BP&R April 2020

British Plastics

and Rubber

bp&r APRIL 2020

all for

One for all

SPECTROPLUS – ONE DOSING SYSTEM FOR ALL EXTRUSION AND COMPOUNDING TASKS — SEE PAGE 4 FACING THE CHALLENGE The plastics company that’s switching from packaging to PPE

TIME FOR OPTIMISM How creativity will produce some worldleading plastics sustainability solutions

CATCH MY DRIFT? A checklist for eliminating dangerous drift from cooling towers

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editor’s letter

www.britishplastics.co.uk head of content: Leanne Taylor

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Assistant Editor: Tom Walker

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Resilience, flexibility and determination

L

ooking at my editorial planner and show calendar, this issue should have been chock full of content garnered from shows and events in the UK and beyond: exclusive interviews about the future of plastics in the automotive industry sourced from PIAE in Mannheim; a feature based on the launch of the innovative packaging take-back scheme, Loop, in the UK; and insight from the speakers set to take part in PVC2020 later this month. The reality, of course, and something I could never have anticipated when I planned out the editorial scheduling many months earlier, was the way the world would be turned upside down by the outbreak and escalation of the Covid-19 virus.

It goes without saying that these planned events did not, and are not, taking place when they should have done. This issue does not contain any of the insight from them that I once expected it would. And that now, instead of working from an ever-changing base of either my desk surrounded by my colleagues at Rapid News headquarters; an airport waiting area surrounded by other business travellers hoping for an uninterrupted flight; or a busy show floor alongside other plastics industry comrades – I am in the very permanent location of my dining room, surrounded by my home furnishings and enjoying only the odd moment’s company of my husband, when he pops down from the office upstairs, where he too, is now permanently based.

All the aforementioned events are rescheduled with the promise of ‘bigger and better’ when the time comes. This issue is still packed full of original and interesting content from key contributors and experts. And it is also one that highlights in its opening news pages the efforts being made by those plastics companies that are reacting quickly to the urgent need of supplies and providing key items in record time. These key workers are crucial in ensuring the ongoing supply of crucial parts and products that are enabling our NHS and other service providers to prepare the country for the battles ahead. It also, of course, serves to reinforce the importance of plastic as a material that offers us myriads of benefits. We can only showcase a few of the many efforts being made on our pages, but from all at BP&R, we extend a heartfelt thanks to everyone helping in the national effort to save lives.

Stay safe and enjoy the issue.

Leanne Taylor, EDITOR AND head of content

Despite these interruptions to life and plans, the uncertainties of the times we are in and the unpredictability of the months ahead of us – one thing is for sure. The plastics industry shows resilience, flexibility and determination in the face of it all.

www.britishPLASTICS.co.uk

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the big story all for

One for all

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AS EFFICIENCY IN PRODUCTION REMAINS A CRUCIAL ASPECT OF PLASTICS PRODUCT MANUFACTURING, THE MOTAN GROUP OUTLINES WHY ITS SPECTROPLUS DOSING SYSTEM OFFERS AN ‘ALL-IN-ONE’ SOLUTION FOR ALL EXTRUSION AND COMPOUNDING TASKS.

hether granulate, regrind, powder, liquids or flakes – motan-colortronics’ dosing and mixing system can be adapted to the most diverse dosing requirements. Specially developed for the extrusion and compounding sector, the Spectroplus ensures perfect and constant dosing for continuous processes.

As one of the most flexible overall systems in the motan product world, the synchronous dosing and mixing unit can be supplied in either gravimetric or volumetric versions, or a combination, and for both starve-fed and flood-fed extrusion applications. Up to eight dosing modules are mounted on a frame and can be easily removed and installed without tools.

The exchangeable dosing modules, as well as the easyto-clean dosing hopper, enable a quick material change and therefore shorter production downtimes. Modules and the most diverse dosing screws can be changed in record time.”

The exchangeable dosing modules, as well as the easy-to-clean dosing hopper, enable a quick material change and therefore shorter production downtimes. Modules and the most diverse dosing screws can be changed in record time. In addition to the dosing modules for bulk solids, gravimetric supply hoppers with dosing pumps for liquids can be used, depending on the application adapted to self-lubricating or non-self-lubricating liquids.

The installation is not only simple, says motan, but also saves space due to its compact design.

Using simple individual adapters, the Spectroplus can be mounted directly on the machine feeder of the extruder or on a customer-specific mezzanine.

Compared to predecessor products, the overall height is massively reduced, the throughputs are, however, still the same. Ideal for low production halls as well as for large projects.

Another highlight, says the group, is the new load cell system, which consists of a combination of high-quality strain gauge load cells and a latest generation digital transducer. Benefits of this new technology include ease of assembly and calibration, long-lasting and low-maintenance hardware, trouble-free signal transmission and low susceptibility to external interference. In just a few minutes, companies can get from the adjustment to the filtered measurement signal.

To complete this versatile unit, a completely new control has been developed – the SpectroNet – which can control not only motan’s own dosing modules, but also third party dosing units. With a combination of advanced software and new highquality hardware, the scope of application has been increased, the control time improved and the susceptibility to interference significantly reduced.

www.motan-colortronic.co.uk 4

www.britishPLASTICS.co.uk

Spectroplus dosing and mixing unit

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PMM Ltd will continue to adapt its working practises to protect the health of its staďŹ&#x20AC; and prevent the further spread of the Coronavirus (COVID-19).

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on the cover

ALL FOR ONE FOR ALL As efficiency in production remains a crucial aspect of plastics product manufacturing, the motan group outlines why its Spectroplus dosing system offers an ‘all-in-one’ solution for all extrusion and compounding tasks.

SEE PAGE 4

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EDITOR’S LETTER

14

INTERVIEW

FACING THE CHALLENGE As the UK plastics industry steps up to the challenge of supporting the fight against Covid19, BP&R’s Tom Walker spoke to James Hill, Managing Director of Kingsmoor Packaging, to find out how it is utilising its expertise and equipment to produce life-saving PPE for NHS frontline workers.

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FEATURE

MAKING AN IMPRESSION To mark 55 years in business, Birminghambased Barkley Plastics has invested in new injection presses and automation equipment, fuelled by major projects in the automotive sector. BP&R looks at why 2020 is set to be an exciting year for the UK manufacturer.

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Feature

AIRBORNE WATER DROPLETS ARE A BIG ISSUE, IF YOU CATCH MY DRIFT Gary Dicker, Director at DHD Cooling, presents a checklist for eliminating dangerous drift from cooling towers.

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Feature

THE FUTURE OF PLASTIC: IT’S TIME FOR OPTIMISM As companies look to new solutions in the move towards more sustainable use of plastics, Nick Cliffe, Deputy Challenge Director of the Smart Sustainable Plastic Packaging Challenge, UK Research and Innovation (UKRI), discusses the future, and why creativity and optimism are key to success.

Regulars and Features 09 INDUSTRY NEWS 16 AUTOMOTIVE PLASTICS 21 Temperature Control 24 RECLAMATION AND RECYCLING 26 EXTRUSION 29 MACHINERY 30 COMPOSITES 32 POLYMERMAN 34 SOFTWARE GUIDE 35 BUYERS’ GUIDE 38 NEWS FROM THE FRONTLINE

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INDUSTRY | NEWS INDUSTRY NEWS SPECIAL: Can you help with the supply of essential medical equipment?

Plastics industry rallies to support Covid-19 fight In recognition of the companies across the UK that are dedicating production, resources and time to the manufacture of vital supplies, components and equipment in the fight against Covid-19, we are dedicating the industry news pages this issue to coverage of their work, help and support.

If you are also in a position to help, please read the following details:

University of Hull face shield design set to increase UK production The University of Hull is leading a collaboration to produce face shields to support the NHS and other healthcare organisations in the region – with new designs and agile manufacturing techniques set to increase production capacity across the country.

The new designs, which are aligned to mass production and which take just minutes to make, will be shared nationally to enable production in other regions, maximising the UK’s supply of urgently needed face shields for the NHS and healthcare organisations to prevent the spread of Covid-19.

The new designs can be

In this unprecedented time in which NHS and other frontline staff find themselves in need of a constant supply of vital equipment, please find below the necessary contact details for all plastics companies with spare capacity to offer support: If you are able to help regarding the manufacture of ventilators, please visit: https://ventilator. herokuapp.com For the manufacture of anything else, email: gcfcovid19enquiries@ cabinetoffice.gov.uk

during what is a difficult and unparalleled situation.

OTHER INFORMATION For the latest government information visit the UK government website: https://www.gov.uk/government/ topical-events/coronavirus-covid19-uk-government-response For plastics industry guidelines on COVID-19, including health and safety, working from home and legal advice, the British Plastics Federation is hosting a dedicated page: https://www.bpf.co.uk/ coronavirus/guidance-main.aspx

The plastics industry is crucial in the fight against Coronavirus and our thanks go to those businesses that are able to assist safely and following key worker guidelines

produced by high volume manufacturing techniques, such as laser cutting and injection moulding, rather than 3D printing.

