BP&R April/May 2015 by BP&R Magazine

British Plastics

and Rubber

bp&r APRIL/MAY 2015

CONTROLLING TEMPERATURE AND COST:

REGLOPLAS TECHNOLOGY FOR SIGNIFICANT ENERGY SAVINGS GLOBAL ADDITIVES MARKET SET FOR GROWTH INCREASE

EXTRUSION MACHINERY FOR POWERFUL PROCESSING

BUILDING IN PLASTICS: MATERIALS FOR CONSTRUCTION

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Email: sales@hiclassmachinery.co.uk Unit 7 Brindley Close Rushden Business Park Rushden Northants NN10 6EN

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

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

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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 rates: UK: £80 Europe and rest of the world: £115 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 (01244) 671074 © 2015 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.

Sitting on the economic seesaw is an uncomfortable ride

fter the overall feeling of visiting the NPE show, we reflect buoyancy in the plastics on the trends that are affecting industry at the end of and influencing the American 2014 following increased sales, plastics market. This includes how investments and growth, the spate EU companies can both influence of organisations that have come and capitilise upon the success out in force over the last few weeks currently being seen in North to express their concerns over America thanks to low energy costs, the fallout from the recent ‘Force re-shoring and reindustrialisation. Majeures’, as well as a worrying That is not to say, however, that international political despite this period situation and the of industry growth, effect prices are the US is immune to having on recyclers, some of the issues have only served most affect the After the rallying that to highlight the EU market. You can volatile nature of cries for a united read the roundup on the influencing page 14. front and for the factors that affect the industry and its industry to work Enjoy the issue. fortunes. So, after Leanne Taylor, the rallying cries for together through Editor a united front and for the difficult and the industry to work together through the difficult and uncertain uncertain current current period, it will period, it will be be a case of riding the storm, or the seesaw, a case of riding until things start to the storm, or look more stable once again. the seesaw,

until things Despite the wider economical situation, start to look there is still good news to be found more stable on the home front, once again. as UK plastics manufacturers – contract moulders in particular – are enjoying full order books as a result of ongoing investments in the automotive and packaging sectors. You can read more about these in our industry news over the following pages. We also look to the USA once again this issue, where, after having not long returned from Orlando, Florida,

bp&r

THE BIG STORY Controlling temperature and cost: REGLOPLAS TECHNOLOGY FOR SIGNIFICANT ENERGY SAVINGS

n addition to the features generally expected of temperature control equipment, such as modern process management WITH TEMPERATURE and ease of operation, energy CONTROL EQUIPMENT consumption is NOW INSTALLED ON coming more ALMOST EVERY INJECTION and more to the MOULDING MACHINE, forefront, says REGLOPLAS AG SAYS Swiss-based ITS INNOVATIVE ENERGY manufacturer of temperature SAVING TECHNOLOGY CAN control PROVIDE MANUFACTURERS equipment, WITH “SIGNIFICANTLY Regloplas AG.

Diagram showing potential savings using the unit

OPTIMISED” ENERGY CONSUMPTION. THE COMPANY SPOKE TO BP&R ABOUT ITS EQUIPMENT IN MORE DETAIL.

The company, based in the Swiss city of St. Gallen, has reached a huge milestone with a landmark solution, which it says reduces customers’ energy consumption “tremendously”. Regloplas is the first manufacturer to offer temperature control devices equipped with a frequency converter. “A change in frequency results in a modified pump speed based on individual requirements,” explained Karl Miller, Managing Director of Motan Colortronic Limited, which supplies Regloplas equipment in the UK. “If, for example, the pump speed is reduced because less flow or pressure is needed in order to maintain the correct temperature, the pump uses less electricity. If a pump speed is reduced by 20 percent, then 50 percent less energy is consumed. At half the pump speed, only 12.5 percent of the energy is required.”

Miller explained that with temperature control equipment now a feature of almost every injection moulding machine, both the demands on the components and the process management required for its manufacture in injection moulding processes are quite challenging. “Temperature management for tools and their moulding components is of the utmost importance for zero-defect production,” he added. The temperature difference between the time of entry and exit of the temperature control medium is dependent on the delivery rate, and, therefore, also dependent on pressure and the flow rate generated. Previously, the delivery rate of temperature control equipment was defined solely by the choice of pump. The test phase for the frequency converter was successfully completed last year at the company’s Technical Centre. As of now, Regloplas says it can offer its customers the frequency converter as an integrated option throughout the equipment range. Options are controlled by means of the RT 100 control unit, which it says is both intuitive and simple to operate. The option can be configured on all temperature control devices and retrofitting is said to be possible for equipment that the customer is already using. Regloplas says the integration of

the regulated frequency converter is an absolute innovation in the market for temperature control equipment, and is already attracting great interest. A well-known Formula 1 racing team has reportedly already ordered a device whose application will fulfill its specific quality requirements for precise pressure regulation of the temperature control medium. “With the frequency converter, Regloplas is introducing a genuine customer solution to the market that ensures significantly optimised energy consumption for both new capital investments and for equipment “A WELL-KNOWN F1 already in RACING TEAM HAS operation,” continued Miller. ALREADY ORDERED “In the UK and A DEVICE WHOSE Ireland we have APPLICATION WILL received extensive FULFILL ITS SPECIFIC enquiries for the frequency QUALITY REQUIREMENTS converters. In FOR PRECISE order to ensure PRESSURE REGULATION we can meet OF THE TEMPERATURE demand we’ve made a significant CONTROL MEDIUM.” investment in our UK stockholding to ensure we can supply a vast range of standard units within days of an order.” WWW.MOTAN-COLORTRONIC.CO.UK WWW.REGLOPLAS.COM

WWW.BRITISHPLASTICS.CO.UK

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contents

PLASTICS &RUBBER

APRIL/MAY 2015

on the cover Controlling temperature and cost With temperature control equipment now installed on almost every injection moulding machine, Regloplas AG says its innovative energy saving technology can provide manufacturers with “significantly optimised” energy consumption. SEE PAGE 4

27 REGULARS INDUSTRY NEWS FEATURE EXTRUSION MACHINERY New cooling system for PE tubes launched

31 FEATURE

Reclamation and Recycling 39

MATERIALS

SOFTWARE

BUYERS’ GUIDE

NEWS FROM THE FRONTLINE

ADDITIVES

EDITOR’S LETTER

Sitting on the economic seesaw is an uncomfortable ride

14 FEATURE NPE REVIEW

Supersize me: BP&R reports on some of the trends and themes from the show

17 FEATURE

TEMPERATURE CONTROL TECHNOLOGY

Precise temperature control process allows improved finish and control for injection moulders

Plastic additives market predicted to be worth $45.5 billion by 2019

35 FEATURE HOT RUNNERS

MHS demonstrates latest solutions as it aims to be “global leader” in valve gate technology

43 FEATURE

TALKING TECHNICAL

In the second instalment of our new series of articles looking at improving productivity in injection moulding, we look at Quick Mould Clamping Systems

21 ]FEATURE

CONSTRUCTION AND INFRASTRUCTURE Plastics for use in building and construction to reach $57.51 billion by 2019 6

WWW.BRITISHPLASTICS.CO.UK

Associations unite in concerns over Force Majeure declarations and call for urgent EU investment Words | LEANNE TAYLOR

everal trade bodies representing different areas of the themselves in Asia where on the face of it a more favourable plastics industry have come out in force to express polymer supply situation persists.” Dangis warned that the their concerns over the number of Force Majeure shortages would spell increases in polymer prices which “will declarations that have been announced since the beginning need to be passed down” the customer chain. of 2015. “For plastics packaging manufacturers, as an example, the The associations, which include the British Plastics raw material component of the selling price of a pack accounts Federation (BPF), the Packaging and Films for as much as 60 percent. If increases on Association (PAFA), the Brussels-based this cannot be passed on; this places the very “For plastics European Plastics Converters Association viability of the manufacturing companies at packaging (EuPC) and the European Compounders and serious risk.” Masterbatchers Association (EuMBC), are PAFA echoed these sentiments, with CEO, manufacturers, Barry united in the opinion that the resulting price Turner, calling on the industry to work as an example, inflations and short supply of raw materials together through the “extremely difficult” could have damaging consequences to the period, to establish to “find a way to the raw material current whole supply chain and the recovery of the avoid these sudden shocks to the market component of the and the enormous damage they inflict.” He plastics industry as a whole. There have been 11 Force Majeure cases remarked that many members, who have selling price of in Europe since the turn of the year, all decades of experience in the industry, have declared because of ‘technical reasons’. A a pack accounts been “left utterly dismayed by the scale Force Majeure is defined as an extraordinary of increases and the accompanying tight for as much as event or circumstance beyond control of the supply”. supplier or ‘act of God’ such as a war, strike, PAFA is one of four plastics packaging 60 percent. If riot, crime, hurricane, flood or earthquake etc. organisations from across Europe that in increases on this the recent days has made a united call for Only under these circumstances the supplier would be relieved from fulfilling its contractual cannot be passed investment in European polymer production obligations towards its customer. facilities and the “urgent restoration” of The European Compounders and on; this places the normal material supply levels. Masterbatchers Association (EuMBC) says it The statement from Elipso (France), IK very viability of has not seen “convincing evidence” to justify (Germany), BPF and PAFA (UK) highlights the manufacturing their concern with the ageing plant used the recent declarations of Force Majeure. The BPF’s Director-General, Philip Law, for production in Europe, which is prone to companies at speaking on behalf of the BPF’s large breakdown and the technical maintenance serious risk” processor community, said that he was issues frequently cited as the cause of the Force Majeure declarations. “Only new receiving an increasing volume of messages — Dangis investment will correct this situation,” it read. indicating that processors are being damaged The organisations said that “Europe is a global leader and through not being able to secure the polymer they need. Law urged their customers to be patient and expressed his powerhouse of innovation” not only in plastics packaging concerns for the wider industry. “The prevalence of ‘just in technology, but also in waste management organisation time’ delivery systems means rapid disruption to a supply and techniques such as recycling and the incorporation of recyclate into plastics packaging products. The development chain if a plastics processor cannot deliver,” Law said. EuMBC added that it is “very concerned” that the low of this expertise in Europe, they say, can support the stronger availability and shortages of material, combined with evolution of plastics packaging markets and the acceptance significant price increases, will affect the whole plastics of plastics packaging around the world. “For this, we need the polymer producers to invest in chain, including consumers, and subsequently will “endanger employment in Europe.” The association reports it has started the production of their raw materials here in Europe,” the further investigation into the matter in order to “appropriately statement continued. respond” to the situation. The four organisations also paid tribute to plastics packaging EuPC says it is concerned about the possible damaging converters who they say have been “skilfully managing” the effects for the downstream plastics industry. “This is situation of interrupted supply and higher prices in recent particularly damaging at a time when many EU states are months. “This has been a high wire balancing act amid trying to claw their way back to recovery and in particular when conditions not witnessed for many years,” it concluded. the EU plastics industry is in such a great position to be in the vanguard of growth with its potential to deliver customers and WWW.BPF.CO.UK broader society carbon savings and resource efficiencies,” WWW.PAFA.ORG.UK said Alexandre Dangis, EuPC’s Managing Director. WWW.PLASTICSCONVERTERS.EU “I am afraid”, he added, “that the force majeure could well WWW.COMPOUNDERS.EU lead to processing companies departing the EU to re-establish WWW.KUNSTSTOFFVERPACKUNGEN.DE WWW.BRITISHPLASTICS.CO.UK

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INDUSTRY | NEWS

PROMOTING PLASTICS TO PUPILS: TEACHERS INVITED TO UNDERTAKE POLYMER STUDY Universities across the UK are once again opening their doors to secondary school teachers to help them garner knowledge of the plastics industry that they can take back to the classroom. The ‘Polymer Study Tours’, which have been running for 28 years and has seen some 2,900 teachers attend, are a vital link between industry and academia in passing on information and insight that could attract and encourage students to choose a career in plastics. Bookings are now being taken for the 2015 tours at Manchester, Edinburgh Napier and London Metropolitan Universities, which will see delegates complete a four-day

PFF PACKAGING CONTINUES EXPANSION WITH ACQUISITION OF IPS Keighley-based plastic food packaging manufacturer, PFF Packaging Group Ltd, is continuing its planned expansion with the acquisition of Intelligent Packaging Solutions Limited (IPS). Following PFF’s acquisition of Thermopak in December 2014, the Group says it has “further enhanced its overall capabilities and product

residential course combining site visits, case studies and laboratory demonstrations. The courses are free to attend for teachers and costs are covered by sponsorship or donations. If you, or your company, could help sponsor the Tours, please contact Liveryman Ed Weeks, Chairman of the organising committee, for more information (ed.weeks@ntlworld.com mobile 07831344823). For those wishing to encourage their local school(s) to participate, the 2015 dates are as follows: • Edinburgh Napier University, 21st - 25th June • London Metropolitan University, 28th June -1st July • University of Manchester, 5th - 8th July Further information is also available on the website: WWW.POLYMER-TEACHING-RESOURCES.COM

offering” through the acquisition of IPS, which manufactures thermoformed and injection moulded packaging products and has capabilities in off- and in-mould labelling and dry offset printing. “This latest acquisition not only further increases our capacity for the production of thermoformed products, but adds injection moulding and product finishing to our portfolio, allowing PFF to deliver a complete turnkey solution

WWW.BRITISHPLASTICS.CO.UK

to our customers’ food packaging requirements,” commented PFF’s Group Managing Director, Andy Bairstow. The integration of IPS within the PFF Group increases its total available production area to 250,000 sq/ft and brings PFF’s extrusion production capacity to over 22,000 tonnes per year. The Group says it is now capable of producing 60 million units per month. WWW.PFF.UK.COM

INDUSTRY | NEWS

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STUDENT PLASTICS DESIGN AWARD FINALISTS SHOW BOTH TALENT AND POTENTIAL Image 3

he results of the preliminary judging session of the 2015 ‘Design Innovation in Plastics’ Award have revealed an impressive range of products, with seven selected to go through to the final.

