increasing feedstock costs are also now acting as a catalyst for price increases and here again it is evident that PMMA lead-times are already starting to increase; a situation which will again support price increases. For many on the supply side there is a strong argument for higher market prices for engineering polymers on both the basis of a long-term decline in price levels and also the reduction in relative cost compared to standard polymers. However, market fundamentals will ultimately dictate price levels and in the case of PC and POM, where capacity to supply appears to readily meet demand, it is likely that any reduction in feedstock cost is likely to lead to price reductions due to competition for market share. On this basis, it is likely that there will be some divergence in the price of different engineering polymers in the coming months.
Who is @polymerman
“The dependence, or perhaps the interdependence or independence of plastics from their input costs is, and is likely to remain, a hot topic of debate.” WWW.BRITISHPLASTICS.CO.UK
Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group, and, most recently, its ‘BREXIT Committee’. He has a broad knowledge of both materials and the issues affecting the wider industry, with over 20 years experience in the field. @polymerman is the title used for announcements made via his Twitter account.
BUYER’S GUIDE
MATERIALS
MOULD RELEASE
ultrasonic welding
CONTROL SYSTEMS AND EQUIPMENT
HOT RUNNER SYSTEMS hot runner controllers
quality monitoring control
MASTERBATCH
Kistler Instruments Ltd
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.
BLACK & WHITE MASTERBATCH Compounding
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Film
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Whitelands Mill, Whitelands Road Ashton-under-Lyne, OL6 6UG, UK Tel: +44 (0)161 308 2550 Fax: +44 (0)161 343 2026 E-mail: aml@abbeymb.com Web: www.abbeymb.com
Motan Colortronic Ltd
InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)
PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.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
gravimetric/volumetric blending 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
Telsonic UK Ltd
Unit 3 Vitrage Technical Park 27 Witney Road , Nuffield Industrial Estate, Poole, Dorset BH17 0GL T: 01202 697340 F: 01202 693674 W: www.telsonic.com Blog: telsoniccuk.wordpress.com
Accurate colour systems for the PVC and additives industries t: +44(0)1942 254006 e: sales@astropol.uk.com www.astropol.uk.com Eclipse Buyers Guide_Layout 1 07
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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.
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DB-Automation specialises in designing and building bespoke high speed injection moulding automation • Reliable and robust machinery with installation worldwide • High performance de-mould automation for injection moulding • High speed axis for reduced cycle times • Dependable after sales support if required
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MATERIALS HANDLING AND STORAGE
pulse staking
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
H.T.E Engineering 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
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MIXING, FEEDING & DOSING 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 FOR SALE W: www.motan-colortronic.co.uk
METAL DETECTION & SEPARATION EQUIPMENT Motan Colortronic Ltd
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
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
47
BUYER’S GUIDE
MACHINERY & EQUIPMENT METAL DETECTION & SEPARATION EQUIPMENT Magnetics Separators Metal Detectors Eddy Current Separators
Bunting Magnetics Europe Ltd European Design & Manufacturing Facility
Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co
RECYCLING SYSTEMS
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
TransXL International Ltd
Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk
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
CHOOSE THE NUMBER ONE.
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Contact: Carlton Hicks
Mould change
I’VE GOT A BUMPER LOAD OF RECYCLED PLASTIC IN ME, THANKS TO VANDEN
50mm high and 35mm We buy and sell high quality plastics
Engineers to the Plastics & Rubber industries, specialising in the following: Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd
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Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com
ANGLO PLASTICS LTD
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
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NOZZLES & NOZZLE TIPS
Cooper Plastics Machinery
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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
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Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries.
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
TESTING EQUIPMENT hardness - IRHD and shore For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk
Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.co.uk
3D Printing in Plastic & Rubber
inspection & measurement
DM Machinery Ltd
Tel: 01420 88645
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
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- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com
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Injection
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3D PRINTING
211 )1733 232 P. +44 (0
• Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks
ulders injection mo
FOR SALE
DTL Machinery UK
www.magog.co.uk
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MAPRA Technik Co — BAREISS
COMPOUNDS
vekacompounds.com +44(0)1322 387 219
PRINTING MACHINES
TRAINING
c.co.uk www.rjgin
www.vandenrecycling.com supply@vandenrecycling.com
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
11 )1733 2322 P. +44 (0
028 9266 8009
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
thermocouples
BUYER’S GUIDE PRINTERS
SERVICES MOULDFLOW ANALYSIS
Gammadot Rheology Testing & Consultancy Services
printers of plastic mouldings Total Print Ltd
Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry
SOFTWARE
TESTINg/CONSULTANCY
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
Component PRINTERS TAMPO.SCREEN.FOIL
c.co.uk www.rjgin
211 )1733 232 P. +44 (0
Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
SOFTWARE DIRECTORY A listing in the Software Directory costs £160 per programme per year. Call Lisa on 01244 680222 for details. 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: info.uk@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). 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. intouch T: 01604 646144 E: enquiries@ intouchmonitoring.com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages. 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, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages). SYSCON – PlantStar Tel: +44 (0)7747 014545 E: ianh@syscon-intl.com W: www.mtec-services.co.uk W: www.plantstar.org
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. Browserbased software and hardware, and wireless Ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include realtime alarms, downtime & reject analysis, capacity scheduling , ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Materials traceability, barcoding. New QuickShot entry level system, provides real-time data collection & reporting, plus drag & drop scheduling and much more for less than £500 per machine!
enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Epicor ERP 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, warehousing and distribution. Available on-site, hosted & SaaS it seamlessly integrates with Epicor Mattec Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.