This will increase the amount that can be produced every day from 100 to more than 2000-5000.

Nathan Brown, Senior Lecturer in the Department of Engineering and lead on this project, said: “As a team, we have invested a huge amount of time and effort in developing the designs. We have been in regular contact with those on the frontline of the NHS – to develop designs that will protect staff but can be produced quickly and with maximum efficiency.

“While it has been brilliant to see our region come together to produce face shields in line with the global initiative by 3D printing, we have established that this method is time-intensive – even with the

best 3D printers available – and may not be able to generate the stocks needed by all the healthcare organisations in our region.”

For more information about this project, or to offer support – please get in touch via fblp-business@hull.ac.uk

www.britishPLASTICS.co.uk

The University has used its 3D printing lab to develop a design that can be scaled-up

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www.ultrapolymers.com | Your partner from design to production

Berry to invest in meltblown capacity serving face mask demand in the EMEIA Region Berry Global Group, Inc. has advanced its investment in an additional speciality meltblown asset to produce high-efficiency filtration media serving the EMEIA markets.

Commercial production is projected to start in the June quarter of 2020.

The company says this investment is targeted to meet increased demand and customer growth, focusing on premium applications, such as FFP2 (N95) and FFP3 (N99) for industrial face mask and cabin air filtration markets.

The new line will be equipped with Berry’s proprietary charging technology to deliver optimal filtration efficiency and pressure drop at lower basis weights. Berry has a unique offering, providing products across technologies and markets. In this instance, the Company is using its resources to provide the highest level of supply across Europe and more.

Cedric Ballay EVP & GM for Europe in Health, Hygiene, and Specialities for Berry, said: “As a market leader in that space, we had been planning to add more capacity shortly after our latest investment in Asia came online.

The opportunity to support the fight against Covid-19 accelerated our decision. Our ability to be agile will benefit our customers and our communities.”

Protolabs supplies critical parts for testing and ventilator masks against Covid-19 Protolabs is supporting the frontline battle against Covid-19 with critical parts for testing and ventilator masks by using its 3D printing, CNC machining and injection moulding expertise.

Protolabs, which employs over 450 people at its European headquarters in Telford, has played a key role in supporting Italian engineers in the conversion of ‘Easybreath’ snorkelling equipment into ventilator masks.

3D printed ‘Charlotte’ valves are being rapidly produced and shipped direct to its customer, Isinnova, who is producing kits that can be used to create a noninvasive ventilator mask that will help save lives.

The company is also urgently working with a highly multiplexed molecular diagnostics specialist, AusDiagnostics, to produce a series of plastic cassettes that will help house a critical medical solution used in testing for Covid-19.

AusDiagnostics approached Protolabs to see if it could injection mould 500 sample parts. The first CAD drawings were not fit for manufacture so were quickly updated and the right material specified, with production now underway and parts expected to have started shipping as of April 9.

“We’re currently working on a number of customer projects that are critical to the fight against the Covid-19 pandemic,” explained

Engel UK offers free service engineer visits to medical customers Engel UK has launched an initiative that extends free-ofcharge service support to its customers moulding medical equipment for the NHS. In a gesture to help support those companies working to provide key plastics items needed to fight Covid-19, Engel is offering visits from its service engineers at no cost.

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The initiative is subject to availability in the event that demand is high and will be in place until the end of April 2020.

Nigel Baker, Managing Director of Engel UK, commented: “Everyone appreciates the

The finished Charlotte valve Bjoern Klaas, Vice President and Managing Director of Protolabs Europe.

“The ‘Charlotte’ valve in Italy is already having a really positive impact on the challenge faced by medical staff and the wider society, whilst our latest involvement with AusDiagnostics is crucial in the national ramp up of testing for the virus.”

He continued: “The tests will be used by over 20 large NHS trust hospitals in the UK, as well as medical diagnostics centres across Europe. The customer makes almost 200 kits a day, but this figure will increase rapidly to meet the demand for more testing, with our injection moulding line ready to manufacture 20,000 cassettes every quarter.

“Digital manufacturing provides incredible speed of development and continues to be essential in equipping frontline staff with the solutions they need.”

sacrifices being made by the emergency services, doctors, nurses and key workers during this pandemic.

“Engel has a significant share of the medical moulding market and we are delighted to be able to offer support to our UK and Eire customers who are manufacturing medical parts for the NHS supply chain.

“These customers will receive free service engineer visits for the month of April 2020.”

To access the support, Engel customers should call the Service Department directly on 01926 334000.

www.britishPLASTICS.co.uk

www.ultrapolymers.com | Your partner from design to production

INEOS begins production of one million hand sanitisers per month after plant completion INEOS has hit its ten-day target to build its hand sanitiser plant near Middlesbrough and has begun producing one million hand sanitisers per month to help the fight against Coronavirus.

INEOS is focusing on meeting the needs of front line medical and care services, as well as making pocket-sized sanitisers for people’s personal use.

INEOS has begun producing one million hand sanitisers per month

ARRK’s UK sites support essential emergency Covid-19 work ARRK has responded to calls from industry, government, health professionals and the NHS and has started production parts from its technical centre in Gloucester.

The company’s team in Petersfield is also supporting the effort by releasing “essential industry” parts into the supply chain from existing stock to help in the fight against the pandemic.

“We are so proud to be able to contribute in some way to helping the country during

now that production of the ineos hand sanitiser has started, we are working on the fastest way to get them where they need to be.

The sanitiser is being produced to World Health Organisation specifications.

Sir Jim Ratcliffe, Founder and Chairman of INEOS, said: “Now that production of the INEOS hand sanitiser has started, we are working on the fastest way to get them to where they need to be. I am confident that within a few days our sanitiser will start to be seen in hospitals, surgeries, and people’s homes.

“INEOS is a company with enormous resources and manufacturing skills. If we can find other ways to help in the coronavirus battle, we are absolutely committed to playing our part.”

these unprecedented times,” said ARRK Europe’s Board of Directors.

“We are equally proud and honoured to have a team of people who did not hesitate in stepping forward to support the effort and return to work to produce essential components into the supply chain.

“Credit to them and all those other workers across the various industry and public sectors.”

In line with Government guidelines, ARRK’s staff, where feasible, are still working but remotely and all UK sites remain closed unless in support of essential emergency work required in the battle against Covid-19.

A selection of Nylacast components

Nylacast places all key industry projects on high priority Manufacturer of low weight, low friction engineered products, Nylacast, is dedicating additional machine capacity and greater priority to projects and components for industries at the front line of combatting the Coronavirus pandemic.

The Leicester-based firm announced the move to further support manufacturers of equipment and machinery being utilised to provide safety and stability during the outbreak.

It is calling on companies from the pharmaceutical, medical, food, packaging, and transport sectors in need of engineered polymers, CNC machining, or stock shape material to get in touch with an aim of facilitating swift production and delivery for key componentry required for new builds or refurbishments.

A Nylacast representative said: “The health and safety of our people and communities is our paramount priority. We are closely following UK Government and World Health Organisation recommendations through the additional precautions and safety measures we have on-site.

“Whilst we thrive to remain operational for as long as possible, we will be dedicating resource and capacity to servicing the increasing demands on these key industries right now.”

www.britishPLASTICS.co.uk

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COMMENT Aquapak offers pellet and process to UK manufacturers of infection control bags With mounting advice for medical, NHS support staff, teachers and other key workers to bag up and immediately wash their clothing as soon as thy return home, demand for infection control laundry bags – for both industrial and domestic use – has increased, with many distributors now being out of stock.

Aquapak Polymers Ltd has both a pellet and process which allows plastic bag manufacturers to switch production efficiently to manufacture a strong, hot watersoluble bag.

“We are responding to the immediate need for infection control bags in the NHS and we want to play our part in the fight against Covid-19,” explained CEO, Mark Lapping.

“Aquapak produces a hot watersoluble polymer in the form of a standard pellet, called Hydropol, that is made from PVOH. We already sell it to manufacturing partners outside the UK, where it can run on most standard blown film lines to make high quality, and strong standard laundry bags, aprons and for other infection control applications. The end users are in hospitals, care homes, hotels and households, where they are needed minimise exposure to contamination as they can be put directly into the washing machine, and dissolve safely and completely (without residue) in a hot wash. We have grades of Hydropol that dissolve fully at 50C, 60C or 70C.” Aquapak is offering support to manufacturers in the form of an assessment of a PE line to identify suitability for Hydropol extrusion, followed by priority supply of pellets, technical transfer support and documentation.

“We are ready to support plastic bag manufacturers, who are currently running PE lines in the UK, to switch production to bags made from hot water soluble Hydropol,” Lapping added.

To discuss this with one of Aquapak’s specialist teams, please contact them on +44 (0)121 516 5656.

The word from Hird

R ICHARD HIRD, CHAIRMAN OF THE POLYMER MACHINERY MANUFACTURERS AND DISTRIBUTORS ASSOCIATION (PMMDA), WRITES FOR BP&R ON THE IMPORTANCE OF THE PLASTICS INDUSTRY COLLABORATING IN SOLIDARITY AS IT EMBRACES A ‘NEW NORMAL’ AS A RESULT OF THE CORONAVIRUS PANDEMIC.