2. Slide Safety Barrier - a low level addition to the standard highway crash barrier that prevents motorcyclists who have been thrown off their bikes from hitting dangerous metal posts. Designed by Sam Billington, University of Huddersfield. Image2

The competition saw 118 submissions from universities throughout the UK, with students challenged to transpose a product traditionally made in metal into plastics, exploiting the benefits of polymers in a fresh and innovative way.

3. Soft Ice S Pump - a redesign of the steel R Pump currently fitted to existing Carpigiani soft ice cream machines, designed by Alexander Bordino, Nottingham Trent University. Image 3

“I am impressed by the wide range of products inspired by the brief,” said Richard Brown, Managing Director at G&A Moulding Technology and Chairman of the judging panel.

Image 7

Following the first judging stage, the finalists are offered feedback from the judges to help them refine their designs for the final judging session, something unique to this award. Sylvia Katz, Co-Ordinator of the Award, said the students are now hard at work applying this professional advice to their entries, which they will present personally to the judging panel on 22 May 2015 at the British Plastics Federation.

Image 4

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5. Polymer TV Antenna - an antenna with innovative installation features and a housing made of Image 5 ECP (Electrically Conducting Polymer). Designed by Robert Miller, University of Northumbria.

Image 5

A second unique benefit of the Award is that not only the winner, but also every finalist, is awarded a work placement with the industry and design sponsors of the competition. “Most students consider this prize to be of more value than cash in their pockets,” said Katz. Below, BP&R highlights the designs that have made it through to the final judging session: 1. Wham Polymer Hammer - a shock absorbing, non-conductive and non sparking hammer constructed from interlocking sections of polymers with different impact absorption properties. Designed by Martyn Billings, Coventry University. Image 1

4. Wash Away Cataract Kit - tools to help surgeons in Third World countries treat a greater number of patients needing cataract surgery. The tool heads are moulded in water soluble PVoH allowing them to be ‘washed away’, making sterilisation unnecessary. Designed by Megan Cattley, University of Northumbria. Image 4

6. Easykeys - extension keys that will make wind instruments such as the concert flute and saxophone easier to use and more child friendly. Designed by Roisin Keyes, Dublin Institute of Technology.

Image 6

7. Oxyturtle Scuba Tank - a redesign of the standard metal diving tank moulded in glass reinforced polypropylene. Designed by Panayiotis Vrizas, London South Bank University. Image 7 The Design Innovation in Plastics Award is organised by the Institute of Materials, Minerals and Mining (IOM3) and the Worshipful Company of Horners, an ancient City Livery Company that has forged strong links with the plastics industry. WWW.DESIGNINNOVATIONPLASTICS.ORG

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Comment: AFFILIATES, APPRENTICESHIPS AND

AVOIDING THE ‘CLARKSON’ ISSUE IN THIS MONTH’S COLUMN, NIGEL FLOWERS, CHAIRMAN OF THE POLYMER MACHINERY MANUFACTURERS AND DISTRIBUTORS ASSOCIATION (PMMDA) INTRODUCES A NEW AFFILIATE MEMBERSHIP SCHEME AND ‘STEERS’ CLEAR OF ALL THINGS TOP GEAR… SHADE SHIELDS FROM BOTH THE SUN AND NOSY NEIGHBOURS

this year, has been Brazilian owned for eight years. The company offers two ranges of injection moulding machine. Ultrapolymers was established in 2002 and is part of the Belgian-based Ravago Group with offices, warehouses and compounding facilities across Europe and also north and south Africa. “We hope this agreement with Ultrapolymers will be a long term and mutually beneficial partnership,” says Neil Bathard, Romi’s UK National Sales Manager. “Sales across the UK and Ireland have been strong over the past 12 months and we remain confident demand will continue to grow.” WWW.ROMIUK.COM WWW.ULTRAPOLYMERS.COM

For more information about the PMMDA, visit: WWW.PMMDA.ORG.UK

Wigan-based design company, Origami Plastics, has launched the iShade, a solution designed for Apple iPads or MacBook laptops, which it says is the “must have” travel accessory to shield the screen effectively from both glare from the sun or prying eyes when commuting. The iShade is made from black, heat-resistant, high-grade polypropylene designed and hand-constructed in the UK from 100 percent recyclable materials, making it ideal for sunny outdoor conditions, commuter journeys or busy environments, says the company. WWW.THEISHADE.CO.UK

ROMI MACHINES APPOINTS ULTRAPOLYMERS AS ITS IRISH AGENT Romi Machines UK has appointed materials distributor, Ultrapolymers, as its exclusive agency for Ireland, including both the Republic and Northern Ireland. The contract will reportedly see Ultrapolymers use its links with the moulding companies of Ireland to create opportunities to sell Romi’s 70 to 1,500 tonne clamping capacity plastic injection moulding machines. “We are an innovative company and, having been involved with joint projects with Romi in the UK, we saw this as a great opportunity to take our relationship to a new level. It will make good use of our technical know-how and expertise,” said Jeff Hobbins, Managing Director of Ultrapolymers Ireland. Romi Machines UK, which celebrates its 85th anniversary

ou will be pleased to know that I intend to stay clear of the two most controversial issues currently in the news, the election and Jeremy Clarkson. Instead, I would like to take this opportunity to bring you up to date with recent developments at the PMMDA. As many of you will be aware, the association has been going through a period of positive change and to continue that theme, the membership of the association has been ‘opened up’ to include affiliate members. What is an affiliate member? Well, this new category of membership is designed to attract companies who are actively supporting our industry but are not equipment suppliers. For example, equipment installers and freight companies, as well as oil and ancillary service providers, are just a couple of examples. Affiliate members will enjoy many of the benefits that full membership brings, but, most importantly, affiliation provides the opportunity to network and shape our industry. If anyone would like further information, please contact either Nikki or myself at: pmmda@pmmda.org.uk There is a ‘little bit of politics’ that I would like to touch on, namely the recent figures from the ONS that reveal — despite manufacturing enjoying the highest level of investment in over 10 years — there has been a steady decline in weekly earnings over the same period, and that the fall was larger for low-skilled (minus 14 percent) occupations compared to highly skilled (minus 10 percent), which proved more resilient. Therefore, it is very pleasing to see, going into the election, that many of the parties are showing positive support for training and apprenticeships, both of which are in short supply in our industry. For a successful and vibrant future for our industry, we need to see sustained and focused investment in training and apprenticeships. Apprenticeships make sense because they deliver added value – companies must be prepared to invest in people on this basis and not simply use training and apprentices as a source of government handouts.

WWW.BRITISHPLASTICS.CO.UK

NPE REVIEW:

SUPERSIZE ME Words | Leanne Taylor

association, VDMA, where the routes to achieving o hard or go home. That epitomises the level of goals of standardisation and collaboration were effort invested by exhibitors at the most recent discussed at length. “Blue Competence is the way iteration of NPE, which took place from 23-27 we approach sustainability in Europe,” explained March in Orlando, Florida. From serenading saxophonists Thorsten Kühmann, Managing Director of the performing atop machinery, a giant robot parading the VDMA. “We are spreading from floors and a pre-show ‘Hakka’ from one Germany, through to NPE here in the exhibitor, there were certainly no holds United States and onto Chinaplas. barred when it came to trying to catch WE ARE SPREADING We do believe if we talk about a visitor’s eye. Gimmicks aside, some sustainability issues then this serious money had been invested in NPE, FROM GERMANY, with Milacron taking the biggest stand in THROUGH TO NPE can be convincing for others.” The two associations said they want the show’s history. There was significant HERE IN THE UNITED to ensure the greatest possible investment from some of the industry’s STATES AND ONTO alignment of technical requirements, most recognisable names, highlighting the CHINAPLAS. WE especially in matters of safety, in level of importance being seen in the US order to simplify machinery deliveries. market warrants. DO BELIEVE IF Kühmann said he thought that And the official post-show figures show WE TALK ABOUT the way SPI had highlighted issues they were right to invest, confirming NPE SUSTAINABILITY surrounding sustainability at NPE 2015 was the biggest in the show’s history ISSUES THEN THIS were “very interesting.” to date, with an increase in size, exhibitors CAN BE CONVINCING and visitors. Registered visitor attendance Innovation FOR OTHERS.– stood at 65,810, some 19 percent higher NPE’s innovation showcase came in than three years earlier, with 26 percent — KÜHMANN the form of a ‘start-up garage’, which of registrants coming from outside the US. contained a mini-hub of some of the “What made NPE 2015 a milestone in the most inventive polymer 69-year history of NPE was not only its size technologies seemingly and international diversity, but just inches from their also the richness of its offerings ‘EUREKA’ moment. The to attendees,” said William R. companies exhibiting Carteaux, SPI President and in the start-up garage CEO. “The hundreds of machines demonstrated promising operating on the show floor, the developments in graphenes, customer service centers provided bioplastics, 3D printing and by material suppliers, the pavilions recycling amongst others, with and programmes on current all the participants I spoke to issues and emerging technologies, in universal agreement that the extensive agenda of co-located standing alongside some of the conferences—this wealth of industry’s biggest companies, content surpassed our previous with a host of potential investors shows and now provides a streaming through the door, was guideline for making future “an incredible opportunity.” NPEs even more attractive to participants.”

Industry 4.0

Sustainability

A cornerstone of the show’s theme was sustainability, with a dedicated sector of the exhibition floor serving as a ‘Zero Waste Zone’ focusing on the industry mandate to reduce, reuse, and recycle plastics. Gene Sanders, SPI’s Senior Vice President of trade shows and conferences, said that the exhibit “reflected the organisation’s commitment to pursuing zero waste.” The SPI reinforced this commitment during a conference held alongside EU-based plastics and rubber machinery

There was an evident nod from several exhibitors to ‘Industry 4.0’, the idea that fully autonomous manufacturing is the future. Helmut Heinson, Managing Director of Sales for Arburg, said that the company was working to develop its provision of IT solutions to enable it to embrace the concept. “Industry 4.0,” he said, is the story behind the company’s future development, as ARBURG becomes a “system supplier for networked production in the digital factory of tomorrow.” Wittmann Battenfeld echoed this, with the company coining the

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Top left: A flag waving robotic display was Wittmann Battenfeld’s latest quirky method of displaying its technology Bottom left: SABIC displayed the “world’s first” 3D printed car at the show and confirmed its commitment to developing the technology

NPE 2015 was held at the Orange County Convention Centre, Orlando

Top left: Eastman displayed a 3D printer alongside its materials innovations for the 3D printing industry Middle left: KraussMaffei Group brought a specially painted machine in the colour of the German flag to show its build heritage Bottom left: Automotive was a key theme throughout the show in Dow’s ‘innovation zone’

moniker ‘Wittmann 4.0’ to describe its approach to the concept. “Industry 4.0 is a buzzword at the moment and as a business we are really embracing it,” explained Michael Wittmann, General Manager. “For us it is all-embracing and uniform technology that covers connectivity through plugin, software updates, condensing of data and hardware accessibility.”

Automated Systems

Following on from above, automation in the form of both systems and robotics were also put in the spotlight. ENGEL said that the US market can look to Europe and its “pioneering” approach to process integration and automation as a key growth driver for the country. Speaking at the show, Peter Neumann, ENGEL CEO, said that this would be key for its own sales agenda in INDUSTRY 4.0 IS the country, as US customers focused A BUZZWORD AT less on standardised machines and more THE MOMENT AND on complex, integrated systems. “Europe AS A BUSINESS is pioneering when it comes to complex WE ARE REALLY process integration and highly functional technologies,” Neumann said. “This is EMBRACING IT. — an area where we see increasing growth — WITTMANN in the USA as the markets here require highly automated processes with stable production and quality.” The key markets identified by the company as having major growth potential in the USA are automotive, medical and packaging. “Where we see a big growth is the automotive sector, especially in the composites sector for lightweighting,” said Mark Sankovitch of ENGEL’s US subsidiary. “In 2012 we made a commitment to this with our specialised centre in composites at the company’s headquarters in Austria and we see a real place for this technology here as

car manufacturers are increasingly interested in lightweighting solutions.” Also focusing on the potential offered by the US automotive sector, robotics manufacturer, Sepro, launched a new portfolio of large robots and automation technologies with clamping forces between 700 and 5000 tonnes. “These robots have been designed with the automotive sector in mind” explained Jean-Michel Renaudeau, Managing Director of Sepro. “We want to grow our market share in large robots, but moulders also want the flexibility that these new lines offer.”

