BP&R Jan/Feb 2022

British Plastics

and Rubber

bp&r jan/feb 2022

2 2 0 2 r o f s n io t lu Reso 1. Eat healthy 2. Get fit 3. Drink more water 4. Be Better 5. Buy Bole

BOLE AIMS TO UTILISE THE CHALLENGES OF THE MANUFACTURING INDUSTRY TO MAKE THINGS BETTER FOR ALL - SEE PAGE 4.

DRIVING FORCE Dr Begoña Galindo discusses her expertise and role in the VETERIA21 Project.

FASTEN UP HCL Fasteners and Sumitomo (SHI) Demag have accelerated productivity and carbon neutrality.

No 3 war pa la

COMPOSED Be Better. Buy BOLE Erin Moussiaux, VP technology at Exel Composites, explains how fire considerations influence design.

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editor’s letter

www.britishplastics.co.uk head of content: dave gray

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General perceptions toward plastics have not been great – frosty, even – and they’re not out of the woods yet.

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rob coker, editor

I

n 2022, many members of the plastics value chain will still be looking to earn their stripes with regards to sustainability and circular economy, particularly as they prepare for extended producer responsibility measures as a result of the introduction of the plastics tax, for which I am assured the BPF is indefatigably encouraging its members to get their teeth into.

Might this also be the year that those vociferously opposing plastics and decrying them as little more than an environmental nuisance finally throw down their spears and help shoulder some of that burden?

What will be interesting, on the other hand, is observing how industry leaders will be rising up to the challenge of such rivals.

Sure, the general perceptions toward plastics have not been great – frosty, even – and they’re not out of the woods yet, but given time and patience, as well as plenty of engagement with the public and in circular economy practices, folk will begin to remember the numerous ways in which plastics can help to improve lives.

the big story

M MATTHEW HOLLYOAKE, BOLE UK SALES MANAGER, EVALUATES THE CHALLENGES AND OPPORTUNITIES OF 2021, AND LOOKS FORWARD TO A PROSPEROUS 2022.

2021 has been a highly challenging year for the UK plastics industry. From lockdowns, material price increases and shortages, to more politically relative issues such as container prices and import delays, UK manufacturers have had to show their mettle, as well as their resilience. As a leading supplier of premium injection moulding machinery and components, BOLE Machinery Limited has managed to support its new and existing customers through these challenges with new machines well-kept delivery promises.

We are very proud to announce an extremely successful 2021 for BOLE, a year in which we have acquired 11 new customers, as well as a record number of machine orders and deliveries.

Furthermore, and in summary of our long list of successes over the past year, we also became proud members of the highly respected industry organisations PMMDA Trade Association and the British Plastics Federation, a huge honour.

In late September, BOLE Machinery Limited made its in inaugural appearance at the UK’s biggest plastics and rubber industry trade fair, Interplas, at the NEC in Birmingham. The event turned out to be a real eye opener into how successfully we could collaborate with various players and stakeholders from across the plastics manufacturing value chain – from materials suppliers and automation equipment specialists, to recyclers and converters – and in spite of the many obstacles thrown our way. We received an overwhelming welcome and a huge number of visitors to the BOLE stand, many of whom came with enquiries

Resolutions for 2022 1. Eat healthy 2. Get fit 3. Drink more water 4. Be Better 5. Buy Bole

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and left with orders. I would therefore like to extend a great big thank you to the Interplas UK team and organisation, and we are already looking forward to returning to Birmingham NEC in 2023.

We also attended our first Plastics Industry Awards as a Prime Machinery finalist, which was a great honour and recognition of our hard work. As the year came to a close, we became a BOLE PARTNER for the UK and Ireland, which now gives us the security to buy a larger facility in the UK to help and support our European colleagues with available stock machines and spares.

After a very successful Christmas promotion on our stock machines, we had to start the new year 2022 with an empty showroom. Thankfully, however, our new stock machines arrived a few days ago to fill up our showroom once again, giving us a full complement of machine tonnage ranging from 100-350t, all ready for immediate delivery.