WWW.BRITISHPLASTICS.CO.UK
Process Optimisation Software RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E ingo@rjginc.co.uk Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.
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NEWS FROM THE FRONTLINE
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bp&r BRITISH PLASTICS &RUBBER 50
marketing absorbed through the classic tomes of Kotler et al. is dead. In a world which is increasingly, as he describes it, “vibrant, unreal, crazy and astounding”, he says that the products of the future, their acceptance or rejection, will be based on the creation of ‘MOVEMENTS’ through social media channels. You can test the relevance of this, closer to home, by plunging into the swirling online debate about plastics. The anti-plastics lobby has a massive presence largely based on negativity or the promotion of spurious alternatives. Collectively, we have an opportunity to enter into this space and exert the influence of our positive actions and beneficial innovations, demonstrating how we really are, in the words of the Ellen MacArthur Foundation, “an innovation powerhouse”. I see this as the next great leap forward in the industry’s communications efforts. One way of starting this off in a very modest way is by establishing a ‘Twitter’ account for your company and by sending positive messages about your company’s activities and products down a chain of followers. We have several thousand companies in the UK plastics industry alone, just imagine the weight of communication if a large proportion of those firms ‘tweeted’ positive stories which were then re-tweeted in geometric progression down supply chains. Back to PVC then, and the industry, which traditionally gathers at Brighton, is large but close knit. Once you enter the PVC fraternity and sorority there is a strong likelihood that you will become a ‘lifer’, and this is the industry’s strength because there is a tradition of co-operation borne of this which led to the success in the UK of the BPF’s Vinyls Group and, more widely across Europe, Vinyl 2010 and VinylPlus. The PVC industry is, arguably, already one of Kevin Robert’s ‘MOVEMENTS’ and social media channels provide an opportunity for all firms in the sector to contribute to its improving image based on their actions. www.bpf.co.uk
ASSOCIATED ORGANISATIONS
he imminence of the Brighton PVC Conference causes me to reflect on the power of industry communications. IN THIS MONTH’S EDITION Without a doubt PVC is in a much OF HIS EXCLUSIVE COLUMN, better place PHILIP LAW, DIRECTOR- than it was, GENERAL OF THE BRITISH say, 15 years PLASTICS FEDERATION, ago. There are a DISCUSSES PVC’S PUBLIC whole range of factors, both internal to the industry and IMAGE, AND HOW SOCIAL external, which have caused MEDIA ‘MOVEMENTS’ COULD this improved positioning. HOLD THE KEY TO PROMOTING Personally, I think that the A MORE POSITIVE IMAGE OF ramping up of PVC recycling PLASTICS ACROSS OTHER in a systematic way across INDUSTRY SECTORS. Europe under the aegis of Vinyl 2010 and VinylPlus have had a lot to do with it because this gave us the substance for positive communications. It was actually doing what we said, across Europe, that made the difference. When challenged ‘What is the industry doing about the PVC issue?’ the answers suddenly became very easy to construct and enabled the industry to speak with absolute confidence and conviction. It should be feasible to do this across the board in the plastics industry. There are innovations left, right and centre to products and processes that are improving the environmental performance and profitability of swathes of customer sectors and also improving the lives of consumers. The individual firms who are making these advances daily are in the best position to communicate the benefits provided by these innovations through social media channels. For those skeptical about the relevance of social media and its usefulness to us as an industry, I would recommend a viewing of a ‘You Tube’ video of a recent presentation given to MBA students at UCLA’s Berkley campus by Kevin Roberts, the former Chairman of Saatchi and Saatchi. Although he was based in New York, Kevin is a hard-hitting Lancastrian who ‘tells it as it is’ and his basic theme is that the attention-grabbing
WWW.BRITISHPLASTICS.CO.UK
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Wet molding RTM Technology Semi-structural components made of recycled carbon fibers, e. g. hybrid components
Surface RTM Technology Fiber-reinforced, paintable surfaces such as roof elements, door inner panels, trunks or engine hoods
RTM Technology Structural and semi-structural components such as underbody structures, side frames or seat structures
IMC Technology Fiber-reinforced, structural components such as front ends, mounting supports, instrument panel carriers
FiberForm Technology Continuous fiber-reinforced components such as crash elements, B-pillar reinforcements or seat structures
Fiber composite solutions for advanced lightweight components Engineering Passion