3D Printing and AM

In materials as well as machinery, 3D printing and additive manufacturing played a recurring tune. SABIC announced its commitment to developing innovations in additive manufacturing, even showcasing the “world’s first” 3D printed car on its stand (pictured) and citing the critical link between materials, design, processing and part performance as the reason for the move. PolyOne followed suit, announcing that it was “actively exploring” the technology to help its customers optimise both the manufacturing process and the performance and aesthetics of a part. Chemical company, Eastman, also highlighted its foray into the area, showcasing its new carbon fibre polymer for 3D printing. Not to be outdone, Arburg chose NPE to mark the sales launch of its Freeformer additive manufacturing technology, something it says has “great potential” in the country. Davis-Standard and Conair also demonstrated the extrusion of printed filament for use in 3D printing. “3D printing is taking off right now,” said Chris Weinrich, Conair General Manager, Downstream Extrusion, “and demand for the plastic rod or filament that feeds the printers has never been greater.” The next NPE will take place once again at the Orange County Convention Centre, Orlando, Monday through Friday, May 7-11, 2018. WWW.NPE.ORG

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www.quick-mould-change.com

TEMPERATURE CONTROL | NEWS NEW RANGE BOASTS ECONOMICAL PRECISION TEMPERATURE CONTROL A new range of water and oil temperature control units can achieve economical and precise results, according to a UK process cooling specialist. Buckinghamshire-based AB

Systems is distributing the new NTC units from Italian cooling OEM, Nova Frigo, to the UK market and says the low-noise range is designed to fulfill accurate heating and temperature control of injection moulds and extrusion barrels/cylinders. To deliver accurate temperature control to plastic/rubber injection mould tools and dies – and thus ensure high levels of plant

productivity and system efficiency – the NTC range is said to be intelligently designed to allow the set temperature to quickly and accurately return to the set point value, minimising temperature fluctuation. This, says AB Systems, is largely thanks to PID logic, which allows continual auto-tuning adjustment and accurate regulation of process temperature. This

High performance packaging solutions El-Exis SP 420 for cap production

controlled action adjusts the power supply automatically and adapts it according to the external load conditions, resulting in “considerable” energy savings. To further reduce energy consumption, the units feature a wide exchange surface of the modulating valves and exchangers, which when combined, allow the temperature to reach the set point value extremely quickly and accurately. In addition to microprocessor temperature control, the NTC units feature digital temperature display, automatic water filling, and allow direct and indirect cooling. Each unit also comes with a range of over temperature alarm and external thermocouple options. Water versions of the NTC, available in models from 3-24kW, offer direct cooling up to a maximum of 90°C, and indirect cooling allowing continuous operation between 90-160°C. The units can be used in conjunction with a chiller to achieve a closed cooling circuit with zero water consumption, offering maximum energy efficiency and productivity. Oil models of the NTC are available with capacities from 3-36kW, and offer indirect cooling between 150-250°C. In total, the range comprises 28 water or oil models with capacities ranging from 3 to 36kW. Leak stopper models are also available. WWW.AB-LTD.CO.UK

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ISOCOOL LAUNCHES NEW CHILLER TO UK MARKET Cooling systems specialist, IsoCool, has launched a new chiller to the UK market that it says can improve product quality and production rates for plastic manufacturers. The ‘ICEtemp’ precision watercooled chiller, manufactured by cooling OEM, Eurochiller, is a beside-the-machine unit that IsoCool says includes a range of technologically advanced features, including three temperature zones, a wide temperature range, integrated free cooling and automatic mould emptying. The ICEtemp multi-circuit chiller is said to allow for simultaneous heating and cooling of the mould thanks to three control zones that automatically adjust temperature, flow rates and pressure according to the heating or cooling demands of the process. Temperature flexibility, says IsoCool, is increased with the

AEC INTRODUCES TRIDENT CHILLER FOR PROCESS COOLING AEC, manufacturer of auxiliary equipment for the plastics industry, has launched a new addition to its series of chiller products that it says is both reliable and intuitive. The new Trident GS Series central chiller uses effective component design and advanced technology to create a product that AEC says is easy to use, innovative and capable. Individual circuits range from 50 to 120 tonnes of chilling capacity and users have the ability to parallel up to five circuits for a maximum of 600 tonnes. Each individual Trident circuit offers dual screw compressor technology and an advanced operator control panel. TS Tech, the integrated toolless strainer technology, is said to allow for rapid maintenance whilst maximising the uptime of each chiller circuit. AEC says that Trident is one of the easiest-to-maintain central chilling systems, owing to its large strainer surface and easy access, combined with integrated Schrader valves for simple service connection and refrigerant recharging.

Schematic of the ICEtemp and cooling water supply

ICEtemps’ temperature range of 5O°C to + 90O°C, while temperature accuracy is achieved – to within a tenth of a degree – thanks to the chillers’ advanced three-way proportional valve. In addition, the ICEtemp is said to boast integrated free cooling when used in conjunction with a free cooling water supply. Depending on the cooling needs of the process and ambient conditions, users can

benefit from “exceptional energy and cost savings”, says IsoCool’s Director, Nigel Hallet, giving the product an “excellent” return on investment. The ICEtemp is available in standard models from 5.6kW to 80.8kW and can also be manufactured according to specific customer requirements.

The Trident is designed to make it simple to parallel multiple circuits. After the refrigerant and water lines have been installed, the addition of a drone circuit is achieved with a simple plug and play connection. As each circuit contains all of the necessary components and programming to take over as the master unit at any time, the time for integration and setup is greatly reduced, says AEC. Pump tanks are also easily integrated in the system. A full suite of electronic sensors with digital readout include leaving and entering fluid temperatures, compressor suction pressure, compressor discharge pressure, condenser inlet temperature, superheat, sub-cool, pump pressure and tank level. Monitoring the conditions of the chiller provides ‘adaptive control’, where the operator can reportedly adjust the operation of certain components when the chiller approaches an alarm condition in an effort to keep the chiller running with minimal to no downtime. All GS Series chillers, available in remote air- and packaged water-

cooled models, offer a leaving coolant temperature range of -1°C to 18.3°C. The AEC range is available through Renmar in the UK.

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FRIGOSYSTEM INTRODUCES LATEST RANGE OF ADIABATIC COOLERS Italian manufacturer of industrial chillers, Frigosystem, has launched a new range of air/water exchangers for process cooling that use the adiabatic principle for a reduction in both water and energy consumption. The new ACE (Adiabatic Cooling Energy) system is an adiabatic dry cooler that uses ambient air for process water cooling. By using powerful fans, controlled by an electronic system, ambient air is drawn initially through a PVC evaporator screen, before being moistened by a patented showering water distribution system that has both anti-scale and auto-clean functions. The flow of air passing through the water-soaked cavities of the evaporator is cooled and so releases heat to the water, which in turn evaporates. This process, says Frigosystem, allows ACE to achieve a higher efficiency when compared to traditional dry coolers, whilst maintaining the requirements of a closed system by eliminating process water consumption and contamination. For industrial processes that require cooling water at temperatures between +5°C and +35°C without using the refrigeration process, Frigosystem says the adiabatic dry cooler range is “the most effective, safe and technologically advanced solution.” The design of the ACE system has been tailored to be highly eco-sustainable, essential in the achievement of energy savings and environmental protection. ACE works in a closed circuit, without any evaporation of the process water. The fluid inside the cooler battery is always clean and free of external contaminants, meaning that other than the correct glycol solution for anti-frost protection, water treatments are not required.

The new ACE system is available in the UK from Intellicare

WWW.FRIGOSYSTEM.IT

The Tempro plus D units as installed recently at Utz UK

WITTMANN TEMPERATURE CONTROLLERS ARE A ‘PLUS’ FOR UTZ Utz UK, part of the global George Utz Group, which manufactures plastic containers, has recently taken delivery of Wittmann Battenfeld temperature controllers as part of a multi-million pound expansion.

The Tempro plus D controllers installed at the Swiss-owned company’s site in Somercotes, Derbyshire, have been purchased alongside four large raw materials silos, and £3 million in robotic injection moulding technology as part of an investment that it hopes will see it double turnover by 2020 and take on 40 additional staff in the next five years. “The Wittmann temperature controllers are efficient and reliable and our latest models – the Tempro plus D – are a valued and integrated part of our manufacturing process,” commented Utz UK Managing Director, Carsten Diekmann. The new Tempro controllers feature direct cooling, as well as a more compact design and enhanced heating and cooling capacities. In

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a pressurised operation, a gauge ensures that the internal pressure is always a minimum of one bar over the steam pressure curve. Because of the smaller heat exchanger there is less circulating water and, as a result, the preheating time and cool down period is reduced. “Demand for Wittmann temperature controllers in the UK continues to rise,” Wittmann Battenfeld Area Sales Manager, Daniel Williams, told BP&R. “We are happy to see many customers buying our temperature controllers in bulk, often through a need to cut energy bills.” WWW.WITTMANN-GROUP.COM

Tel: 01952 671918

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TECHNOLOGY SPOTLIGHT: NEW PRECISE TEMPERATURE CONTROL PROCESS ALLOWS IMPROVED FINISH AND CONTROL FOR INJECTION MOULDERS

UK-based company that develops processing technologies for advanced materials says it has made a breakthrough in adapting its products for use with injection moulding. Surface Generation, based in Rutland, Leicestershire, says its ‘Production to Functional Specifications’ (PtFS) process, which uses a range of active thermal management technologies to control temperatures to exact requirements of each mould area and process stage, could “considerably improve” the quality and efficiency of injection moulding manufacturing. The process has already been widely adopted by aerospace and automotive manufacturers to assure quality and maximise the throughput of compression moulding processes. Following four years of research and development, Surface Generation says it is now possible to use PtFS to heat and cool injection moulds in real-time. This allows manufacturers to precisely control how long materials remain molten in the mould and dynamically control material flow to fill thinner complex moulds accurately using up to 75 percent less pressure. Trials with major consumer electronics and automotive manufacturers, says the company, have confirmed PtFS “significantly improves” the ability to create thin fibre-reinforced plastic components. In some cases, weight and raw material consumption has been cut by half and the need to paint parts eliminated due to a higher quality finish.

By reducing the pressure required to form components, PtFS also makes it possible to use smaller and more energy efficient injection moulding equipment. Combined with multi-zone heating and cooling, this allows a large range of electronics and dissimilar materials to be encapsulated within the moulding, as they are no longer damaged during the forming process. “With heating and cooling integrated into the mould, PtFS provides manufacturers with unprecedented control and flexibility for injection moulding,” explained Ben Halford, Chief Executive at Surface Generation. “Rather than having to inject at high pressure and speed to ensure a mould is filled before solidification, users can instead introduce molten material slowly, guiding flow through complex sections, and then avoid shrinkage issues through precise localised cooling. “Armed with a more precise process, manufacturers using PtFS for injection moulding have reduced the amount of raw material they require to form components dramatically and achieved a better surface finish in the bargain. This technical breakthrough means that next generation consumer electronics, automotive, lighting, sporting, medical, household and packaging products can be significantly lighter and easier to produce, without compromising strength or quality.”

ARMED WITH A MORE PRECISE PROCESS, MANUFACTURERS USING PTFS FOR INJECTION MOULDING HAVE REDUCED THE AMOUNT OF RAW MATERIAL THEY REQUIRE TO FORM COMPONENTS DRAMATICALLY AND ACHIEVED A BETTER SURFACE FINISH IN THE BARGAIN.

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The PtFS process has already been widely adopted by aerospace and automotive manufacturers

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CONSTRUCTION AND INFRASTRUCTURE | NEWS Plastics market for use in building and construction

to reach $57.51 billion by 2019

he findings, compiled by market research firm, Transparency Market Research, suggest the growth, which has THE MARKET FOR increased from its 2012 PLASTICS USED valuation of US$35.92 FOR BUILDING AND billion, will come from CONSTRUCTION the “rapid expansion of the construction PRODUCTS IS industry worldwide.” FORECAST TO Of the materials REACH $57.51 studied, PVC holds a BILLION (APPROX. dominant 35 percent £39 BILLION GBP) of the market share, AT A CAGR OF 7.1 with the category of composite materials PERCENT BY 2019, trailing behind. Acrylics ACCORDING TO A are expected to be the NEW REPORT. fastest growing category among all types of building and construction plastics, while the other three categories, namely polyurethanes, polystyrene

and thermoplastic elastomers, are not set to experience any drastic change. In terms of end-use applications, pipes and ducts hold the major market share, at 30 percent, and are expected to stay well ahead of the other applications of building and construction plastics. This is due to the poor thermal and electrical conductivity of plastics, which makes them the perfect building material for pipes as well as insulation. The regional market of North America is the global leader in the market for building and construction plastics, with a 30 percent market share in 2012. The highly affluent and developed lifestyle common in the United States and Canada means that the continent has the highest demand for construction material due to the high amount

of residential construction. The booming construction industries in China, India, and Southeast Asia are expected to boost the share of Asia Pacific in the market. The European OF THE MATERIALS market, however, is STUDIED, expected to experience a PVC HOLDS A fall. DOMINANT 35 The report also PERCENT OF highlights the opportunities THE MARKET for bioplastics in the construction and building SHARE, WITH products market, as THE CATEGORY growing environmental OF COMPOSITE awareness increases MATERIALS interest in the use of these TRAILING BEHIND materials. WWW.TRANSPARENCYMARKETRESEARCH.COM

There is growth potential for plastics in the building and construction markets, finds the report

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The world’s largest suspension bridge benefits from Saint-Gobain’s Rulon and Fluoroloy products

PFTE MATERIALS PROVIDE EARTHQUAKE PROTECTION IN JAPAN Polytetrafluoroethylene (PFTE) materials from Saint Gobain Seals have been utilised in several large buildings and key structures in Japan as seismic base isolation systems to offer high-level protection from earthquakes. The company’s Rulon and Fluoroloy PTFE materials are installed as part of the isolation systems, installed between the ground and upper structure, which have proven to be extremely effective in earthquakeprone regions globally. By their response to an earthquake impact, all isolation units can be divided into two basic categories:

“PLASTICS TO BECOME CONSTRUCTION BUILDING MATERIALS OF CHOICE IN EUROPE” At an innovation workshop held recently focusing on the opportunities in R&D projects for building products and solutions in Europe, plastics were hailed as “the material of choice.” Speaking at the event, organised

shear units and sliding units. SaintGobain Seals’ polymer materials are used for the latter as a sliding tape due to their very low friction, high resistance to wear and resistance to deformation. When an earthquake occurs and the shaking intensifies, the sliding seismic isolator (a laminated bearing with a sliding mechanism) works to absorb strong tremors. The idea behind base isolation is to detach (isolate) the building from the ground so that earthquake motions are not transmitted up through the building or are greatly reduced. As an earthquake prone country, Japan has been concentrating on base isolation research and development for almost 20 years.