So, whilst we are in isolation, let’s use this time to be creative, in planning and developing our strategies to grow our industry, using collaboration and PARTNERSHIP.

I

t is my view that now, more than ever, we need to adjust the traditional ways of working together as we enter the ‘new normal’ that is developing as a result of the Coronavirus pandemic.

For example, through strong links within the PMMDA and the wider industry, we are in a position to support each other in an effort to keep our customers (most of whom we share) and the UK Plastics industry moving forward. We can do this by sharing resources, common spares parts etc, or just by a simple call to our friends within the industry.

We have already seen how such collaborations and partnerships have produced extraordinary results in producing ventilators and other medical devices, not just in the speed of development and production, but also in innovation.

All of these skills and working practices should be carried forward as the pandemic diminishes to ensure a strong UK supply chain across all sectors with a stronger, resourceful and skilled manufacturing base. In doing so, we should see an increase in reshoring to the UK of all stages of the manufacturing process, from development, toolmaking, component manufacture and fully assembled products, all of which can be exported to our European neighbours, who I am sure will be looking to source from ‘local’ suppliers.

With the wider public seeing the amount of plastic being used by our clinicians, we have a two-fold opportunity, the first and obvious one is the improvement of the ‘image’ of plastics and polymers. Added to this, the exposure to a technical and innovative industry to future potential plastics engineers who are being home schooled, with access to online content, such as the BPF’s ‘Polymer-Zone’ website.

So, whilst we are in isolation, let’s use this time to be creative, in planning and developing our strategies to grow our industry, using collaboration and partnership, to deliver a strong and innovative supply chain.

It is my hope that we will return to our usual social norms in time for Interplas and make it the best plastics event the UK industry has seen in years.

Take care or yourselves, your family and your colleagues. Stay Safe.

www.britishPLASTICS.co.uk

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INTERVIEW | TOM WALKER

FACING THE CHALLENGE:

How Kingsmoor Packaging is protecting the front line The sample visor Food packaging company, Kingsmoor Packaging, has turned its expertise towards producing personal protective equipment (PPE) for NHS staff fighting the coronavirus pandemic.

AS THE UK PLASTICS INDUSTRY STEPS UP TO THE CHALLENGE OF SUPPORTING THE FIGHT AGAINST COVID-19, BP&R’S TOM WALKER SPOKE TO JAMES HILL, MANAGING DIRECTOR OF KINGSMOOR PACKAGING, TO FIND OUT HOW IT IS UTILISING ITS EXPERTISE AND EQUIPMENT TO PRODUCE LIFESAVING PPE FOR NHS FRONTLINE WORKERS.

The Somerset-based company is making a single-use, full face visor for front line NHS staff, and expects to distribute the visor in large numbers within two weeks.

There has been a widely reported shortage of PPE for workers across the country, which has led to numerous companies throughout the plastics industry producing their own alternatives.

A DESIGN PROCESS SUITED TO PPE Kingsmoor specialises in thermoformed food packaging, and its existing design process was well suited to producing PPE on a wide scale, as Managing Director James Hill explained.

He said: “On the whole it wasn’t too much of a challenge to get the visor designed and produced, as we’re so used to doing quick projects for the food industry. We’ve got in-house design and in-house tooling, so in terms of turning a product around, it’s what we’re used to doing.

“Our initial processes started off with masks, and then we looked at substrates of that, as well as what’s being used in the NHS at the moment.

We’ve obviously seen in the media that there’s a shortage of PPE and a real need to get it to the front line.

“We’ve seen examples of visors and wondered why none have been thermoformed, and from that it started to take shape. We prototyped internally, looking at average head and face sizes, and we already had some information on this because some of our processes use visors and welding masks.

“We looked at a welding mask, and how we could thermoform something similar from a single piece of plastic.

“The design process kept evolving through the week. Usually with these sorts of products we’d work with a food manufacturer, and there’d be a timeframe of getting the product ready, whereas this has evolved very quickly.”

EASE OF USE ESSENTIAL Ease of use was a major feature of the design, and this is shown in some of its smaller details.

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“Someone came up with an idea that we should put sizing numbers on the strap at the back of the visor, so for example if someone knows that it fits their head when it’s at slot number five, they can just click it in before putting it on, and that saves times fiddling about with it,” Hill continued.

The visor is made from clear APET, is low gauge, and only weighs 35 grams, while also incorporating anti-fog to avoid steaming up.

He added: “Due to the visor being light, the feeling of it is minimal. We know that people will be wearing these for long periods of time, so they needed to be comfortable to wear.

“We made a point of making sure a face mask could fit underneath, and that it could also accommodate glasses. It’s a real testament to our engineering and technical teams, and what they’ve done in the high-pressure is amazing, and that applies across the board to the private sector at the moment.”

Kingsmoor is aiming to have 30,000 visors a day produced from the 10th April, which will eventually raise to 90,000 a day, and can be delivered to NHS Trusts throughout the UK. As they are single-use, the length they last will differ, but as Hill explains, this is no different to standard PPE. He said: “We’re slightly unsure on the lifetime of the visors. We thought that the benefits of them is that they’re made from a single piece of plastic and very lightweight, so they’re hugely costeffective.

“We looked at it from the point of view of existing PPE, for example latex gloves. They’re stored in a tissue style box, a pair gets taken when they’re needed, and then easily disposed of, and this also goes for something like medical aprons. We tried to mimic these types of PPE, so it can all get wrapped up and disposed of together when someone has been in contact with a patient.”

www.britishPLASTICS.co.uk

“We’re hoping with the design that it’s cost-effective enough so that it can be utilised as a disposable item, and therefore limit the risk of further contamination once it’s been disposed of.”

TO THE FRONT LINE AS QUICKLY AS POSSIBLE Due to the shortages of PPE, and the unprecedented nature of the crisis, the NHS is making an effort to get equipment to the front line as quickly as possible, and this means that standard procedures regarding testing and certification have been reduced in favour of making it available.

Hill said: “Now we’ve gone live with the visor, we’re trying to put out as many samples out to as many people as we can within the NHS. It hasn’t yet been through the normal channels of certification, so we’re working hard with various people at the moment to see if that can be fasttracked and approved to get it on the front line where it’s needed.

“From our perspective we think it’s a very good idea, we think it’s an angle that’s not been looked at yet, and primarily we just want to help the NHS. We hope with people crying out for PPE, that the NHS and other bodies will get this fast-tracked.”

It’s really rewarding being within the industry at the moment. Not only has everyone come together to help, it also shows there’s a place for plastics and there always has been.”

PLASTICS PROMINENT IN COVID-19 FIGHT Whether through the production of PPE or ventilators, the plastics industry has been hugely prominent in the fight against coronavirus, something that Hill sees as a potential redeeming moment for plastics.

He said: “It’s really rewarding being within the industry at the moment. Not only has everyone come together to help, it also shows there’s a place for plastics and there always has been.

“While we recognise the pressure of plastics over the last few years, the qualities of singleuse plastics are showing to be so important, especially in a scenario where you’ve got such an infectious disease, as plastic can be easily disposed of, is cheap and durable, and most importantly is extremely medically safe.”

Samples from Kingsmoor are now available for testing and trials at visor@

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AUTOMOTIVE | NEWS Audi uses recycled PET in seat upholstery Audi has begun using recycled PET in the upholstery of its A3 model.

A total of 45 PET bottles are used per seating system, with 62 bottles used in the carpet.

Other components in the interior are also made from secondary raw materials, including the insulating materials and absorbers, side panel trim and the loading floor.

At the moment, the seat upholstery is not yet made of completely recyclable material, but Audi plans to change this.

Ute Grönheim, from the Textiles Division at Audi, said: “The lower layer of woven material, which is connected to the upper material with adhesive, is what poses the challenge. We are working on replacing this with recyclable polyester.

“It is our goal to make the seat upholstery completely from unmixed material so that it can be recycled again. We are no longer very far away from this.”

Trinseo launches new ‘eco’ materials for the automotive industry Trinseo has launched a new portfolio of PC/ABS containing recycled content for automotive applications.

The new Pulse Eco series contains between 30 and 50 per cent recycled content, combining European-sourced post-industrial recycled polycarbonate with Trinseo’s virgin Magnum ABS. Developed using Trinseo’s unique Pulse GX technology, the new product family boasts strong technical features, such as superior flow properties, low temperature ductility, a low carbon footprint and low density.

The material’s low odour performance makes it highly suited to automotive interior applications such as mid and floor consoles, instrument panels and pillars.

Frank Schumann, Global Marketing Manager for Trinseo, said: “The launch of our new Pulse Eco series further extends our Eco portfolio of recycled contentbased polycarbonate and PC/ABS

materials.