2022 has started on a very positive note with six new machine orders (some of which are multiple) from six new customers in the UK that have now joined the BOLE Family and taken advantage of our stock machine availability.

Our EKS Servo Hydraulic machines with unparalleled energy efficiency and reliability makes this choice the only one on your new year’s resolution list.

Matthew Holyoake is responsible for machine and project sales across the whole of the UK and Ireland along with the management of the sales team to ensure the rapid sales growth continues.

Be Better - Buy BOLE

The Interplas event turned out to be a real eye opener into how successfully we could collaborate

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In cooperation with

#newlifetoplastic

1st EDITION

Resolutions for 2022 1. Eat healthy 2. Get fit 3. Drink more water 4. Be Better 5. Buy Bole

On the Cover

17 FEATURE

BOLE, evaluates the challenges and opportunities of 2021, and looks forward to a prosperous 2022. See page 4

The partnership between HCL Fasteners and Sumitomo (SHI) Demag has accelerated productivity and carbon neutrality.

Rise of the machines

Regulars and Features 8 INDUSTRY NEWS

3 EDITOR’S LETTER

20 FEATURE

12 MACHINERY NEWS

14 FEATURE

Erin Moussiaux, VP technology at Exel Composites, explains how fire considerations influence composite design.

15 WOMEN IN PLASTICS

Stäubli’s Simon Jenkins looks at the need to ensure an automation dividend for employees if businesses are to maximise the benefits of their investment in robotics and automation, through the retention and upskilling of their workforce.

27 FEATURE

15 INTERVIEW

Europe mixed plastic waste supply to further tighten

Delivering the automation dividend for employees

Women in Plastics

Dr Begoña Galindo, AIMPLAS Sustainable and Future Mobility Group Leader, discusses her expertise and role in the VETERIA21 Project.

6

Fasten up

Composed

From the waterways to better days

Bell Packaging introduces Reused Ocean Plastic to its 2022 portfolio.

33 COMMENT

Mark Victory, Senior Recycling Editor at ICIS, discusses why single-material bale prices have surged and mixed-polyolefin bale supply continues to tighten.

21 POLYMERMAN 26 PACKAGING NEWS 31 MASTERBATCH & ADDITIVES NEWS 35 BUYERS’ GUIDE 38 NEWS FROM THE FRONTLINE

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www.cjpsales.co.uk | Specialists in technical polymers

INDUSTRY | NEWS Michelle Bryson named Global Sustainable Packaging Leader for BW Packaging Systems BW Packaging Systems, the packaging equipment arm of Barry-Wehmiller, has announced the appointment of Michelle Bryson to the role of Global Sustainable Packaging Leader.

Bryson will lead the development of a sustainability roadmap for BW Packaging Systems, and collaborate with team members and customers on several fronts, including the usage of responsible materials, recyclability,

packaging design, waste, carbon footprint reduction and more.

Bryson brings more than 30 years of packaging development experience to BarryWehmiller. In her previous roles, she developed and supported the development of packaging innovation and sustainability roadmaps, having led PepsiCo’s packaging team in an initiative to commercialise rPET for

Composites Evolution expands Evopreg range Composites Evolution has announced the launch of a new range of unidirectional thermoplastic tapes to sit alongside its existing line-up of Evopreg prepregs.

Thermoplastic tapes, also known as thermoplastic prepregs,

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can be used in a wide variety of markets and applications, including flexible pipes for oil and gas and water transportation, pressure vessels, and for providing local reinforcement to preformed components.

Marketing Director,

the Tropicana flagship brand, “I’m honoured to be working with an organisation that is so eager to drive sustainable change across the packaging industry,” Bryson said.

“The BW Packaging Systems team has already taken steps to lower its carbon footprint, and together, we will incorporate sustainable design principles that will create lasting, positive change.”