Seismic base isolation engineering can be seen on several well-known Japanese structures that use Saint-Gobain’s Rulon and Fluoroloy products, such as the world’s largest suspension bridge where it protects the cable connection underneath the road from earthquake and wind/wave vibration. In addition, One of Japan’s most famous baseball stadiums adopted a seismic isolation system with the Rulon and Fluoroloy products to its roof over the grandstand, which has a no-pillars structure. The materials have also been used on smaller-scale buildings, such as hospitals and residential housing.

by EU-level trade association, EuPC, Geoffroy Tillieux, Building and Construction Division Manager, said the workshop had lead to the vision that “plastic is to become the material of choice for building and construction products in Europe within the next 5 to 10 years.” During the workshop, speakers from R&D centres all around Europe presented their work and

current projects in the building and construction sector to 40 participants. Follow up of this workshop will be held during the EuPC Building and Construction Forum on 21st May in Warsaw, with a focus on Horizon 2020 new calls. Those interested in attending should visit the website below. WWW.ECP4.EU

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WWW.SEALS.SAINT-GOBAIN.COM

Tel: 0845 34 54 560 Email: sales@plastribution.co.uk

www.plastribution.co.uk 14/04/2015 16:23

EVONIK LAUNCHES FR AND HALOGEN-FREE GRADE FOR CABLE JACKETS IN CONSTRUCTION Evonik has launched a new, halogen-free polybutylene terephthalate (PBT) grade for optical fibre jackets and wire bundles that it says benefits from excellent flameretardant properties (HFFR). New ‘Vestodur X9426’ has been specially tailored for building and construction projects where stringent fire safety regulations for cable material are increasingly becoming the norm in calls for tenders. Vestodur X9426 has a high limiting oxygen index (LOI) and low smoke density, and any smoke gases emitted are of low toxicity. The extruded material is also extremely flexible, kink- and crush-resistant and has good hydrolysis properties, says Evonik.

VESTODUR X9426 for optical fibre jackets

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STYROLUTION LAUNCHES NEW STYRENICS GRADES FOR CONSTRUCTION INDUSTRY Global producer of styrenics, Styrolution, has launched new grades specifically tailored for the construction industry that it says will bring new solutions for building and

construction applications, such as siding, decking, fencing, railings or gutters. The new Luran and Luran S product lines, introduced at NPE, are targeted at applications requiring high heat resistance, good extrusion processability, durable aesthetics and miscibility with other materials, such as PVC.

Styrolution has launched new grades specifically developed for building and construction applications

The new grades include Luran HH120 Q530, a powdered alpha methyl styrene acrylonitrile (AMSAN) grade offering improved heat deflection temperature in PVC compounds and Luran S 797 Q530, an acrylonitrile styrene acrylate (ASA) powder for enhanced weathering resistance in PVC blends. For applications requiring a highgloss appearance, the company launched Luran S 777 ME, an ASA grade that also offers good extrusion processability and finally, Luran S 747 R UV, an ASA for excellent capstock coverage over foamed PVC cores. “Our customers in the construction market are at the leading edge of innovation and are continually challenged to bring higher endurance, longer lasting, more cost effective and aesthetically pleasing products to the marketplace,” explained Thomas Hazenstab, Specialties Business Director, Styrolution. “Styrolution prides itself on working very closely with customer partners to develop new products to meet their specific needs. Material innovations like the new Luran and Luran S grades are a direct response to these new and more rigorous market requirements.” WWW.STYROLUTION.COM

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Comment: CrysticROOF BBA Premier system installed at London King’s Cross Station Southern Colonnade entrance

NEW GRP ROOF ARRIVES AT KING’S CROSS STATION A refurbishment project has seen two flat roofs at King’s Cross railway station replaced with a glass reinforced polyester system developed and manufactured by Scott Bader in the UK. The chemical company supplied its CrysticROOF BBA Premier, a seamless, coldapplied, liquid resin GRP roofing system for flat roofs, either side of the central clock tower of the Southern Colonnade entrance at King’s Cross after the existing bitumen roof was beyond repair. As part of the rigorous specification and product View from above of the approval process, a new roofing system representative from Network Rail visited Scott Bader’s UK plant in Northamptonshire, where the CrysticROOF unsaturated polyester resin and topcoat GRP raw materials were developed, and are manufactured. When correctly applied, the system provides long term UV resistance and weathering performance, remaining watertight and maintenance-free. WWW.SCOTTBADER.COM

PLASTICS BRING RETRO HOUSE UP TO DATE

A retro ‘Futuro’ house from the 1960s was brought to life in London for an exhibition late last year with the help of Ludlow-based DMS Plastics, who replaced all of the windows

with reverse-engineered blow moulded replacements. Finnish architect, Matti Suoronnen, built the spaceship-style prefabricated houses in the 1960’s, with this salvaged model one of only 60 thought to be in existence today. WWW.DMSPLASTICS.CO.UK

BUILDING BLOCKS FOR THE FUTURE OF PLASTICS

he Construction Industry Training Board (CITB) has announced the exciting news that the former Springfield Brewery site in Wolverhampton will be the new home to a multi-million pound University Technical College in 2016. Led by the CITB and co-sponsored by the University, it will open in September 2015 on a STEVE SHAW, temporary site at Northicote School before moving EXECUTIVE into a new building at Springfield in September 2016. DIRECTOR AT The plans will enable the Springfield site to be turned RAPRA, REVEALS into a centre of excellence for construction, providing skills and training for future leaders of the industry. WHY A RECENT As an organisation that helps members and DEVELOPMENT businesses deal with the very real problem of AT THE recruiting staff with appropriate engineering UNIVERSITY OF and science based skills and experience, this WOLVERHAMPTON latest development announced by the University COULD PROVIDE of Wolverhampton is extremely welcome, as it addresses this major issue, including initiatives to THE PLASTICS attract more women into engineering careers. INDUSTRY WITH Plastics have properties that make ideal THE SKILLS IT building materials, including strength whilst being NEEDS FOR THE extremely lightweight for easy manoeuvrability and FUTURE. consequently transportation, reistance to rotting or corrosion, very durable with excellent weatherability and are easy to install, offering limitless possibilities in design achieved by extrusion, bending, moulding etc. According to statistics from the British Plastics Federation, the construction sector is the second highest user of plastics after packaging. Elsewhere in the UK, at Buckinghamshire University Technical College (UCT) they specialise in the Built Environment and IT and run regular taster sessions where potential students can go in on a Saturday, or during the holidays, and undertake practical construction and IT activities. Recently, a year-nine female student attended, as she wanted to specialise in IT. However, when she had finished the taster morning, she had completely changed her mind and enrolled onto the construction programme. The session had opened her eyes to engineering and construction and in just that short time she discovered that there is so much more to it than laying bricks. Beverley Flanagan, Principal at Buckinghamshire UTC, is passionate about encouraging and engaging with young women and introducing them to the academic disciplines of science, technology, engineering and mathematics (STEM). “Giving young girls good quality careers is key, good advice isn’t just about encouraging them to become more ambitious it’s about dispelling the myth that there are ‘girls’ jobs and ‘boys’ jobs. Only seven percent of the UK’s engineering workforce is female, the lowest percentage of female engineering professionals in Europe,” she said. RAPRA sees the initiative at Wolverhampton as essential to encouraging and attracting young minds to maintain and develop new careers in the construction industry, and, with the example seen in Buckinghamshire, particularly to attract young women to consider the sectors. WWW.RAPRA.ORG

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EXTRUSION MACHINERY | NEWS BATTENFELD-CINCINNATI DEMONSTRATES ITS MOST POWERFUL PE-XA EXTRUSION LINE battenfeld-cincinnati has demonstrated its most powerful extrusion line to date for the production of pipes made of crosslinked polyethylene. During the event in Vienna recently, the company displayed an twinEX 93-28 PE-Xa extruder with an output of up to 150 kg/h, which it says reaches substantially higher throughput rates than conventional lines or RAM extruders and offers the advantage of an extremely short, lowmaintenance cross-linking station. “PE-Xa pipe extrusion is not

an easy task, due to the special demands of the material,” commented Dietmar Stani, Product Manager at battenfeld-cincinnati Austria. “Through intensive testing, we have gathered experience with PE-Xa, which we have subsequently incorporated in the creation of our specialised extruder and pipe die for PE-Xa processing. As a result, we can offer our customers an optimal system for processing this material.” Core components for crosslinked PE pipe production, beside the optimal material blend and the cross-linking unit, are the twin-screw extruder and the pipe head. battenfeld-cincinnati says with its screw geometry specially designed for this application, the twinEX 93-28 PE-Xa extruder used ensures homogeneous melt processing at low melt temperatures. Thermal stress and flow stagnation are reportedly eliminated and a PE-Xa pipes offer an enormous degree of temperature resistance as well as optimal stress crack resistance, and are used for heating, district heating and geothermal systems, as well as for transport of hot and cold water in buildings

COPERION TO LAUNCH LATEST STS TWIN-SCREW EXTRUDER SERIES AT CHINAPLAS The next generation of Coperion’s STS twin-screw extruders is making its world public debut at Chinaplas 2015 from 20-23 May. The new STS Mc11 series features an increase in torque from 10 to 11.3 Nm/cm³ and for the first time uses the high-performance, patented technology of the company’s ‘ZSK MEGAcompounder’ series, a high-capacity extruder for the homogenisation of polyolefins after the polymerisation reactor. When it comes to compounding with high energy input, Coperion says the new STS Mc11 series provides increases throughput by up to 27 percent, as well as decreasing melt temperature due to higher screw filling, improving the quality of the resulting compound. The new STS Mc11 series, which is produced at the company’s plant in Nanjing, China, is equipped with European gearboxes. Screw speed has been increased from 800 to 900 rpm. To improve cleaning and quick change for masterbatch applications, the STS Mc11 is equipped with

The twinEX 93-28 PE-Xa extruder specially designed for PE-Xa processing ensures homogeneous melt processing at low melt temperatures, says battenfeld-cincinnati

favourable dwell time profile is achieved. The same principles, says the company, apply to the RK32PEX pipe head used in the line. The pipe head has been specially adapted to the task in terms of pipe head volume and streamlined flow channels, in order to prevent material deposits and cross-linking inside the die. The pipes pass directly into the infrared oven via an elbow adapter. Eight IR heating elements installed inside the vertical oven ensure a high cross-linking rate at line speeds of up to 30 m/min. In combination with the matching downstream equipment for pipe calibration, cooling, haul-off and cutting, a high quality standard for the pipes is achieved. WWW.BATTENFELD-CINCINNATI.COM

new hoppers with inserts and a redesigned die head. The screw shaft coupling is similar to the design of the ZSK Mc18 series, explained Coperion. To increase stiffness during operation with a torque of 11.3 Nm/cm³, the STS Mc11 series is equipped with a totally redesigned base frame (finite element method). This base frame dampens vibrations and ensures smooth operation of the twin-screw extruder. It increases operation safety and promotes long service life of the extrusion system. WWW.COPERION.COM The new Coperion STS Mc11 series with increased torque of 11.3 Nm/cm³ is equipped with new Coperion-branded gearboxes from renowned European suppliers.

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EXTRUSION LINE DEMONSTRATES QUALITY AND PRECISION FOR 3D PRINTER FILAMENT At NPE 2015, auxillary systems

provider, Conair Group, and extrusion machinery manufacturer, DavisStandard, collaborated to show how to bring productivity and precision to the extrusion of plastic filament used in 3D printing. An extrusion line, incorporating a Davis-Standard extruder and Conair upstream and downstream equipment was in operation on the Davis-Standard stand, with Conair showing a live video stream. “3D printing is taking off right now,” said Chris Weinrich, Conair General Manager, Downstream Extrusion, “and demand for the plastic rod or filament that feeds the printers has never been greater. Yet, the extrusion lines producing filament today tend not to be as efficient as they could be and there is room for quality improvement as well. In bringing this line to NPE, we wanted to demonstrate how using the latest equipment and a complete systems approach can result in significant improvement.” The demonstration line achieves throughput rates of 400 to 600 ft/ min (122 to 183 m/min), which, say the companies, is three or four times greater than the typical production rate in the industry and at better quality. Conair has recorded just 0.0005 inch (0.1524 mm) variation on diameter and less than 0.001 inch (0.305 mm) on ovality or roundness of the filament.

At NPE 2015, the Conair Group teamed up with extruder maker Davis-Standard to show how to bring productivity and precision to the extrusion of plastic filament used in 3D printing.

“The best producers in the industry today are running at ±0.002 on diameter and also on ovality,” said Weinrich. “However, most of what we have seen otherwise is ±0.003. Tight tolerances are critical for filament used on high-end printers. If diameter and ovality are off too much, the printer can misfeed.” The extrusion line used starts with drying of the ABS resin in a Conair mobile drying and conveying system, which also loads the resin to the extruder hopper. A two-inch DavisStandard Super Blue extruder feeds the Conair GRH-1.0 extrusion die designed specifically for filament/rod production.

After exiting the die, the extrudate enters a Conair HTMP multi-pass cooling and sizing tank. The filament makes three passes through the tank before exiting to a precision belt puller and the Conair servo-driven automatic cut-and-transfer coiler. A Zumbach laser gauge, positioned between the cooling tank and the puller, continuously monitors diameter and ovality and provides a feedback loop to the extrusion line control to maintain consistent product.