“Our automotive customers are increasingly looking out for recycled materials that deliver the quality required to ensure consistent and high-performing interior applications. Not only will the Pulse Eco series meet sustainability objectives for our customers, but it will also deliver design advantages equal to allvirgin premium products.”

He added that features such as easy flow and high impact strength at low temperatures are now possible with an improved carbon footprint.

BASF and Hengst develop first reusable plastic spin-on oil filter module BASF and Hengst have developed the world’s first reusable plastic spin-on filter module for cars.

Blue.on is a sustainable alternative to conventional spin-on modules made from metal, since it does not need to be replaced during filter change. It is made from Ultramid Structure LFX, a long glass fibre-reinforced highperformance plastic from BASF. Blue.on offers a solution to a key problem in the automotive industry when it comes to oil filter change, as each year around two billion oil filters are replaced and disposed of.

Christian Janeba, Senior Key Account Manager in BASF’s

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Blue.on is a sustainable alternative to conventional spin-on modules made from metal (Credit: BASF SE)

www.britishPLASTICS.co.uk

Performance Materials division, said: “Hengst presented to us the idea of developing a resource-saving alternative to metal housings showing the same performance. We supported the development process constructively with material development and a comprehensive engineering package, focusing on sustainability at all times.”

Michael Böhm, Product Manager at Hengst, said: “The development took a lot of time, but the result is highly convincing. All partners were not only eager to find an innovative technical component, but also a sustainable solution for the automotive industry and car drivers. Innumerable tests and trials to which BASF contributed its comprehensive know-how in plastics finally led to a positive outcome.”

WWW.QUICK-MOULD-CHANGE.COM | QUICK MOULD CHANGE SOLUTIONS

Polyplastics highlights DURANEX PBT grade for highvoltage automotive applications The Polyplastics Group is now offering an improved PBT grade which provides improved tracking resistance for a range of highvoltage automotive components.

Duranex PBT CG7030 is a 30 per cent glass-filled grade which delivers strong dimensional stability and highly stable electrical resistance and dielectric breakdown properties.

As car makers move increasingly to electric vehicles, the demand for high-voltage components is expected to increase, and Polyplastics therefore conducted extensive testing of both PA 66 and PBT in temperature environments ranging from -40°C to 140°C for electric car applications such as batteries, power control units, and motors and generators.

Since the properties of PBT grades experience little change even in hot and moist environments, Polyplastics determined that they are more suitable than PA 66 for use in highvoltage applications.

These results suggest that using PBT could produce less variation in electrical properties when environments change.

Duranex PBT CG7030 exhibits highly superior dimensional stability, and Polyplastics has reported that both moisture absorption and dimensional change rate for PBT grades are around one-tenth of the values observed for PA 66.

Duranex PBT CG7030 is a 30 per cent glass-filled grade which delivers strong dimensional stability and highly stable electrical resistance

A part produced with Zotek T

Zotefoams OFFERS new TPE foam to automotive manufacturers Cellular materials specialist, Zotefoams, has extended its line-up of High-Performance Products (HPP) with a thermoplastic elastomer (TPE) that boasts a range of unrivalled benefits for the automotive industry.

Zotek T is the latest addition to the HPP range of foams manufactured from fluoropolymers, engineering polymers and speciality polymers. The TPE foam exhibits light weight, outstanding energy return, excellent high- and lowtemperature resistance, high impact strength at low temperatures, ease of thermoforming and superior protection against noise, vibration and harshness (NVH).

Zotefoams says that like its other foams, Zotek T is highly pure by nature, with a volatile organic compound (VOC) content minimal compared to that of foams produced by other manufacturers, thanks to its unique production method. The three-stage process uses only nitrogen gas as the foaming agent; the absence of chemical foaming agents removes the major potential source of VOCs in foams. Zotek T has a high resistance to many chemicals including greases, brake fluids and coolants and, due to its closed cell nature, does not absorb or transmit water or water vapour.

With physical and chemical properties that create the potential

to replace current foamed rubber, silicon or solid TPE solutions in the automotive sector, Zotefoams says Zotek T offers real cost and weight savings in applications such as interior flooring, air ducts and wire and cable insulation, previously unsuitable for foamed materials.

Zotefoams Group CEO, David Stirling, explained: “Thanks to our growing portfolio, we are now able to offer to the automotive industry the best and most extensive range of foams to help manufacturers meet their objectives and obligations at a time of considerable change in how the industry is perceived and its regulatory framework.

“Recent capacity investments, combined with ever-closer relationships with our customers, mean that we are better placed than ever to help automotive manufacturers look to the future and drive performance.”

www.britishPLASTICS.co.uk

We are now able to to offer the automotive industry the best and most extensive range of foams to help manufacturers meet their objectives and obligations”

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People. Think. Plastics.

More Sustainable ECOMID® – recycled PA compounds Your environmentally friendly alternative – recycled post-industrial PA compounds from Celanese made from high-quality polyamide fibres and textiles. We offer you high quality and batch consistency – service and customised logistics concepts included.

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FEATURE

Making an imPRESSion

TO MARK 55 YEARS IN BUSINESS, BIRMINGHAMBASED BARKLEY PLASTICS HAS INVESTED IN NEW INJECTION PRESSES AND AUTOMATION EQUIPMENT, FUELLED

BY MAJOR PROJECTS IN THE AUTOMOTIVE SECTOR. BP&R LOOKS AT WHY 2020 IS SET TO BE AN EXCITING YEAR FOR THE UK MANUFACTURER.

Barkley Plastics’ Mark Harwood and Pete Tedd

A £250,000 investment in new presses and robots is proving to be a perfect ‘big’ birthday present for a UK plastic injection moulding and toolmaking specialist.

Barkley Plastics, which employs 120 people at its Highgate facility in Birmingham, is celebrating 55 years of business by increasing its capacity to help take on new orders it has won in interior parts and lighting for the automotive sector.

The latest installation takes its total capital machinery spend to over £800,000 in the last five years and highlights the firm’s desire to move into more cosmetic and technical products that require industry-leading processing accuracy.

A COLOURFUL HISTORY It marks another step-change in what has been a colourful history for the manufacturer, which started life after founder, John Barkley, placed a job advert for four toolmakers in the Birmingham Evening Mail.

In the 55 years that followed, the company has evolved its offer to remain a strategic supplier to the automotive sector, whilst also building a strong reputation in the domestic products, construction, electrical and leisure sectors.

“Things have never been quiet over the last 55 years, but I suppose that’s UK manufacturing for you,” explained Mark Harwood, Managing Director at Barkley Plastics.

“We’ve already tried to stay one step ahead of what the customer wants, and this is reflected in the latest process that gives us additional capacity and production control to take on more automotive work. There will also be news of a ground-breaking development in injection moulding before the end of the year.”

Harwood continued: “The £250,000 investment is a perfect birthday present for us and will immediately be put to use on supporting a new project that will see us manufacture a selection of small, high

volume JLR parts that will go across its range of vehicles.

“There’s no getting away from the fact that the capital spend is vital, but our people continue to be crucial to our ongoing success. We’ve got more than ten people who have been with us for forty years and David Challinor, the son of one of the founding members, only retired from the toolroom at the end of the year having given us 48 years of service.”

TOOLMAKING EXPERTISE Barkley Plastics, which is IATF16949 accredited, has one of the largest toolmaking facilities in the UK, producing high precision tools capable of delivering 50 million mouldings for distribution throughout the UK, Europe and across the world.

It can support its client base with initial design and product development, right through to manufacture and assembly, with over 40 modern moulding presses – ranging from five to 650 tonne – able to produce the most intricate of components.

This is evident in the creation of a dedicated interior lighting assembly cell to mainly support a new project for the Nissan Juke, which has now gone into full production.

EXCITING OPPORTUNITIES Technical Director, Pete Tedd, who will take over as MD when Mark Harwood moves to the position of Chairman in April, said: “The increasing range of new electric and hybrid vehicles presents some exciting opportunities that suit our expertise, whilst work is being undertaken to increase our share of the construction, electronics, medical and retail sectors.

“We’re predominantly a sub-contractor, but over the last few years have been looking to develop our own range of products, such as the Plasfloor floor tiles and an anti-static ESD option.”

He added: “This is an exciting year for Barkley Plastics and I’m looking forward to moving into the MD role next month.

Succession planning is a priority for the business, and we have been working hard to develop our senior management team, which will culminate in a number of new Directors being appointed in October to support our ambitious growth plans.”

www.britishPLASTICS.co.uk

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

TEMPERATURE CONTROL | NEWS THROUGHOUT THE WORLD, TOOL-TEMP STANDS FOR QUALITY, SMART AND LEADINGEDGE TEMPERATURE CONTROL AND COOLING TECHNOLOGY DEVELOPED AND MADE IN SWITZERLAND. IN OTHER WORDS, WE HAVE GROWN INTO A BRAND. THAT’S WHY WE’VE DECIDED TO REPOSITION TOOL-TEMP.

Tool-Temp unveils new look to reflect company journey and ambition Manufacturer of water and oiltemperature control and cooling units, Tool-Temp, has unveiled a new brand for 2020 to coincide with its ambitious goals for the future.