Ben Hargreaves, said: “Lightweighting is a key enabling technology for a number of markets – particularly transport-related ones such as battery electric vehicles, hydrogen fuel cell vehicles, eVTOL passenger vehicles and drones. These are all, potentially, high-volume applications that demand short production cycle times. Evopreg thermoplastic

This ability to be repeatedly re-formed opens the door to much easier recycling

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unidirectional tapes are ideally suited to this demand as they can be rapidly processed via a number of methods, including automated tape placement, tape winding and compression moulding.

“Because they can be repeatedly re-formed (via the application of heat and pressure), Evopreg thermoplastic tapes are also very wellsuited to multi-stage processing, meaning they are an excellent choice for producing hybrid structures, inserts or over-moulded components. In addition, this ability to be repeatedly re-formed opens the door to much easier recycling than is currently possible with thermoset composites.”

The first product families being launched are Evopreg PA polyamide tapes, and Evopreg PP polypropylene tapes, with further product lines expected as new customer requirements emerge.

www.britishPLASTICS.co.uk

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Specialists in technical polymers | www.cjpsales.co.uk

Plastribution Group moves to new state-of-the-art offices Plastribution has moved into new state-of-theart offices close to its existing premises in Ashby-de-la-Zouch, Leicestershire. Being part of the Japanese Itochu Corporation, the new offices were opened at a recent event by Takanori Morita, Executive Officer of Itochu Corporation, Chief Executive for Europe and the CIS Bloc; CEO of Itochu Europe.

The group had outgrown its former premises and needed a new space that could provide ample room for further expansion, while meeting the needs of different types of worker – both remote and officebased. The fit out of the new offices, which was carefully chosen and designed to match the needs of all employees, was carried out by workplace consultants and commercial office interior fit-out specialists, Blueprint Interiors, based locally.

Digital display

solutions, virtual white boards and advanced digital technology have all been included to allow hybrid style meetings, providing an environment where employees can communicate better.

Creative feature walls have been added, utilising the design assets of each brand within the group, and materials and furniture were carefully selected to provide a consistent feel throughout the offices.

Managing Director Mike Boswell said: “As the pandemic has forced the adoption of new ways of working, our challenge was to make the workplace environment more attractive than home.

Like most businesses,

As the pandemic has forced the adoption of new ways of working, our challenge was to make the workplace environment more attractive than home we have had to reimagine the role of our offices in creating a safe, productive, and enjoyable environment for employees.

“I cannot speak highly enough of BluePrint, who have taken time to understand who

we are and what we do, before designing a space that is a perfect fit for our business. They have very much adopted our working title of the ‘Plastisphere’ which is an adaptation of Plastribution’s commitment to being a learning organisation, incorporating an outstanding physical environment, a great business culture, excellent human capital, robust systems and processes and strong leadership.

“Our new environment is a thing of beauty in a multitude of terms including design and ergonomics.”

recycle over 100 tonnes of product generated by the manufacturing process every year – the equivalent to 10kg of waste every hour.”

The new project will develop an innovative process for cost and

energy-efficient recycling and repurposing of this waste.

Pete Lee, Head of Quality at Globus Group, added: “At Globus Group, we acknowledge our responsibility to the NHS, supporting it in delivering a ‘net zero’ sustainable future, and the long-term welfare of future generations. This technology will be a real game changer in the way we tackle our PPE waste.”

10kg of plastic PPE waste to be recycled every hour Plastic PPE waste is to be given another life in a ground-breaking recycling collaboration between Heriot-Watt University and UK-based PPE manufacturer Globus Group.

The soaring quantities of plastic PPE that have been thrown away during the pandemic has been widely criticised as the world strives to reach Net Zero goals. Since the start of the pandemic, an estimated 8.4 million tonnes of plastic waste has been generated from 193 countries, the majority of which ends up in landfill or the environment.

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A new Knowledge Transfer Partnership (KTP) project is set to revolutionise how used plastic PPE is treated to turn the waste into pyrolysis oil, which can then be refined into new commercial products. The project, which aims to create a robust circular economy approach for plastics, will run for two years.