PTI IN FINAL STAGES OF COMMERCIALISING PATENTED LAYER-FLIPPING TECHNOLOGY

position of extrudates from two extruders in a coextruded structure without disassembly and shutdowns. The final announcement on commercialisation will follow upon completion of a formal agreement. “Since this technology accompanies the sheet die and feed block, it is a natural fit to align ourselves with a global tooling entity,” said Dana Hanson, president of PTi. Hanson added that changeovers in piston position due to hydraulic actuation of the piston cylinder and unique flow design are accomplished in “a matter of seconds” as opposed to conventional techniques, which require some machine disassembly and can take up to several hours. The

Processing Technologies International (PTi), a global manufacturer of high-performance sheet extrusion machinery, has announced that it is in the final stages of formalising a commercial agreement with a leading global tooling manufacturer for the exclusive sourcing of its patented layer-flipping technology. The technology, says PTi, allows processors to quickly change the The new layer-flipping technology is in the final stages of commericalisation

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WWW.CONAIRGROUP.COM WWW.DAVIS-STANDARD.COM

www.kraussmaffei.com

NEW COOLING SYSTEM FOR PE TUBES LAUNCHED BY KRAUSSMAFFEI BERSTORFF KraussMaffei Berstorff has launched a new paternoster cooling system that it says provides up to a ten percent increase in the cooling time of PE insulation foam tubes and has minor space requirements. The challenge when producing PE insulation foam tubes on highperformance foam extrusion lines is that they generally require sufficient cooling time prior to packaging. With conventional foam tube extrusion processes based on physical foaming, the products are cut to a length of two meters at the end of the cooling section and directly discharged into boxes provided for this purpose. The paternoster system is equipped with a circulating chain system including 126 transport trays

diverter valve can be utilised on new or existing systems. “Since being awarded our original design patent in 2013, we’ve continued to develop this technology and have filed a second design patent just over a month ago,” Hanson continued. “This real-time capability delivers major improvements in efficiency and productivity for processors of coextruded product.” The diverter valve features a dual-piston valve, which is moveable in a stationary body. The body has two entrances that feed from separate extruders. The first position of the valve allows the material to enter the piston valve

KraussMaffei Berstorff says its new paternoster system offers a cost-effective alternative to conventional cooling systems

Depending on the tube diameter and wall thickness, the material still exhibits substantial residual heat with this cooling method. Even when appropriate reversing systems are used to return the foam tube to the extruder in order to pass the cooling section once more, a maximum threefold increase in the cooling time can be achieved. A further extension of the cooling section is often limited by the available floor space. In order to make the process more efficient, KraussMaffei Berstorff has developed a solution equipped with a circulating chain system including 126 transport trays. The precut foam tubes are automatically placed in the trays and discharged after having passed the paternoster system. A total of 104 trays are filled with tubes, which corresponds to a cooling section length of over 200 metres. “Based on a typical production speed of 20 m/min, the residence

and permits a straight through flow path. Normally, this would produce an A-B structure. When the alternated position two is selected, the materials are routed through crossover flow paths that changes extrudate positions. This produces a B-A structure. During position changes, a unique flushing channel design keeps flow from stagnating for quick and efficient changeovers. The practical use for the diverter valve is its quick “real-time” purging of cap layers in a multilayer co-extrusion structure for sheet production, according to Hanson. The diverter valve enables the processor to purge the cap layer extruder back into the inner layer

WWW.BRITISHPLASTICS.CO.UK

The KraussMaffei Berstorff paternoster system is said to be suitable for PE insulation foam pipes with different diameters

time in the paternoster is about 10 minutes,” explained Matthias Reimker, Product Manager for foam tube lines at KraussMaffei Berstorff. “As compared to standard production processes, the cooling time is thus extended by up to ten times.” In addition, a cooling air system supplies cooling air in longitudinal direction in order to cool the tubes from the inside. After having passed the paternoster system, the PE foam tubes have almost completely cooled down before they reach the boxes, says the company. WWW.KRAUSSMAFFEIBERSTORFF.COM

of the structure while an alternate cap layer extruder runs a specific resin formulation (i.e., different colour). Each cap layer (both inner and outer layers) can utilise this special valve to permit this real-time purging for rapid changeovers. This occurs without shutting down the line, thus permitting recovery of the purged resin directly back into the structure instead of losing the material onto the production floor and recovery through a grinder. PTi will offer the layer-flip technology on new coextrusion systems or as a retrofit to existing machines. WWW.PTIEXTRUDERS.COM

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MASTERBATCH AND ADDITIVES | REPORT

Plastic additives market predicted to be worth $45.5 billion by 2019

new report published by market research analysts, MarketsandMarkets, suggests that the plastics additive market is projected to register a CAGR of five percent between 2014 and 2019 to reach $45.5 billion (appox ÂŁ30.9 billion) The findings published in â&#x20AC;&#x2DC;Plastics Additives Markets by Type, Plastic and Applicationâ&#x20AC;&#x2122; reveal that Asia-Pacific is the key location for plastics additives, dominating the market in 2013 and accounting for over 40 percent of the market share, by volume. Country-wise, China is projected to be the top consumer of plastic additives globally by 2019, and is estimated to register a high CAGR between 2014 and 2019. The US is currently the largest plastic additives consumer in the world but the report anticipates that it will be overtaken by China in the near future. The demand for plastic additives is driven by diverse applications ranging from packaging, construction, consumer goods, and automotive among others. Growing GDP, rapid pace of industrialisation, increased consumption of plastic materials, consumer goods, and packaging products remain the key growth drivers, with future growth in the market hinging heavily on developing economies in Asia-Pacific, South America, and Eastern Europe.

Packaging sector as a growth driver

The packaging sector led the plastic additives market in 2013 and is projected to continue to be the largest market, registering a CAGR of 4.7 percent between 2014 and 2019 in terms of volume. This is due to food and beverage manufacturers

Food and beverage packaging will act as a growth driver for plastics additives, finds the report

The packaging sector led the plastic additives market in 2013 and is projected to continue to be the largest market, registering a CAGR of 4.7 percent between 2014 and 2019 in terms of volume.

continuing to enhance their focus on attractive and sophisticated product packaging, in order to gain consumer attention. In addition, with the advent of new packaging technologies such as antioxidant, UV resistant, heat resistant, antimicrobial, and anti-fog packaging, the use of plastic additives has surged significantly over the last few years. Second to packaging, the next fastest growing sector for use of plastic additives is automotive, where increasing plastic consumption is expected to benefit the plastic additives market over the next five years.

Flame retardants predicted to see highest growth

The plasticisers segment of the plastic additives market had the largest share in 2013 and is projected to dominate the global market by 2019 mainly due to the growth in demand of DOP. The demand for DOP is showing upwards trends owing to its low cost and suitable plasticising properties that are further employed in a variety of end-use applications. Flame retardants are projected to have the highest growth rate between 2014 and 2019. Increasing demand by the consumer goods and construction sectors, especially from the Asia-Pacific region, will continue to drive the growth of this segment. WWW.MARKETSANDMARKETS.COM

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MASTERBATCH AND ADDITIVES | NEWS

The new range of additives are ideally suited to use in automotive interiors, says Croda

CRODA LAUNCHES NEW LOW BLOOM ANTI-SCRATCH ADDITIVES FOR PLASTICS Speciality chemical company, Croda, has developed a new range of stable, anti-scratch additives for use in plastics. The UK-headquartered company says these additives reduce scratch width and visibility, while the superior stability results in reduced blooming on the surface. This combination of benefits, it says, makes them perfect

ANTIMICROBIAL ADDITIVES ARE A SOUND ADDITION TO HEADPHONES Audio specialist, Sennheiser, has selected antimicrobial additives from Steritouch for its latest line of performance headphones. For the ‘Sports’ range, launched at the CES show earlier this year, a silver ion-based additive in powder form was developed at the SteriTouch technical facility in South Wales, specifically for Sennheiser’s range of coloured silicones and utilising the latest in both antimicrobial and anticounterfeit technology.

for use in a variety of plastics, used in applications such as automotive interior parts. “We have undertaken a significant project in the area of anti-scratch so that we are able to advise our customers which product and addition level will give optimum performance in their formulation,” explained Croda’s Technical Expert, Martin Read. “We are continuing with this work and would like to engage further

“Our new Sports headphones have been built on Sennheiser’s passion for sound and insight into the impact and challenges of extreme movement on audio, comfort and fit – all of which guided the design and selection of materials,” said Daniel Chee, Product Manager for Sennheiser. “One of the core reasons why Sennheiser is working with SteriTouch for our Sports headphones is their independently lab tested and proven antimicrobial solutions.”

with our customers to continue this process and meet future needs in the area of anti-scratch for a wide range of plastics.” Croda is presenting a paper on its range of speciality additives for the automotive industry at the upcoming ‘Automotive Thermoplastic Composites’ conference in Stuttgart, held on 7-8 May. WWW.CRODAPOLYMERADDITIVES.COM

of performance The new range ures the headphones feat ive dit ad ial ob antimicr

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The new masterbatch has been developed for use in foam insulation boards made of XPS

GABRIEL-CHEMIE INTRODUCES NEW FLAME RETARDANT MASTERBATCH FOR XPSBOARDS Gabriel-Chemie, the Austrian masterbatch specialist, has developed an HBCD-free flame retardant concentrate for use in foam insulation boards made of extruded polystyrene (XPS), more than six months before the cutoff date for use of HBCD flame retardants in Europe. Use of the new active ingredient, ‘Poly-FR’, is said to enable XPS insulation boards to comply with applicable European fire safety standards, even with low masterbatch dosage. The relevant process parameters and the formulation of all other components can be kept unchanged in the manufacturing process, namely polystyrene type, propellant gas, nucleating agents and colour. “Our investment in new flame retardant production equipment enables us to guarantee high product quality and reliable supply

performance to the insulation manufacturers,” explained Erich Guttmann, CCO of Gabriel-Chemie. The new masterbatch is specially formulated to ensure that the temperatures which occur in foam board production and recycling cause no degradation to the active flame retardant and that no machine corrosion is experienced. Austrian insulation manufacturer, Austrotherm, is one company working

with the flame retardants. “Working in close collaboration with the development team from GabrielChemie has resulted in an effective Poly-FR based solution,” commented Gerald Prinzhorn, Managing Director of Austrotherm. “This enables us to continue to offer products in our usual high quality independent of new regulatory requirements.” WWW.GABRIEL-CHEMIE.COM

HOW TO CHOOSE THE RIGHT ANTIMICROBIAL ADDITIVE FOR THE RIGHT APPLICATION

aking a polymer antimicrobial via the introduction of additives is similar to making it fire resistant or BY DR ANDREW a particular colour, SUMMERFIELD, or so you may REGULATORY AFFAIRS think. However, OFFICER, BIOCOTE the reality is there are many factors to consider which may make this process more involved than expected for the uninitiated. The objective as always is to

deliver superior antimicrobial performance – but what determines the active substance chosen to deliver this is a combination of technical and regulatory factors. Whatever is being manufactured, the material or product still needs to deliver on its original purpose. The additive selected should not negatively affect the aesthetic or mechanical properties of the treated article in any way. The additive itself should also be formulated in such a WWW.BRITISHPLASTICS.CO.UK

way that is easily integrated into the manufacturing process. Other than the obvious reasons, this is also likely to ensure optimum antimicrobial performance is achieved in the finished product. Of course, this is best assessed using an appropriate test method and whilst previously undertaken simply to prove concept, this is now a requirement of law if antimicrobial claims are to be made. Legislation surrounding the use of antimicrobial additives is becoming increasingly well defined. These differ from region to region around the world, they are put in place to protect people at all stages of the supply chain and the environment. In the EU these are known as the Biocidal Products Regulation (BPR) and in the USA, Federal Insecticide, Fungicide and Rodentacide Act (FIFRA). Regulations are region-specific and stipulate which, where and how antimicrobial additives can be used. The implications of using an inappropriate additive can be severe depending on the hazard or risk presented. Therefore it is not only your choice of antimicrobial additive you should consider at length, but also your choice of supplier. WWW.BIOCOTE.COM 33

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HOT RUNNERS AND CONTROLLERS | NEWS The SMV compact valve gate system opening up new applications

Eastern Plastics Machinery Ltd

launches Seiki’s latest hot runner

eiki Corporation, Japan’s longest standing hot runner maker known for its dual voltage probes, has now ESSEX-BASED EASTERN designed a PLASTICS MACHINERY compact valve HAS ANNOUNCED THE gate probe AVAILABILITY OF THE which has a NEW SEIKI SMV COMPACT hot runner side VALVE GATE SYSTEM, ON build height of 120mm, SALE FOR THE FIRST making it TIME THIS WEEK. ideally suited to small size injection moulding machines for

the production of small products moulded in engineering plastics such as LCP and Nylons. Key to the success of the system is said to be its ability to create a temperature profile through the hot runner unachievable with conventional single heater valve gate systems. “We are really excited about the possibilities this new system offers,” commented Chris Siddall, Managing Director of Eastern Plastics Machinery. “From our own tests, single heater valve gates can never perform as well

Independent gate heaters can offer production advantages, says Siddall

as the dual heater systems when it comes to heat sensitive materials and if you mould small products in engineering plastics, the issues of degradation and temperature control become even more important. That’s why we build both single and dual heater body valve gate options and we work closely with the customer to identify which will perform best for them. This SMV system really offers performance at a level not seen before for small compact moulds.” Siddall added that raw material cost savings when switching from cold to hot runners can be huge, but an unreliable hot runner that causes downtime “THIS SMV SYSTEM due to over heating, REALLY OFFERS or degradation of lost PERFORMANCE AT production at startup or A LEVEL NOT SEEN shut down that impacts on productivity and BEFORE FOR SMALL uptime, can lead to even COMPACT MOULDS.” greater hidden extra costs. “Good temperature control through every millimetre of your hot runner flow channel is one key to better productivity and product quality,” Siddall concluded. WWW.EASTERNPLASTICS.CO.UK