The company says the new, refreshed look reflects the company’s transformation over its 45-year history and its transition from being a trusted name to a brand in its own right.

“Over the last decade, we have transformed ourselves into a leading supplier in the manufacturing industry,” explained Jeremy Radcliffe, Director at Tool-Temp’s UK division in Northamptonshire.

“Throughout the world, ToolTemp stands for quality, smart and leading-edge temperature control and cooling technology developed and made in Switzerland. In other words, we have expanded and grown into a brand. That’s why we decided to reposition Tool-Temp and

radically overhaul our image.”

The new brand and image will be a key part of Tool-Temp’s future strategy, which focuses on exceeding the demands and requirements of both the markets it serves, as well as its customers.

“The new Tool-Temp brand embodies our core values of expertise, quality awareness and an international outlook.

We have given the logo and entire typography a self-image that does justice to the stature of a global brand, with our 15 branches and 30 agents worldwide. Our colour scheme not only reflects hot and cold, but also its Swiss origin. With the new visual concept, we’re focusing on what keeps us on the road to success – our customers, our employees, our products and our expertise,” Radcliffe added.

The company offers a range of over 60 standard models and solutions suitable for processes across a variety of industries, including plastics manufacturing, metal die-casting, printing, laminating, chemicals and composites, as well as spare and maintenance parts.

Logos showing the transformation of the Tool-Temp brand

www.britishPLASTICS.co.uk

Frigel launches new temperature control unit with optimised cooling time Processing cooling specialist, Frigel, has launched a new mould temperature control unit specifically designed to enhance product quality whist minimising cycle cooling times.

The new Microgel is available in two different versions, the singlezone RSM and double zone RSD, with each consisting of a watercooled chiller combined with either one or two temperature controllers with high flow booster pumps and with or without an inverter, as well as heating elements and freecooling valve.

The units, which are ideal for applications in the automotive, packaging, medical and technical moulding sectors, are digitally synchronised with the moulding machine, enabling the researching and recording of the best settling of flow rate and temperature for each zone. This optimises product quality, whilst ensuring the minimum cycle cooling time.

Rob Pritchard, Sales Manager at Frigel’s UK distributor, Summit Process Cooling, said: “The new Microgel chillers bring specific advantages, not least a production increase up to 50 per cent thanks to cycle time reductions of up to 35 per cent. They also offer high energy savings, with some versions offering automatic free cooling, as well as intelligent inbuilt technology to ensure synchronisation of process and upto-date digital comsumption data across several parameters.”

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FEATURE

Airborne water droplets are a big issue, if you catch my drift

G ARY DICKER, DIRECTOR AT DHD COOLING, PRESENTS A CHECKLIST FOR ELIMINATING DANGEROUS DRIFT FROM COOLING TOWERS.

ABOUT THE AUTHOR Gary Dicker is a Director at DHD Cooling, a Worcester-based company providing design, installation and maintenance solutions for industrial cooling throughout Europe. He has a solid background in cooling tower design and installation and specialises in delivering bespoke solutions in cooling technology, with proven expertise in the design of cooling tower systems, hybrid coolers, adiabatic coolers and also advising on legislation, compliance and industry standards.

D

rift from a cooling tower can be a huge problem. Drift is the aerosol emission of process water from a cooling tower. These emissions are capable of travelling upwards of 1km, with a properly treated system the level of bacteria must be controlled within safe parameters but even in these systems the water droplets could be carrying Legionella Bacteria, so the potential for an outbreak is increased, if more drift is created. This is why it is critically important that as a plant operator you can spot the signs of excessive drift, and do something about it before it becomes a problem.

CAN YOU FEEL WATER DROPLETS WHEN YOU ARE NEAR YOUR COOLING TOWER? It is often the first sign that you have a potential problem. If you feel water droplets hitting you as you are in the vicinity of the cooling towers, then it is imperative that you do some further investigation.

DO YOU HAVE THE CORRECT FLOW RATE GOING OVER THE TOWER? If the flow rate is too far above the design, then the fill pack or distribution system can become flooded which in turn can cause increased drift rates. If the flow rate is too far below the design flow of the tower, then in certain types of system this can lead to poor distribution and higher air velocities, which can lead to increased drift.

A sure sign that there is excessive drift is if there is localised scale build or staining on the rear face of the drift eliminator. the cause of this is usually related to process water exiting the tower,â&#x20AC;? to meet your specific needs, and as such needs to be correctly selected for both performance and safety reasons. The wrong type, or incorrectly installed fill pack, can lead to large amounts of water being entrained within the airstream, resulting in the drift eliminator being overloaded and water droplets being ejected from the Cooling Tower.

ARE YOUR DRIFT ELIMINATORS DAMAGED? Drift Eliminators work by having an available surface for water droplets in the air stream to impact, and thereby be caught and prevented from exiting the Cooling Tower. If these surfaces are damaged or the panels are not tightly fitting, then the water will be able to pass straight through.

IS THERE STAINING ON THE DRIFT ELIMINATORS? A sure sign that there is excessive drift is if there is localised scale build or staining on the rear face of the drift eliminator.

The cause of this is usually related to process water exiting the tower, and if there is water visible on the rear of the drift eliminators, then you have a problem which needs immediate attention.

DO YOU HAVE THE RIGHT FILL PACK CORRECTLY INSTALLED? There are a number of types of fill packs available for cooling towers, as this is one of the main thermo-hydraulic features of your equipment, which is usually selected

Biological staining of Drift Eliminator

www.britishPLASTICS.co.uk

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www.ultrapolymers.com | Your partner from design to production

RECLAMATION AND RECYCLING | NEWS Mainetti launches global Polythene recycling initiative Retail solutions provider, Mainetti, has announced the launch of a world first global initiative that addresses the need for more packaging made from recycled plastic.

PolyLoop will provide a global closedloop recycling system for polythene film

Evian to introduce 100 per cent rPET bottles in the UK Danone has announced it will introduce 100 per cent rPET bottles for its Evian range in the UK and Ireland, alongside a pledge to also become carbon neutral across its Evian and Volvic brands in these territories.

The move will be introduced as of this month (April 2020) and will bring the use of recycled plastic content to 70 per cent across its Evian range in the UK. The company has also committed to using no virgin plastic across its Evian UK and Volvic UK bottles by 2025.

In addition, Danone Waters UKI reports that it is actively supporting the implementation of a Deposit Return Scheme to increase the UK recycling rate to a minimum of 90 per cent.

The company is also collaborating with expert partners

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PolyLoop is a closed-loop recycling system for clear polythene that will leverage Mainetti’s network of 14 manufacturing and recycling operations around the world.

The combination of Mainetti’s global network means that, for the first time, it can offer customers a genuine circular economy and the ability to source clear polythene film containing 30 per cent postconsumer recycled scrap material from any of its production sites in the world.

The process sees post-consumer scrap materials collected, cleaned and processed within the UK before being distributed to Mainetti’s manufacturing sites offshore.

This news comes on the heels of the UK Government’s decision to impose a plastics packaging tax, where manufacturers and importers will be charged £200 per tonne on packaging made of less than 30 per cent of recycled plastic by April 2022. Mainetti says PolyLoop”will

be instrumental” in supporting the Government’s aims of boosting the use of recycled plastics by 40 per cent.

Extensive development work and quality testing of PolyLoop has been completed over the past 18 months and the first industrialscale processing line will become operational in the UK in July 2020.

Keith Charlton, Chief Operations Officer at Mainetti said: “We recognise this move is needed to accelerate the changes we all need to make if we are to reduce carbon emissions in line with the commitments made in the Paris Accord. However, we are also aware of the challenge this brings our retail clients in an already tough market environment.”

He added: “To assist customers with accurate reporting, we are also able to provide customers with transparent and auditable process traceability through the RCS (Recycled Claim Standard) compliance scheme.”

such as Loop Industries, Hubbub, The Ocean Cleanup and Plastic Patrol, in the hopes of helping to create a circular economy.

These announcements have been made in light of the start of Danone’s €2billion (approximately £1.7billion) investment acceleration plan, a project taking place between 2020-2022 that seeks to further transform the company’s agriculture, energy and operations, packaging and digital capabilities.

James Pearson, Managing Director for Danone Waters UKI, said: “The challenges of plastic pollution and climate change that we face are more pressing than ever, therefore we need to accelerate the actions to reduce our footprint.”

Danone will introduce 100 per cent rPET bottles from this month.

www.britishPLASTICS.co.uk

www.ultrapolymers.com | Your partner from design to production

FEATURE

AS COMPANIES LOOK TO NEW SOLUTIONS IN THE MOVE TOWARDS MORE SUSTAINABLE USE OF PLASTICS, NICK CLIFFE, DEPUTY CHALLENGE DIRECTOR OF THE SMART SUSTAINABLE PLASTIC PACKAGING CHALLENGE, UK RESEARCH AND INNOVATION (UKRI), DISCUSSES THE FUTURE, AND WHY CREATIVITY AND OPTIMISM ARE KEY TO SUCCESS.