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eastern Plastics Machinery Ltd

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Selling the science of injec�on moulding

Some of the nozzles available in Thermoplay’s FN range

NEW PRODUCT LAUNCHES FROM THERMOPLAY AND GROWTH IN UK Developer and manufacturer of hot runner systems for plastic injection moulding, Thermoplay, has launched two new products to market as the company, including its UK subsidiary, continues to enjoy a record period of growth. Firstly, the company’s new slim line single gate system has been developed to fit inside the mould and maintain optimum balancing of the melt flow. “Our new compact design inline cylinder enables us to achieve significant stack height reduction. Thermoplay has, without compromise, now made the single valve gate more compact than the system launched on the market 18 months ago,” Chris Whitlam, Director at Thermoplay UK, explained. “By securing it to the intermediate plate it now allows the cylinder to protrude through the location ring.” The system can be fitted with nozzles ranging from 16 – 46mm and can be interchanged. Thanks to four flow channels through the cylinder, the system is said to be perfectly balanced, with no dead spots surrounding the pin. Whitlam added that the new generation pin and pin guide is designed to substantially reduce the risk of leakage and plastic adhering to the valve pin. In addition, the company has also enhanced its online hot runner design system, with more flexibility coming from the all-new VS system configuration. The online web design system, ELS (Easy Line System), allows customers to generate a hot runner design to meet their specific needs. The 36

HUSKY ANNOUNCES RENEWED FOCUS ON HOT RUNNER TECHNOLOGY

system parameters are 2, 4, 6 and 8 drop hot runner manifolds – both thermal and valve gate. “The VS option has taken this to a new level with more variables than ever before,” said Whitlam. Information about both products is available in the UK from Thermoplay’s Leighon-Sea site in Essex, where a “record year” in 2014 means the company has expansion plans in place to accommodate future growth. “We are moving to a new larger office next month in preparation for future additional staff,” Whitlam told BP&R, “as we build the business in the UK this year.” Whitlam attributes part of the Thermoplay UK growth to the fact that the company is “one of the few suppliers that are actively stocking spares locally in the UK and are investing in improved service to meet customer demands.” The UK division is looking to enhance its position in the automotive sector in 2015, with a new project and design department. It also continues to develop systems in the packaging sector. WWW.THERMOPLAY.IT/EN The UK team says it has seen “record growth”

Husky launched two new hot runner products at NPE, in what is says is part of a “renewed focus” by the group on the technologies. The first is the UltraHelix Valve Gate, which it says moulds better parts and provides the lowest total cost of ownership when compared to any other valve gate. The second its Altanium Servo Control that enables servo motors to replace mould pneumatics or hydraulics. “We are getting great feedback from the market in terms of our direction, separating hot runners from the rest of our business has given us focus and our investments have given us capacity,” explained Dave Morton, Vice President, Americas, for Hot Runners and Controllers during the show. “Of course, hot runners have long been a focus for Husky, but in the last two years we have renewed our attention in this area.” Husky says it conducted extensive research to deeply understand the fundamentals of valve gate dynamics, wear, and gate quality before developing the UltraHelix. Coming as close as possible to zero gate vestige performance, the UltraHelix valve gate is claimed to dramatically reduce moulders’ cost of quality, provide thermal uniformity, and virtually eliminate mechanical wear on the valve stems and cavity steel. “I am especially excited to introduce our UltraHelix Valve Gate,” said Gerardo Chiaia, Husky’s President of Hot Runners. “It’s a remarkable product that incorporates many ideas that our customers have shared with us, and when combined with UltraSync-Electric actuation, it performs at a level that will really astonish the industry. Customers can invest once and mould worry-free, perfect parts for millions of cycles.” The company said NPE was an opportunity to display its full range of Altanium controllers. WWW.HUSKY.COM

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eastern Plastics Machinery Ltd

Cost saving with Renmar A significant problem that can occur with moulding machines is when the tool overheats. When this happens, the only options are to increase the cycle times or stop production altogether. Neither option is in anyway desirable but there is a simple and relatively economic, answer; install an AEC TCU or VCU mould heater. The high flow rates delivered by the TCU and VCU range of mould heaters mean that as the water is delivered through the tool, turbulence occurs which increases the efficiency of the unit and gives better heat transfer. Because the water is delivered at a higher rate and at a potential higher temperature, the tool is heated more

w renmarltd.com

quickly and reaches the desired operating temperature in a much shorter time. This not only reduces the cycle times but does so using less energy than many competitive heaters. Both the TCU and VCU ranges are more than capable of handling mould tools with complex cavity designs. We have a number of customers who have successfully reduced the number of older competitors heaters - in one instance where 6 x 6kW conventional units were replaced by 3 x AEC TCU300-9kW units, essentially halving their running costs. For more information contact Renmar on 0844 6933225 or go to www.renmarltd.com

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RECLAMATION & RECYCLING | NEWS PRN REFORM COULD HAVE PREVENTED PLASTICS RECYCLING INDUSTRY CRISIS SAYS BPF The British Plastics Federation’s Recycling Group (BPF RG) has reiterated its claim that the packaging recovering note (PRN) system needs urgent reform before more UK recyclers become victims of the current market failure affecting members such as Closed Loop Recycling (CLR). Commenting, the Group says reductions in oil and commodity polymer prices, coupled with strong demand from global low cost economies for waste plastics, have undermined confidence in the UK plastics recycling industry, putting jobs and economic security at risk. BPF RG believes that the current situation “could have been avoided had the UK government taken decisive action and implemented the proposals it published last year in its manifesto.” The proposals focussed on identifying drivers to achieve a sustainable future for the plastics recycling sector by introducing two fundamental changes in the PRN system. The first, a split on the plastics packaging recycling targets, to distinguish virgin and losing their relief from what is a “THE CURRENT recycling in the local market (UK and hugely unpredictable cost under Producer SITUATION] COULD EU) from that which is exported outside Responsibility obligations”. Moreover, had Europe. This would be achieved through HAVE BEEN AVOIDED the split target escalator been adopted, the existing PRN/PERN mechanism, CLR would be in “an increasingly strong HAD THE UK leading to a progressive weighting position” to compete against demand from GOVERNMENT TAKEN towards increased local recycling yearexports for waste plastic bottles. DECISIVE ACTION on-year. Not only could this deliver the Roger Baynham, Chairman of the BPF best environmental outcomes, says the RG, said: “We have effectively reached a AND IMPLEMENTED BPF RG, but it would also encourage and fork in the road. Do nothing, accept that THE PROPOSALS incentivise innovation and investment – the UK recycling sector will struggle to IT PUBLISHED enabling the UK to future-proof markets for compete with global low cost economies LAST YEAR IN ITS plastic waste. and become increasingly dependent on The second relates to an ‘offset’ such markets for our waste, or implement MANIFESTO.” proposal, which calls for a modification to changes which can deliver successful and the producer responsibility framework to investable long term recycling businesses encourage retailers and brand owners to increase the use which create green UK jobs as part of a sustainable of recycled polymers. circular economy. Events at CLR show that this is a In the case of CLR, the BPF RG believes that had a PRN decision which can no longer be ducked.” offset model been adopted, the dairy sector and retailers would “have thought twice before switching back to WWW.BPF.CO.UK

RECOUP REFRESHES GUIDELINES AROUND RECYCLABILITY AND DESIGN RECOUP’s guideline document for packaging technologists and pack developers who use plastic packaging has been refreshed and revised for Spring 2015 to encourage and increase recyclability. ‘Recyclability by Design’ provides guidelines for those wishing to make their packaging more recyclable and also provides information on the different sectors of the plastic recycling chain to enable brand owners to ensure their packaging is compatible with recycling schemes.

Alan Davey of Linpac Packaging, a contributor to this edition of the guide, added: “It’s important that we make recycling as efficient as it can be for those products in the market, and this guide moves us another substantial step in the right direction. Of course recycling must never be an end in its own right, or we will make retrograde decisions that actually harm the environment and stifle innovation”. Contributions also include a view from the recycling industry on how product design and material selection can help improve the commercial viability to recycle more

WWW.BRITISHPLASTICS.CO.UK

The BPF says reform to the PRN system could have prevented the industry crisis currently affecting the market

pots, tubs and trays. It also features an update from Milliken on the latest technology now available for producing ultra-clear polypropylene recyclable packaging. RECOUP says it believes that the quality of flake and pellet produced, and ultimately the quality of products made from recycled material, can be improved by encouraging product designers to consider the recyclability of their plastic pack during the design stage. The new version is now available to download from the RECOUP website. WWW.RECOUP.ORG

UK CLOSED-LOOP FUEL CELL COMPONENT RECYCLING GETS A STEP CLOSER Advanced techniques for recovering a high-value polymer from fuel cell membrane electrode assemblies (MEAs), has brought closed-loop recycling of these components a step closer, according to Axion Consulting. The Manchester-based resource recovery specialist developed the process in the collaborative ‘RECOVER’ R&D project with fuel cell components supplier, Johnson Matthey Fuel Cells (JMFC), and nonwoven materials manufacturer, Technical Fibre Products (TFP). The project was co-funded by the UK’s innovation agency, Innovate UK. The financially-viable process is low hazard and extracts PFSA (Perfluorosulfonic Acid), a fluorinated membrane polymer, from the MEAs of Proton Exchange Membrane (PEM) fuel cells without incineration or the creation of hydrogen fluoride gas, a corrosive and toxic substance. This membrane acts as a proton conductor, allowing the passage of electrical current to provide power. The current incineration route does not recover the membrane as it is burned and lost. Platinum recovery from the MEAs

is also easier with no loss of yield as the process generates a metal-rich material for further refining. “The unique aspect of our recycling route for this challenging co-polymer ensures the successful recovery of both platinum and PFSA without any nasty by-products. This is now being processed commercially for Johnson Matthey Fuel Cells,” explained Axion Consulting Director, Roger Morton. The process, he says, offers three major benefits: economic recovery of valuable and critical materials; preservation of resources for reuse in new fuel cell products and elimination of the technical challenges and cost of tackling harmful emissions. “This closed-loop recycling route will be essential when fuel cells become the power packs of the future for vehicles in both remote and domestic locations,” continued Morton. “The hydrogen economy will continue to develop and grow; it is the future. Significant quantities of fuel cells will reach the end of their lives in 10 to 15 years’ time so the technological capability to recover their valuable resources will be crucial.” WWW.AXIONCONSULTING.CO.UK

Closed loop fuel cell recycling is a step closer to reality

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CLOSED LOOP CEO “OVERWHELMED” BY SUPPORT AFTER ADMINISTRATION WARNING Chris Dow, CEO of Closed Loop Recycling, has thanked the supply chain for its “overwhelming support” since the company announced it was facing administration due to both the slump in oil prices and the supermarket price war. Support for the UK’s largest plastic milk bottle recycler has come from companies throughout the supply chain, said Dow, with Dairy UK, Dairy Crest and the Co-Operative Food Group just some of those who have been vocal in their backing. “We have been overwhelmed by the support across the supply chain for the UK plastic recycling industry,” Dow said. “This is a message that has been repeated by all the key stakeholders across the Dairy Roadmap. They have made their support public, and WRAP now has a solution on the table to ensure the future of plastic recycling. The cost to secure the future of this industry is just a tenth of a penny on a two-pint bottle of milk.” Dairy UK said: “[The industry is] keenly aware that the plastic recycling industry is facing difficult times and we have every intention to meet our targets…It is crucial that all sides of the supply chain work together with government to achieve these results.” Echoing these sentiments, a spokesperson for Dairy Crest said that the company “remains committed to rHDPE” and will continue its involvement with the Dairy Roadmap. A spokesperson for The Co-operative Food said the company has “no plans” to move away from using recycled content in its milk bottles and that it will “continue to help in the progress”

NAMPAK LATEST TO PLEDGE SUPPORT FOR RHDPE The UK’s biggest producer of plastic milk bottles is the latest to pledge its support for recycled high density polyethylene (rHDPE) during the current period of uncertainty. Nampak Plastics, producer of the ‘Infini’ lightweight bottle, is urging the dairy industry to maintain its commitment to using recycled materials, not least due to the environmental benefits they bring.

towards the Dairy Roadmap targets for recycled content. Concluding, Dow added that environmental group, Friends of the Earth, has launched a campaign of support with its members who want to see recycled milk bottle content in their plastic milk bottles. “We know from a recent You Gov survey that 68 percent of UK consumers support the future of the industry and are happy to pay the additional tenth of a penny to ensure this,” he added.

CEO of Closed Loop Recycling, Chris Dow, has thanked the supply chain for its support

WWW.CLOSEDLOOPRECYCLING. CO.UK

“At Nampak we feel very passionately about upholding the recycled plastic industry in the UK, and we want others to join us in supporting this initiative,” Eric Collins, Managing Director of Nampak Plastics, commented. “This is a crucial issue that we’ll continue to support – current rHDPE inclusion rate of up to 20 percent in our bottles means a 14 percent

WWW.BRITISHPLASTICS.CO.UK

reduction in the amount of carbon used. Lightweighting with our Infini range of bottles delivers a further 20 percent carbon reduction. That’s a huge amount.” WWW.EU.NAMPAK.COM

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Suppliers to the Tooling & Plastic Industry

Hales Tool & Die are now the European Channel Partner for Athena Controls inc.

Maestro

The art of precision control

Foundation Series TM

A higher level of control

FEATURED PRODUCT

Bedros Controller Bedros hot runner controls are compact, robust, and deliver more functionality than standard medium-sized multizone runnerless controls. You get 8 to 64 zones of control with 15 amps per zone, expanded mould storage capabilities and and easy-to-use, fully featured touchscreen and joy stick interface.

Kongskilde offers complete systems for conveying and handling large volumes of plastics materials generated from todayâ&#x20AC;&#x2122;s production lines. These systems ensure a high efficiency, significant savings and an improved working environment.

Bedros and Bedros XL are used in a variety of applications in injection moulding, thermoforming, extrusion and heat trace operations. For more information on Athena, or to see the full range of Hales products, Contact Hales.

Phone: 0800 634 8800 Fax: 0800 634 3800

Kongskilde UK Tel. 01263 713291 mail@kuk.kongskilde.com www.kongskilde.com

www.halestooling.com

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Talking technical: Improving productivity in injection moulding

I [Part 2] QUICK MOULD CLAMPING SYSTEMS IN THE SECOND INSTALMENT OF OUR NEW SERIES OF ARTICLES LOOKING AT IMPROVING PRODUCTIVITY IN INJECTION MOULDING, CRAIG FORRESTER OF STÄUBLI CONNECTORS UK, ADDRESSES HOW INVESTING IN QUICK MOULD CLAMPING SYSTEMS COULD HELP MANUFACTURERS ENHANCE BOTH PROFITABILITY AND PRODUCTIVITY.

nvesting in a quick mould clamping system to speed up changeovers can contribute significantly to both productivity and profitability. The latest systems not only speed up mould changes, but also improve machine performance and build operational confidence. There is a quick mould clamping technique to meet any production or technical requirements. Mechanical, hydraulic or magnetic – systems that provide operational confidence on the production line improve productivity and yield a rapid return on investment. The financial benefit of investing in a quick mould clamping system can be readily determined and the payback calculated. This analysis needs to take into account the number of times a mould is changed on a machine, the time currently taken to change moulds and the cost incurred. Comparison can then be made with the quick mould changing system in place. The major benefits are reducing the costly downtime during mould changeovers, thereby increasing machine availability for production. Payback times of less than a year frequently result, in some cases payback can be achieved in just a few months from investment in a quick mould clamping system that precisely meets production requirements.

What type of quick mould clamping system is required? The simplest option is a

mechanical system where the mould is held in position by a manual bayonet locking mechanism. This type of system is suitable for injection moulding machines up to around 250 tonne capacity. These are simple, low cost systems that are relatively easy to install. Nearly all injection moulding machines are suitable; the system requires no electric or hydraulic connections. Existing moulds will require modification; a recess has to be machined into the mould to accept the centring ring in place of the normal register ring. The complete working surface of the platens remains available for use and any shape of mould can be accommodated. Hydraulic systems are suitable for any size of injection moulding machine up to the highest capacity. Single acting or double acting hydraulic clamps, conforming to EUROMAP requirements, are available for the automatic clamping of moulds on both existing and new machines. The clamps operate on a steel backplate, which is securely bolted to each mould. Moulds require a bit more modification than in the manual bayonet locking system and the backplate dimensions are critical to ensure clamping effectiveness. The backplates have to be left permanently attached to each mould, adding to the overall cost of this type of clamping system. Magnetic systems are suitable for all moulding machines. One of the key

advantages of magnetic systems is that no modification to moulds is required and the use of backplates can be eliminated. The system will readily accept any shape of mould. Magnetic systems are quick to install, fast in operation and virtually maintenance free, having no moving parts. The latest development in magnetic clamping systems has improved their ease of use and provides enhanced data flow to bolster confidence in operation. The technology actively manages and secures the clamping operation, providing direct control of clamping/ declamping, guiding the operator through the process sequence with a direct display of the clamping force. The operator has access at all times to additional information e.g. plate temperature (both fixed and moving sides), identification of the moulds on the machine, clamping force for each mould half and mould movement detection. The platens stay magnetised even under power failure adding to the safety of the system. These user-friendly features make magnetic clamping systems extremely reliable, while the increased data flow to the operator improves confidence. Magnetic, hydraulic or mechanical, the choice of a quick mould clamping system will depend on the specific operating parameters of any moulding shop but the benefits are clear and will significantly improve both productivity and profitability.

“MAGNETIC, HYDRAULIC OR MECHANICAL, THE CHOICE OF A QUICK MOULD CLAMPING SYSTEM WILL DEPEND ON THE SPECIFIC OPERATING PARAMETERS OF ANY MOULDING SHOP BUT THE BENEFITS ARE CLEAR” WWW.BRITISHPLASTICS.CO.UK

MATERIALS | NEWS CASE STUDY: NO NEED TO TAKE YOUR EYES OFF THE ROAD

nformation from road safety charity, Brake, suggests that an increasing number of drivers are being distracted by the use of mobile phones, satellite navigation systems and music players and radios whilst WITH IN-CAR TECHNOLOGY driving. In order to counteract FAST BECOMING A STAPLE OF this practice and allow drivers MODERN VEHICLES, SAFETY OF to utilise the best of modern USE IS A KEY CONSIDERATION technology whilst remaining FOR DESIGNERS AND safe on the road, automotive supplier, Continental, MANUFACTURERS. MERCEDES developed a multimedia control HAS DEVELOPED A MULTIMEDIA unit for Daimler with a unique, SYSTEM, FOUND IN MANY three-dimensional touch pad, OF ITS CURRENT MODELS, where drivers can simply use WHICH CAN BE OPERATED their hands to get a response without having to look. The WITHOUT THE DRIVER HAVING device uses CoverForm TO TAKE THEIR EYES OFF technology from Evonik and THE ROAD. THE INNOVATION KraussMaffei to help make the WAS DEVELOPED WITH idea a reality.

TECHNOLOGY AND KNOWFunctional and comfortable HOW FROM THE FIELD OF devices SPECIALITY CHEMICALS. BP&R The innovative touchpad LOOKS AT THE DETAILS. is integrated into the centre

a very big problem for many materials,” he added. The company found a solution for this challenge when developing the materials behind the new touchpad, namely the hardest type of polymethyl methacrylate (PMMA) combined with an additional coating for particularly demanding requirements. Traditionally, the method used for manufacturing three-dimensional components with special features like these was injection moulding followed by a separate lacquer coating—a process involving 14 steps in total. A complex method. It would have been possible to lower requirements and change design, but this was not an option here. That was until Evonik worked in combination with machine manufacturer, KraussMaffei, to come up with a new, special technology as the answer to such demanding applications, called ‘CoverForm’. It enables injection moulding and the application of a scratch-resistant coating to be combined in a single, fully-integrated process, making the manufacture considerably quicker and more costeffective—and the component suitable for mass production.

console of several of Mercedes’ current model lines. It allows drivers to operate the Potential for the future multimedia system in the intuitive way smartphone users are The touchpad is the result of several years of joint accustomed to—by swiping, zooming and scrolling. Drivers development work between Evonik, KraussMaffei, can also write letters on the touch-sensitive surface using Continental and Daimler. For a number of months now, their fingers, to enter a satnav destination, for example. Continental has been using the CoverForm process to The touchpad then confirms the action via a vibration that manufacture the top layer of the touchpad and also the driver can feel, similar to a button, which means the assembles the entire device. More than a million faceplates driver can use the system without having to are expected to be produced there as early as “THE NEW TOUCHPAD 2016. look at it and can therefore concentrate on the road at the same time. The touchpad, But it’s not just the automotive industry IS THE RESULT which is slightly curved, can even be where CoverForm has found its purpose—it OF SEVERAL used as a palm rest, as it is able to detect is also used as an alternative to produce YEARS OF JOINT whether contact with the surface was purely anti-glare, scratch-resistant plastic coverings DEVELOPMENT WORK for consumer electronics, household devices, coincidence or whether it was intentional. With features like these, the multimedia home technology and watch covers. Evonik BETWEEN EVONIK, system is setting new benchmarks in the is marketing CoverForm, together with KRAUSSMAFFEI, automotive industry. KraussMaffei, and Schröbel sees clear CONTINENTAL AND advantages in this collaboration. “It means More durable than smartphone surfaces customers only have to deal with practically DAIMLER.” Touchpad surfaces naturally come under one source—from the conceptual phase more strain the more they come into contact with human through to the start of series production, with expert support hands, and it is therefore important that the faceplate of the from two strong partners.” touchpad is even tougher than that of a smartphone—that is, media The 3D multi extremely scratch and chemical resistant, explained Evonik’s WWW.EVONIK.DE ad uses hp uc control to Sven Schröbel. “Rings and freshly-moisturised hands pose gy WWW.KRAUSSMAFFEI orm technolo Coverf

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MANCHESTER UNIVERSITY CONFIRMS RENEWABLE POLYOLEFINS CUT FOSSIL FUEL USE BY 84% REPSOL REPORTS 20 PERCENT INCREASE ON EU POLYOLEFINS SALES IN Q1 2015 Repsol has announced that during the first quarter of 2015, it achieved over 20 percent increase in its polyolefins sales in Europe compared to the same period of 2014. The company says efforts to focus production growth on premium and differentiated products, geographical diversification outside the Iberian Peninsula and increased contact with distributors, have allowed the company to take advantage of increased domestic demand and export opportunities. This improvement in sales volumes is the result of the recent investments, such as the technical enhancements and the use of propane as feedstock in the company’s crackers in Tarragona (Portugal) and Sines (Spain), as well as the good performance and productivity of the plants in the first quarter of 2015. At the beginning of April, Repsol restarted its cracker at Puertollano (Spain) after a programmed shutdown, during which more than 60 million euros were invested to downsize the cracker to adapt its capacity to the availability of naphtha alternative feed-stocks such as fuelgas stream from refining, and also to replace all critical cracker equipment with cutting-edge technology to improve energy efficiency, sustainability and productivity. The downsizing of the cracker has limited its capacity of ethylene to 100,000 tonnes per year, which has led to the closure of the old High Density Polyethylene (HDPE) plant. Nevertheless, Repsol says this has enabled it to optimise the occupation rate of its five EVA units, increasing production of these differentiated products by seven percent. Additionally, the improvements achieved in the refining FCC unit allow an increase in propylene production that Repsol says subsequently enables it to increase its polypropylene production to over 30,000 tonnes per year. This makes Repsol’s petrochemical complex in Puertollano a fully integrated site, with polyolefin units focused on differentiated products and a competitive cracker combining energy efficiency and alternative feedstock from refining. WWW.REPSOL.COM

SABIC’s new, second-generation renewable polyolefins dramatically reduce the amount of fossil fuels used in the production of polyethylene (PE) and polypropylene (PP), the University of Manchester has confirmed in a peer review of SABIC’s life cycle analysis (LCA) study.

From feedstock to plastic, the use of renewable feedstock made from waste fats and oils instead of traditional feedstock reduces the amount of fossil fuels needed by 84 percent. “This confirmation of our LCA study by a reputable, independent party confirms some fantastic

0845 34 54 560

results in terms of the sustainability advantage of using renewable feedstocks for the production of polyolefins,” commented Steven de Boer, Director, Innovation and Sustainability at SABIC. “In addition, we are proud to announce that up to 4kg of CO2 is also saved, for each kilogram of product used in the

@plastribution

market.” SABIC’s LCA study also confirmed that the renewable feedstock used is not in competition with food production, thus ensuring that the final product is a sustainable solution for both packagers and consumers alike. WWW.SABIC-IP.COM

www.plastribution.co.uk

Price instability and raw material shortages affecting your business? Plastribution is now able to offer enhanced supply chain solutions for processors who want to ensure greater security of supply and reduce price volatility. And for part loads, Plastribution holds some 3,500 tonnes of physical inventory, providing the opportunity for peace of mind both in terms of availability and price. Plastribution. Delivering the services that are important to you.

Please contact our customer services team to discuss your requirements.

PLA0162_BP&R April 190x125_02.indd 1

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15/04/2015 16:01

In association with Hardie Polymers – www.hardiepolymers.com

// Materials Technical //

Blog

This month, polymer expert and technical blog author, Dr Charlie Geddes, goes back to the classroom when it comes to friction.

What determines friction between thermoplastic components? Friction is an important property for thermoplastics in bearings and gears, but it also has a part to play in assembly of plastic parts (snap-fit and interference-fit) and ejection during moulding. When two surfaces rub together, the resisting force is the combination of two effects at the surfaces; an adhesion force, caused by attraction between the two surfaces at a molecular level, and a deforming force, related to the deformation of the nanoscale ‘peaks’ on the surfaces. Because these two mechanisms stem from different characteristics of thermoplastics, it is difficult to predict overall friction from first principles and values of the coefficient of friction have to be acquired from physical tests. Despite what you learned at school, the coefficient of friction for thermoplastics is not entirely independent of load and velocity. You would be correct in thinking that temperature is another variable. For smooth surfaces and low speeds, the adhesion factor dominates, favouring non-polar materials such as PTFE and HDPE. At high speeds and rough surfaces, the deforming force is more important, favouring more rigid thermoplastics, either from high crystallinity (polyacetal) or with reinforcing fillers (glass or carbon fibre). Low levels of additives (PTFE, silicone and molybdenum disulphide) can significantly reduce friction. Friction data for thermoplastics rubbing against steel are fairly readily available, but not for two thermoplastics in contact. In both cases data will be for a limited set of conditions, probably unrelated to the service condition in question. Friction between components of the same thermoplastic can be considerably higher than for dissimilar materials, which is why different thermoplastics are used for alternate cogs in gear trains. If no friction data is available, selecting HDPE for the alternate gears is normally a safe choice for minimising friction…but wear is another story.