ABOUT THE AUTHOR: Nick Cliffe is Deputy Challenge Director of the Smart Sustainable Plastic Packaging Challenge, which aims to establish the UK as a leading innovator in smart and sustainable plastic packaging for consumer products, delivering cleaner growth across the supply chain, with a dramatic reduction in plastic waste entering the environment by 2025.

The Future of Plastic: it’s time for optimism

I

n the final scenes of the 1981 film, Time Bandits, the situation for the protagonists is looking bleak, Evil personified is preparing to unleash its ultimate power when, at the last moment, the Supreme Being arrives and in a flash of light Evil is reduced to a black, smouldering mass. This material is ‘concentrated evil’ and even to touch it results in instant death.

For many of us working in in the polymer industry today it can feel like that’s how the world currently views plastic. But I don’t believe that plastic is intrinsically evil, it is instead our relationship with plastic that leads to these narratives.

FUNDAMENTAL BUILDING BLOCK Plastic is a fundamental building block of our society, underpinning many of our systems, from food production, distribution and prevention of food waste to medicines and provision of healthcare. Plastics are integral to achieving the UK Government’s clean growth objectives and the global shift away from the high carbon emission, petrochemical system to the zero-emission future. It is therefore imperative that we change our relationship with these materials and develop a more circular approach to their use. However, plastic’s best qualities often work against it.

Plastics are lightweight, strong and efficient, a little material goes a long way and provides a lot of functionality. These qualities mean that an individual plastic item doesn’t add much to the weight of a recycling collection in systems where performance is measured by weight. Moreover, plastics are versatile and have diverse properties and performance.

But this diversity means that at the end of its life the plastic waste stream is more diverse than any other, making recycling and recovery challenging and expensive. Many plastics are cost effective but this means that the value of recovered plastics is often very low.

ADDRESSING THE CHALLENGES There are many approaches and areas for research and innovation to address these challenges that UKRI programmes are supporting, including plastics’ three Rs. Reduce is being addressed through innovation in light-weighting and design. Reuse is more challenging, but as an approach it does seem to be gaining acceptance in the market, from reusable shopping bags, water bottles and beverage cups at the level of the individual consumer to the increased reuse of bulk containers and refillable product delivery systems in the grocery supply chain.

The R with the most focus at the moment

plastic is a fundamental building block of our society,” is Recycle. Recycling plastic is a multi-step process and innovation is taking place at all steps. New sorting technologies using advanced photonics, such as redesigned near infrared-red cameras to identify plastic by type and colour, can facilitate high-speed and accurate sorting. Invisible markers are also being developed which can be applied to plastics to provide additional information, which sorting systems can detect but don’t impact on the appearance or performance of the product. This could be used to allow high-speed, high-accuracy sorting of plastic packaging, or to identify automotive plastic components which contain particular additives, such as fire retardants, from others which don’t. The more effective the sorting of plastics the higher quality, value and ‘use-ability’ of the recyclate. For example, new approaches to shredding using cryogenic techniques are reducing losses. This increases yields for recyclers and improves the economic viability of recycling.

The most significant development in recycling is the development and commercialisation of chemical recycling technologies and there are a number of systems developed and being trialled in the marketplace.

FUNDING IDEAS UKRI is actively funding research and innovation in plastics, in particular the Smart Sustainable Plastic Packaging Challenge, part of the Industrial Strategy Challenge Fund. This £60m investment in R&D will run until 2024 and will deliver a core programme to support networking and collaboration building. The fund will also co-invest with industry across a series of funding competitions, ranging from earlystage research to first-of-a-kind demonstrator projects.

For more information about our work in this area please visit https://www. ukri.org

www.britishPLASTICS.co.uk

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EXTRUSION | NEWS Magog offers fast turnaround screw and barrel repair as UK manufacturers ramp up production Hertfordshire-based engineering company, Magog Industries, is offering a fast-track turnround on screw and barrel refurbishment and repair to the plastics and rubber industry across the UK and Ireland.

The company says the move comes as a result of the uncertainty and rapidly changing situation brought about by the coronavirus, with many producers within the industry facing increased activity from food and medical sectors needing to keep machine downtime to an absolute minimum.

“In addition to specialist screw and barrel manufacturing facilities, we offer repair and refurbishment of pre-used parts, saving our customers money not just against OEM items but in turnround too, saving valuable downtime,” explained John Allsop, Director and General Manager.

“One of our key advantages is that we design everything to meet our customers’ specific processing and production requirements.”

Screw designs are configured to maximise performance from single start compression to a range of mixing elements for optimised distributive and dispersive mixing.

Magog is offering fast turnaround on screw and barrel refurb and repair

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In addition to specialist screw and barrel manufacturing facilities, we offer repair and refurbishment of pre-used parts, saving our customers money not just against OEM items but in turnround too, saving valuable downtime” The company also advises and offers design configuration for complex parallel and conical twin extruder screws.

Manufactured from high quality metals, including EN 41B Steel, provides hard wearing properties but also allows refurbishment of hard welded flights at a later date.

Depending on material type, surface treatments are on offer to include ceramic, chrome, Hastelloy, armoloy in addition to Nitride and bi-metallic hardened.

“We’ve been focussing on looking at measures, particularly surface treatment for abrasion and potential corrosion, to increase resilience and longevity specifically in ceramic and chrome seal coatings for demanding applications such as blown film extrusion,” Allsop explained.

“By working closely with our customers, we continue to innovate and develop our products to ensure we are always offering the most up to date solutions to meet the most demanding process applications.”

He continued: “For example, the recycling and re-processing market has grown in recent years for both new and refurbished screws and barrels for the company.

“Regrind material can bring its own challenges but are successfully met thanks to many years of expertise within our design, engineering and production teams.”

www.britishPLASTICS.co.uk

Film converter invests in infrared to overcome system inefficiencies Film converter, Mid South Extrusion (MSE) has invested in new technology to improve production efficiency after a period of growth saw the firm looking to expand.

The company supplies polythene film for a number of markets, including packaging, lamination, construction, and pipe wrapping applications.

Following a recent expansion of its production facilities, MSE wanted to target new markets and customers in the food packaging sector.

MSE’s use of electric tubular heaters was proving inefficient to its existing system and processes and so, in searching for solutions, it was recommended the technology and efficiency of infrared heat as a way to increase productivity and improve operations.

As a result of the recommedation, MSE purchased a bespoke order from Ireland-based Ceramicx, a prodiver of custombuilt infrared (IR) industrial heating ovens, heating systems, and solutions.

Ceramicx recommended MSE’s machinery should be fitted with arrays of industry standard ceramic, square hollow elements (SFEH).

With a flat body, these particular elements have a much shorter heat up time, increased energy efficiency, and have the ability to produce a diffused, radiant outputto-target distance.

Following installation of a full and complete IR system, Mid South Extrusion says it is benefitting from improved productivity and efficiency across its machines.

Mike Hengan of Mid South Extrusion commented: “The new IR system provided by Ceramicx was delivered in a timely manner within budget.

“The pre-heating process improvements to our embossing equipment have increased production and reduced scrap within the extrusion process.”

Novamont launches new grade of Mater-Bi for extrusion coating

Screw solves chronic problem of rejects on pipe extrusion line

Novamont has launched the newest grade in its family of Mater-Bi biodegradable and compostable bioplastics.

The new grade has been designed specifically for extrusion coating and extrusion lamination on paper, board and other substrates which can be composted in standard industrial plants.

Developed through work which has combined various Novamont production technologies and, in comparison with previous versions, the new grade offers an improvement in process stability, coating thicknesses and processing speed comparable with LDPE, and excellent adhesion to different substrates including paper, board and plastic films.

Objects manufactured using the new grade – such as cups, dishes for catering and thin board for food use – are GMO-free, biodegradable, can be composted in accordance with standard UNI EN 13432 and can be recycled along with wastepaper.

With excellent toughness and resistance to perforation, such objects are also suitable for contact with food and microwave use and offer excellent resistance to oils and fats.

With the new Mater-Bi grade for extrusion coating, Novamont says it is in a position to satisfy the rise in demand for disposable products that can be composted together with paper and board, therefore solving the problems associated with the limited availability of some raw materials.

A newly installed Xaloy screw designed by Nordson Corporation has put an end to a long series of troubles on a pipe extrusion line that had defied numerous attempts at a solution.

The line, operated by US-based pipe manufacturer, Polyethylene Technology, would exhibit wide fluctuations in throughput caused by surging and, for heavy-wall HDPE pipe, consistently exhibited variation from the target wall thickness of 2.46 mm.

“We tried all sorts of solutions,” said Brad Williams, Senior Manufacturing Manager. “We looked for problems with the motor drive and the puller, tested four or five alternate resins, and finally got a new screw and relined barrel—all with no success. Our gravimetric extrusion control showed fluctuations occurring every five or ten seconds.”

An additional trouble with the extrusion line was poor mixing of carbon black, whose required addition level was two per cent.