Got a view on the above?

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

INNOVATIVE NEW BIOPLASTIC DEVELOPED IN UK GETS PATENTS GRANTED A UK-based bioplastic technology company has been granted a patent for an innovative bioplastic material that it says uses unique technology to produce a bioplastic that is much tougher and easier to process than current materials. This new patent, which took just over four years to obtain, covers Floreon, a novel and biodegradable, polyester-based polymer blend with a standard bioplastic called polylactic acid, or PLA, which was developed by Floreon Transforming Packaging Ltd. Conventional PLA is produced from sustainable (plant) feedstock, which means it has a lower carbon footprint and nonrenewable energy usage than any mineral-based thermoplastic. However, until now it has been renowned for its poor toughness and tendency to lose strength on storage in warm conditions, which means its use has been restricted to niche areas. Floreon Transforming Packaging Ltd says Florean addresses the need for a PLAbased bioplastic suitable for manufacturing degradable and compostable articles, such as bottles, but with improved mechanical, physical, chemical and thermal properties. Not only does Floreon have improved toughness, higher strength and durability compared to PLA, but also it is recyclable, biodegradable and requires far less energy to process compared to rival products, the company claims. Improved mechanical properties and optimised flow rates mean Floreon can be used in a variety of process moulding techniques to produce a wide range of types and sizes of applications, including packaging trays, cutlery and thin walled injection moulded parts, where the use of PLA has been limited in the past. In addition, improved processing efficiency means production time and energy consumption have been greatly reduced. Dr Andrew Gill, Floreon Technical Director, explained the value of the new patent. “This patent is very important to us – Florean has had a new patent granted

as a technology-led company it provides a competitive advantage that will enable us to create proprietary solutions that others cannot copy. By definition, patented compositions need to be novel and provide a benefit to society over previously available technology. So this patent, which protects our innovative bioplastic material called Floreon, is a clear demonstration that we have created a new way of gaining performance benefits not achievable by others.” Awareness of the need to reduce the amount of landfill waste and the desire to reduce dependence on fossil resources is increasing the interest shown in bioproducts by plastic processors and compounders. By delivering advanced technical properties, which increase product attractiveness and expand the range of uses for bioplastics, strong growth in demand for these materials is expected across the globe. Currently the patent has been granted in the UK, New Zealand and Australia. This success gives CEO and company founder, Shaun Chatterton, confidence that other patent offices will also approve the application. “With global demand for bioplastics set to rise by around 20 percent per year, we can see a huge export potential for Floreon. We are delighted with these first patent approvals, and are rapidly progressing patent applications across all major population centres - including US and Canada, China and Europe. Our aim is to have global protection for our technology so that we can promote Floreon internationally.” WWW.FLOREON.COM

BUYER’S GUIDE vibration welding

MATERIALS

Branson Ultrasonics

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

MASTERBATCH

CHILLERS/TEMPERATURE CONTROLLERS 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

BUY/SELL

Burgess Colours & Compounds, 1-10 Burgess Street, Middleport, Burslem, Stoke-on-Trent, ST6 3PD, T: 01782 819670 F: 01782 816133 Email: sales@burgesscolours.co.uk We are one of the UK’s leading supplier of black, white, colours and additive masterbatches

We at Vinyl Ltd

Vinyl Ltd Unit 40 Bishopton Drive Macclesfield Cheshire SK11 8TR

BUY/SELL & RECYCLE...

1 Flexible PVC compound, Prime, Repossessed, Regranulated, and Pulverised 2 Dry Blends 3 Polymer 4 PVC Raw Materials 5 Scrap Please let us have details of your requirements and/or materials you have for sale.

E info@summitsystems.co.uk W www.summitsystems.co.uk T 01827 265 843

DEHUMIDIFIERS Motan Colortronic Ltd

EXTRUSION SYSTEMS new and used

Cooper Plastics Machinery

Unit 12, Harmill Industrial Estate, Grovebury Road, Leighton Buzzard, Bedfordshire LU7 4FF T: 01525 850610 F: 01525 218008 E: cooperplastics@googlemail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, fly knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.

+44 (0) 1625 500912 07860 371294 +44 (0) 1625 420991 vinyl_ltd@mail.com

website currently being updated

MOULD RELEASE

n Premium granulators n Closed loop systems n Beside the press granulation n Cut out 3rd party recycling n Low energy design n 99% self-cleaning options n Full spares and services available

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

(with over 60 years experience in the vinyl industry)

Tel: Mob: Fax: Email:

NEW Suppliers for TRIA Granulators For thermoforming, blow moulding and film

ASSEMBLY hot plate welding Branson Ultrasonics

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

HEATING EQUIPMENT

pulse staking 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

colour masterbatch

ultrasonic welding

CONTROL SYSTEMS AND EQUIPMENT quality monitoring control 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.

DRYERS

Eclipse Buyers Guide_Layout 1 07

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.

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

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

MACHINERY & EQUIPMENT ANCILLARIES InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) New and used Granulators, Shredders, Pulverisers, Wash Plants Blades and Screens

The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

Blade Sharpening Ancillary Items Service – Repair - Spares UK & Ireland Agents for

Tel: 01827 838840 Email: info@granulators.org www.granulators.org

Telsonic UK Ltd

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

induction heating for platens and tools MF Induction Heating

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 F: 01543 574460 E: sales@mfinduction.com W: www.mfinduction.com BS EN ISO9001: 2000 registered. BS EN ISO9001:2008

HOT RUNNER SYSTEMS hot runner controllers

BUYER’S GUIDE

MACHINERY & EQUIPMENT LABORATORY MACHINES

METAL DETECTION & SEPARATION EQUIPMENT Motan Colortronic Ltd

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

NOZZLES & NOZZLE TIPS

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

STATIC CONTROL Arrowquint Ltd

Unit 2 Sanders Close, Finedon Road Industrial Estate, Wellingborough, Northamptonshire NN8 4HQ T: 08450 655455 F: 08450 655456 E: sales@arrowquint.co.uk W: www.arrowquint.co.uk Static control solutions, equipment sales and rental, repairs and on-site servicing. UK/Eire agent for Eltex – market leaders in static control systems.

TESTING EQUIPMENT

SERVICES TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

MATERIALS HANDLING AND STORAGE

INJECTION MOULDING

gravimetric/volumetric 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

PRINTING MACHINES pad

SCREEN CHANGERS

hopper loaders

Industrial Plastics Ltd

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

SECONDHAND AND RECONDITIONED ANGLO PLASTICS LTD

RECYCLING SYSTEMS Motan Colortronic Ltd

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

MIXING, FEEDING & DOSING

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

CHOOSE THE NUMBER ONE.

SCREWS & BARRELS

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

DM Machinery Ltd

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

DTL Machinery UK

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

Ray Ran Test Equipment Ltd

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

hardness - IRHD and shore MAPRA Technik Co — BAREISS For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

MOULDFLOW ANALYSIS

inspection & measurement MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER

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

3D PRINTING

3D Printing in Plastic & Rubber

TransXL International Ltd

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

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

Tel: 01420 88645

www.projet3d.co.uk

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

BUYER’S GUIDE PRINTERS printers of plastic mouldings

TESTINg/CONSULTANCY

Total Print Ltd

manufacturing management directory

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

enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com

PRINTERS TAMPO.SCREEN.FOIL

Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com

PARTS & SERVICE

SOFTWARE DIRECTORY

Gammadot Rheology Testing & Consultancy Services

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

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

BPR online ad_Layout 1 07/12/2012 11:41 Page 1

Keep up with the social side of BP&R The Word on the Tweet… @BritishPlastics, the official Twitter feed for British Plastics and Rubber magazine, keeps followers informed of breaking news, the latest event updates and industry insights that will keep social butterflies at the cutting edge of all things plastic and rubber. www.twitter.com

Let’s link up sometime Our ever-growing BP&R LinkedIn group provides a great forum for discussion if you are looking for a specific supplier, needing advice or looking for recommendations. It’s also a great way to provide feedback and share your experiences with colleagues or fellow readers. www.linkedin.com

www.britishplastics.co.uk

Epicor’s ERP (on-site, hosted & SAAS) manufacturing software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution. It seamlessly integrates with Epicor Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

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

real time production monitoring, scheduling and process monitoring intouch T: 01604 646144 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). PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/ SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts. Easy to use systems from a €600m company with over 30 years experience. SYSCON-PlantStar MTec Services Ltd T: 0114 2476267 F: 0114 2476267 E: mt@mtec-services.co.uk W: www.mtec-services.co.uk W: www.syscon-intl.com PlantStar systems provide customised, scalable applications that deliver real-time plant floor data from any machine, shift, and plant anywhere in your business. Affordable systems available for all size of processor. 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, Material traceability, bar-coding.

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

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NEWS FROM THE FRONTLINE

bp&r BRITISH PLASTICS &RUBBER 50

ASSOCIATED ORGANISATIONS

eaders of a certain age will remember the good for one, we have new Governments, groping towards fortune of Jed Clampett of ‘The Beverley Hillbillies’ greater legitimacy, struggling to restore oil production in the late sixties, who struck oil on his ramshackle to former levels. Territorial disputes, such as that between Tennessee holdings. The oil was China and Vietnam in the South China Seas, also have PHILIP LAW, DIRECTOR- hailed as “Black gold, Texas tea,” the potential to cause serious international stress, GENERAL OF THE BRITISH and even then, with oil just a few even threatening to escalate into full-scale warfare as in the Ukraine. If this is not enough, conspiracy theorists, PLASTICS FEDERATION, dollars a barrel it was seen as an immediate passport to untold if they are to be believed, maintain that the price of oil TAKES A LOOK AT THE can be manipulated and used as a diplomatic weapon to riches. Poor old Jed would certainly SLIPPERY SITUATION OF have lost count of his wealth by isolate offending states. OIL AND HOW WITH SOME the 1970s and become quite All these factors of course are much less susceptible to COMPLEX INFLUENCING bewildered by its fluctuations. traditional risk management techniques and quantitative FACTORS, WE MIGHT Indeed, he wouldn’t have had any analysis. They are not only beyond the comprehension of Jed Clampett, but also the most sophisticated analysts HAVE TO “LEARN TO tools to help him anticipate oil price the financial world can sport today. We will have to learn movements because ‘event risk’ LIVE” WITH INCREASING suddenly entered his settled world to live with increasing unpredictability. UNPREDICTABILITY. and this gradually became the chief One very unfortunate ‘unintended consequence’ of determinant of oil prices. the drop in oil prices is that the business of recyclers involved in the plastics packaging market has been Whilst the recent decline of oil prices and its consequence of dramatically lower polymer prices may, severely compromised. The problem, however, doesn’t in one sense, have come as a shock, if we take a much stop with the recyclers, as the recycling record of the longer perspective we realise that we whole plastics packaging supply chain have actually been on one very long ‘big is put at risk. The BPF has called on dipper’ rollercoaster ride since 1973 companies in the downstream of the industry, when they are considering their and that the political risk factors which materials selection policies, to keep to the have come to shape oil prices have never WE WILL HAVE TO fore the fact that high recycling targets been as intense as they are today. Their LEARN TO LIVE first serious manifestation was in 1973, have to be met under the Packaging Waste WITH INCREASING (Producer Responsibility) Regulations and with an OPEC oil export embargo by several Arab states prompted by their hostility UNPREDICTABILITY. that many individual Corporate Social Responsibility programmes support to Western support for Israel. This was increased recycling levels. The carbon followed in 1979 by the Iranian revolution, which caused a further oil crisis. In the saving and resource efficiency benefits of meantime, the development of competing plastic products has been enhanced by the sources of energy, nuclear power, renewables and now increased levels of plastics recycling seen today. Plastics shale gas added to an increasingly complex picture. recycling is such an essential component of the whole Today, we now have the unpredictable behaviour chain’s sustainability message and we cannot allow our of new ‘states’, some self-styled, like ISIS, others, more record to regress. legitimate, like Southern Sudan, taking control of oil production. In some older established countries, Iraq WWW.BPF.CO.UK

WWW.BRITISHPLASTICS.CO.UK

Temperature Control Units Thermo-5 • Highly accurate ultrasonic flow rate measurement • Solely non-corroding materials in the hydraulic circuit • Bypass and proportional valve result in vaporisation-free cooling without scaling • Sealless pump in stainless steel Agent for UK & Ireland KraussMaffei Group UK Ltd 410 Europa Boulevard, Gemini Business Park Warrington, WA5 7TR Phone +44 (1925) 644100, Fax +44 (1925) 234284, info@kraussmaffei.co.uk

AF-Complex GA

AF-Complex® GA – bad odours haven’t got a chance!

8th - 9th July 2015 Come and meet us at stand E4!

Bad odours can occur wherever organic materials decompose, and the volatile components of decomposition reach the ambient air – in the waste bin, for example. Whilst these unpleasant odours cannot be avoided, they can be drastically reduced before they become an annoyance.

With AF-Complex® GA, odour-causing substances are absorbed into the plastic. A combination of special additives chemically bind the molecules, preventing them from spreading. Optionally, the odour absorber can also contain a fragrance, such as citrus, which is released gradually. AF-COLOR – active and intelligent masterbatches!

Our partner in UK: K.D. Feddersen UK Ltd. Member of the Feddersen Group Venture Point · Towers Business Park

info.uk@kdfeddersen.com

Rugeley · Staffordshire WS15 1UZ

www.kdfeddersen.co.uk

Phone:

+44 1889 5802 12 / 13

Fax:

+44 1889 5802 11