“We couldn’t get a good mix, and there were always areas of the pipe with too little carbon black,” Williams added.

Polyethylene Technology turned to Nordson within months of receiving the screw from another supplier. “We recommended our Xaloy Efficient barrier screw with a Nano mixer in the metering section,” explained Brad Casale, Nordson Regional Sales Manager.

“By preventing premature break-up of solids and increasing

Coperion’s multilayer film recycling concept helps avoid production waste

reprocessed and fed back into the production process.

For a customer installation, Coperion will deliver a recycling system, including bulk material handling, high-accuracy feeding from Coperion K-Tron, and a ZSK Mc18 twin screw extruder.

Peter van Hoffmann, General Manager of Business Unit Engineering Plastics and Special Applications at Coperion, explained more about the project: “Sustainability is becoming more and more important, and the topic of the circular economy is moving further into the foreground for

Coperion has developed a closedloop concept for the production of flexible multi-layer film.

Recycling multi-layer film has long posed a challenge, since such films can only be reclaimed in very complicated ways and not without residues.

However, Coperion has now developed a closed-loop approach in which up to 100 per cent of multilayer film production waste can be

Xaloy Nano Mixer from Nordson melting rates, the Efficient screw has enhanced mixing and increased throughput in the Polyethylene Technology extrusion line. The Nano mixer has provided intensive dispersionary mixing of the carbon black.”

Besides solving the surging problem and delivering a homogeneous melt, the new Xaloy screw increased the output of the extrusion line. “As a result of using the new Xaloy screw, our target output rate has increased by 12 per cent,” concluded Williams.

AS A RESULT OF USING THE NEW XALOY SCREW, OUR TARGET OUTPUT RATE HAS INCREASED”

companies, and that is much more so for multi-layer film producers,” he said.

“We’re proud that, with our years of process know-how and our visionary technological solutions, we can contribute to a promising, forward-looking and sustainable closed-loop approach.”

www.britishPLASTICS.co.uk

Coperion closed-loop multi-layerproduction ZSK Extruder

27

I adapt precisely.

Locating ring, adapter Z 7500 /. . .

Enables centering, through an integrated spring tensioning system, flexible, tool-free adjustment of injection moulds on injection moulding machines with larger machine openings.

– 8 mm guide in the injection mould – Large lead-in chamfer to the injection moulding machine – Rapid production change possible – No machining work necessary for adjustment

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Anz_Z7500_190x124_EN.indd 1

07.04.20 13:32

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22-May-19 2:01:01 PM

www.kraussmaffei.com

| celebrating 180 years

MACHINERY | NEWS ENGEL releases nextgeneration e-cap machine ENGEL has released the latest generation of its all-electric e-cap injection moulding machine series for beverage caps.

The new e-cap 380 is said to meet the increasingly performanceefficient requirements of cap producers, combined with shorter cycle times, highest precision and lowest energy consumption.

When developing the new generation of machines, ENGEL says its main focus was both on performance and on stability.

Scottish moulder saves 60 per cent energy with Intelect2 machines Midlothian-based McLaren Plastics says recent tests performed on two new injection moulding machines installed in 2019 show the firm is making savings of over 60 percent on its energy bill, saving in excess of £7,000 a year.

The firm purchased the two all-electric IntElect2 machines to replace two older hydraulic Demag moulding machines midway through last year. In order to secure an interest-free loan with Resource Scotland for the purchase, McLaren needed credible evidence that the investment would result in reduced energy consumption and a more sustainable carbon footprint.

Installed in 1995, its exisiting Demag hydraulic machines had been operating 24/7 for nearly two decades. The initial measurement performed by Sumitomo (SHI) Demag’s revealed that each legacy machine was consuming 7.2 kilowatts for each kilogram of raw material converted per hour.

At the time of placing the IntElect2 order, Sumitomo (SHI) Demag estimated that McLaren could save on average over 5kw per hour replacing both hydraulic machines with all-electric ones. This was enough to satisfy Resource Scotland, who approved McLaren’s

The new e-cap achieves even faster mould opening and closing movements that previous editions and is designed with an even more stable machine bed for more frequent load cycles.

To demonstrate the capabilities of its new machine, ENGEL used an e-cap 2440/380 to produce 29/25 caps in a 96-cavity mould.

The shot weight was 1.3 grams per cavity with a cycle time of less than two seconds processing a HDPE from Borealis/Borouge.

The resulting part, says ENGEL, thanks to technology including a reinforced frame and mould mounting platens, a more powerful

plasticising unit and all-electric drive technology is “outstanding reproduction” of surface detail and a maximum number of good parts.

The new e-cap is available in the sizes 220, 280, 380 and 420 with clamping forces from 2,200 to 4,200 kN.

loan grant.

In order to provide a like-for-like comparison, Sumitomo (SHI) Demag revisited the moulder in early December 2019. Both machines by this stage had been fitted with the same ancillary equipment, replicating the mould vent and cavity balance configuration and exact processing conditions.

The first measurement comprised a square packaging black end cap, using a single cavity mould, with a shot weight of 8.2 grams and 11.5-second cycle. Previously consuming 4.52kw p/h at an average cost of £0.56 p/h, the results for the new IntElect2 dropped to 1.93kw p/h, saving 58

per cent and the company £0.32 p/h, or over £2,700 annually for a machine operating 24/7.

The second test measured the production of a white automotive bracket for a premium passenger car. With a shot weight of 29.9 grams and a 31.5 second cycle time, the component comprises two different parts moulded in a 1+1 cavity tool. A 62 per cent energy saving was documented on the IntElect2 test, reducing from 7.33kw p/h to 2.81kw p/h.

Calculating the physical costs and how this could impact the bottom line for a moulding business, this reduction in energy usage equates to a saving of approximately £4,360 per year, according to Sumitomo (SHI) Demag.

In addition to scrutinising energy performance, the tests also examined other factors including the parallel movements and the impact of drive cycle times on output and other indirect costs.

McLaren’s Plant Manager, David Graham, said: “With the majority of our tools, the injection, hold and cooling time are pretty much the same.

“However, as a result of the parallel mould movement, we estimate that we have shaved between one and two second off each cycle. For a high volume and technical moulder like McLaren, this equates to higher profits.”

The recently installed IntElect2 machines are providing energy savings for McLaren

www.britishPLASTICS.co.uk

29

www.ultrapolymers.com | Your partner from design to production

COMPOSITES | NEWS Covestro provides sustainable solution for new Toyota concept car Covestro has been chosen by Toyota to jointly develop a new polyurethane composite material for the new Toyota LQ concept car.

The material is based on a combination of Covestro’s advanced Baypreg F NF technology and Toyota’s expertise in using kenaf fibres, which is attracting attention as an alternative raw material within the automotive industry.

In the ‘LQ’, the new product is used in door trim panels.

The kenaf fibre-reinforced polyurethane foam composite is characterised by a very low area density of less the one kg/ m2 and high strength, making the door trim 30 per cent lighter than that produced from conventional materials.

Hiroaki Ido, Head of Polyurethanes Application Development for Transportation at Covestro’s Japanese Innovation Centre, said: “Our joint development makes an important contribution to the design of particularly lightweight and sustainable vehicles.

“It is also a good example of our company’s focus on using alternative raw materials and establishing a circular economy.”

In the ‘LQ’ the new product is used in door trim panels.

30

BÜFA to expand in the UK by acquiring AOC BÜFA Composite Systems has acquired AOC UK, a UK supplier of composite products.

The acquisition took place on March 3, 2020, and AOC will trade as BÜFA Composites UK. With the purchase, BÜFA says is not only expanding its presence in the UK market, but also consolidating its leading position as a speciality manufacturer for the composites market in Europe.

Felix Thalmann, CEO of BÜFA Group, said: “This will strengthen more than just our market activities. This is the coming together of two strong and complementary partners.”

Joe Salley, Global CEO for AOC, said: “We are glad to strengthen our trusting, successful cooperation with BÜFA, and at the same time create a stronger company in the UK. “This will serve our customers even better and create a bright future for our UK employees.”

Against the background of the acquisition, distribution in other European countries is being reorganised.

In future, BÜFA distribution companies will also offer the AOC Aliancys portfolio as well as all BÜFA specialities and selected merchandise in Spain, Belgium, the Netherlands and Finland, as well as Great Britain and Ireland.

Tepex helps reinforce child seat headrest Lanxess is to use its Tepex continuous fibre reinforced thermoplastic composite materials in the lightweight construction of structural safety components, including a child’s seat headrest.

The component is produced in a particle-foam composite injection moulding process, and is part of a transnational research project involving Germany and Poland.

Dr Klaus Vonberg, from the Tepex Automotive Group of the High Performance Materials business unit at Lanxess, said: “The insert made of Tepex can reduce the weight of the headrest by up to 30 per cent in comparison with the commercially produced component variant, and with comparably good crash performance too, as well as simplifying the production process.”

Norbert Schramm, Scientific Assistant at the Chemnitz

www.britishPLASTICS.co.uk

er light The weight rest head

University of Technology in Germany, said: “Not only is the new, highly integrated production more energy-efficient than the previous procedure, it also results directly in the finished component.

“This reduces the total number of parts from six to one, which also lowers production costs in terms of logistics and the machine expenditure required.

“ If a reinforcement based on carbon fibres is used in the composite semi-finished product and in the injection moulding material, the result is an assembly that is almost 30 per cent lighter.”

Composite materials help bring revolutionary exoskeleton to life The University of Central Lancashire’s Engineering Innovation Centre has developed an exoskeleton for children suffering from Spinal Muscular Atrophy, thanks to the use of composite materials.

The exoskeleton can allow children living with the condition to live a more conventional life, by supporting their skeletons and giving extra strength to their back muscles and spine.

The original design of the exoskeleton was too heavy due to it being constructed from metal, but the University completely redesigned the suit to incorporate composite materials.

It is has also been identified as a potential treatment of the victims of stroke and other related medical issues.

The suit was also produced using

3D printing, which allows much quicker construction.

The University is working towards taking the suit to clinical trials, but this could be held up due to fact that the testing standards of materials used in the suit are continuously changing.

To help reduce this time, Tinius Olsen Testing Machines is supplying testing equipment free over the next two years, a major investment by the company.

Richard Coombs, Director of Creativity at Tinius Olsen, said: “When we first heard about this amazing invention, we were keen to help in any way possible with its development, especially if it results in giving children suffering from SMA the opportunity to enjoy a better quality of life.

“The fact it also has the potential to aid stroke victims with their recovery is also extremely exciting.

Our 5ST UTM machine and its accessories are ideal for the testing of the composites being utilised within the design.”

Dr Matthew Dickinson, Senior Lecturer at UCLan’s School of Engineering, said: “This SMA exoskeleton is a perfect example of the way that engineering can have a direct impact on people’s lives.”

The exoskeleton

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IN THIS EDITION OF HIS REGULAR COLUMN, OUR RESIDENT MATERIALS EXPERT, MIKE BOSWELL, ASSESSES THE IMPACT THAT THE COVID19 PANDEMIC IS CURRENTLY HAVING ON THE GLOBAL PETROCHEMICALS INDUSTRY AND WHAT THE FUTURE MARKET SITUATION MAY HOLD.

Who is ‘Polymerman’?

Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’.

‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution.co.uk | www.pieweb.com

32

Could reduced demand for transport fuel impact the availability of feedstock for polymer production?

Many of us will, to some extent, be familiar with the crude oil refining process. In the first stage, crude oil is heated and distilled into various fractions according to the relative boiling points of the hydrocarbon molecules in the crude oil. Thereafter, some of these various outputs may be subject to additional processes in which that component of the crude oil is modified by chemical reaction.

Typical refinery product split

Of greatest interest to the polymer industry are Naphtha; Propylene as a by-product from the production of motor gasoline; and Benzene.

It is notable that crude oil refining is a coproduction process, within which there is limited opportunity to adjust the output of any given product. Perhaps of greatest note is the option to put Naphtha through a ‘Reformer’ to manufacture high octane gasoline. If the Naphtha is not ‘Reformed’ it can be used as a ‘Heavy Cracker’ feedstock producing important ingredients to the manufacture of polymers including C2 (Ethylene), C3 (Propylene), C4 (Butene), C6 (Hexene) and others.

THE IMPACT OF THE CORONAVIRUS CRISIS A typical split of a refinery products is depicted in the graph (above to the right), with Naphtha composing a significant proportion of the output labelled as ‘Other Products’.

At the start of the Coronavirus crisis there is a glut of refinery products and this –coupled with a massive reduction in crude oil prices – has resulted in significant price reductions for all refinery products, including feedstocks for polymer production. However, there is now the question of how future demand may shape petrochemical feedstock availability in a situation where demand for ‘fuel’, which compromises 85 per cent of refinery output, is severely depressed due to Government imposed and self-imposed travel restrictions.

This situation is exacerbated by the fact that most of the outputs of the crude oil refining process are more volatile liquids and gases for which storage capacity is very finite.

OPPORTUNITIES FOR FLEXIBILITY? The limited opportunities for flexibility in the crude oil refining process include ‘reforming’ less Naphtha and so making more available for petrochemical production.

Another option is to use more natural gas as a feedstock, although this option highly favours C2 (Ethylene) production and would mainly be used in the manufacture of PE and PVC, which would potentially leave other feedstocks in short supply for the manufacture of other key polymers, including PP. It is for the reasons of feedstock availability concerns and the fact that polymers are relatively easy to store that the reaction to lower demand for plastics and/or lower feedstock pricing that polymer prices are not likely to be so reactive to the present, and rather unusual, market circumstances. And for many suppliers of polymer the current circumstances are not entirely dissimilar to those that prevailed at the end of 2014 when there appeared to be a glut of polymer only within a matter of weeks to face some of the worst shortages within living memory.

The future market situation looks uncertain and physical availability of material may become a dominant factor in determining availability as the global petrochemicals industry deals with the consequences of the Covid-19 pandemic.

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PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com www.visionbms.com/plastics Affordable and flexible MES system for the plastics/rubber industry.

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intouch T: 01604 537100 E: enquiries@ intouchmonitoring.com www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses.

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• 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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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.

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35

BP&R BUYER’S GUIDE MACHINERY & EQUIPMENT DRYERS

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www.britishPLASTICS.co.uk

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NEWS FROM THE FRONTLINE

IN IN THE LATEST INSTALMENT OF HIS EXCLUSIVE COLUMN FOR BP&R, DIRECTORGENERAL OF THE BPF, PHILIP LAW, OUTLINES THE DIFFICULTIES THE INDUSTRY FACES AS A RESULT OF THE CORONAVIRUS PANDEMIC, BUT ALSO HIGHLIGHTS THE FINE CONTRIBUTION TO THE NATIONAL EFFORT BEING MADE BY PLASTICS COMPANIES ACROSS THE BOARD.

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ecent events have been surreal. They have occurred dramatically and so quickly. In the space of three weeks, the BPF estimates that about 20 per cent of plastics manufacturing plants have closed, with more to come. Many employees in the industry have been put on furlough and absenteeism is high because of self-isolation, suspected coronavirus or school closures.

Some bright lights

This is a long catalogue of woe but there are some bright lights. We are seeing companies with spare capacity stepping forward to help the national effort. INEOS turning its manufacturing operations to produce hand sanitiser is one example. BPF member, Rutland Plastics, is another, having been recognised

by Rutland MP, Alicia Kearns, for producing medical equipment which will be used in the Nightingale Ward Hospital at the Excel. Polystar Plastics has committed £5 for every tonne of its new PCWflex material sold in 2020 to be donated to the NHS. Ultimate Packaging has been recognised on BBC News for providing packaging to keep food fresh on the shelves during the crisis. Likewise, Cromwell Polyethylene is providing Personal Protective Equipment such as gloves and aprons. Numatic – of Henry Hoover fame – has developed a face shield currently in use with Worcestershire NHS Trust, West Midlands Ambulance Service, Birmingham Children’s Hospital and The Gibraltar Health Authority. These are just a few examples. More can be seen on the industry news pages of this issue of BP&R.

in particular bottles for hand sanitisers and face masks. We have produced a list of BPF member suppliers of products helpful in the fight against Coronavirus and have distributed this to key Governmental contacts, including the Cabinet Office, the Department for BEIS and the Scottish Government. Typical was a request from researchers at the London School of Tropical Medicine who wanted to be put in touch with BPF members who could help them develop an innovative face mask concept to production stage.

daily briefings

There are a great many more companies providing the packaging that is enabling food to be placed on the table, the manufacturing of essential products for healthcare, the distribution and drainage of fresh water supplies and the distribution of energy. Parts made for vehicles and aircraft are keeping essential products moving along their supply chains. All sectors of the UK plastics industry are making a fine contribution to the national effort.

Over the last two weeks BPF has been providing members with daily briefings on Coronavirus impact, in particular on the evolving package of financial assistance available from the Government. I wrote to the BEIS Secretary of State, Alok Sharma, making a case for key sectors of the plastics industry to be regarded as essential industries. Every day for two weeks we have had a telephone conference with senior civil servants at BEIS, raising member issues with them and seeking clarification - in particular on the Job Retention Scheme. A major subject is cashflow in small and medium sized businesses pressed on both sides by large suppliers and customers.

Additionally, with lower throughputs energy consumption is down but companies are tied into contracts where the tariff is determined by usage at earlier, higher levels.

There is now a growing realisation as to why plastics are used so extensively. We have been deluged by requests from Government asking for help in sourcing key products,

In spite of immense difficulties, the UK plastics industry continues to provide a vital service to UK society. Never has the phrase ‘plastics save lives’ had a truer ring.

A fine contribution

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In spite of immense difficulties, the UK plastics industry continues to provide a vital service to UK society. Never has the phrase ‘plastics save lives’ had a truer ring.

www.britishPLASTICS.co.uk

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