Aimaro Sanna, Assistant Professor in chemical and process engineering (EPS) at Heriot-Watt University, said: “Initially, the research will help to

www.britishPLASTICS.co.uk

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pioneering plastics

MACHINERY | NEWS Wittmann’s Sonic 108 can pick and place at speed Wittmann’s new SONIC 108 robot was launched at the end of last year for use with moulding machines of clamping forces from 150 to 500 t.

In contrast to the larger SONIC models, the SONIC 108 has been fitted out with a fixed demoulding axis, which has proved extremely advantageous for small injection moulding machines. Short overhangs and a compact control cabinet simplify the CE-compliant housing of the automation cell.

During the active demolding stroke movement above the mold space, no axis elements are pushed towards the injection unit, which substantially simplifies the enclosure especially in the area behind the fixed clamping plate of the machine.

Wittmann has

optimised the robot for high-speed parts removal – particulary for packaging sectors and for pick-andplace applications. It is designed for cycle times below 4 s, with IN/OUT times kept below 0.9 s.

To facilitate high-speed removal, the robot’s drive system concept has been completely re-engineered, with the SONIC 108 still able to handle payloads up to two kilogrammes.

The familiar Wittmann functions, such as iVac vacuum control with blow-off function, axis activation, SmartRemoval and digital visualization of the axial movements are all part of the appliance’s standard equipment.

The robot is supplied with horizontal strokes of up to 1,500mm and vertical strokes of up to 1,000mm.

Wittmann has optimised the robot for high-speed parts removal particularly for packaging sectors and for pick-and-place applications

Borche UK reports another highly successful year during 2021 Borche UK gained 10 new customers during 2021, averaging one new customer every five weeks over the course of the year for the business’s increasingly popular range of Servo Hydraulic Moulding Machines.

Borche UK now have over 80 individual customers in the UK and Ireland from both independent moulders right through to a number of multi-national groups of which Borche are and remain the preferred supplier, the company now have in excess of 330 machines installed on the UK and

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Irish plastics market up to and including 2,200 tonne.

The company’s presence at Interplas 2021 was extremely positive for Borche UK both in terms of confirmed orders placed on the stand during the exhibition together with the high level of enquiries and visitor attendance over the three days from both existing and potential customers alike.

In line with the continued sales growth for Borche, the service team was also expanded during 2021 and a further expansion is

The service team was also expanded during 2021 and a further expansion is planned for the coming year

www.britishPLASTICS.co.uk

planned for the coming year as Borche UK are a very service-focused business.

The company has a very positive order book to carry over into 2022 and looks forward to further expansion over the coming months and in the future.

The parent company Borche China market throughout the world and have also experienced a very strong current order book. Based on the success of Borche UK, which represents the first direct branch for Borche in Europe, the company has now established similar business models elsewhere in other key markets.

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pioneering plastics

Steady Eddy: Bunting sees Eddy Current Separator and ElectroMax sales growth in 2021

The demand for metal separators increased in 2021 on 2020, with exceptional growth in sales of both Eddy Current Separators and ElectroMax Overband and Suspension Magnets.

Sales growth followed an expansion in representation in overseas markets and increasing manufacturing capacity at Bunting’s Redditch facility in the UK. At the Redditch manufacturing plant, Bunting specialises in the design and manufacture of magnetic separators, electrostatic separators, and metal detectors.

Sales of Eddy Current Separators grew by 50 per cent in 2021 on 2020.

Adrian Coleman, General Manager of Bunting-Redditch, said: “Our range of Eddy Current Separators includes both concentric and eccentric designs, which has proved very important. We are also able to conduct controlled material tests in our Recycling Test Centre, often with the customer present. During such tests we get to understand the material and separation objective, which then enables proposing the optimum solution for any given project.”

The Eddy Current

The separation technology has evolved with design optimisation Separators use a highspeed magnetic rotor to separate non-ferrous metals from non-metallic materials. BuntingRedditch first developed an Eddy Current Separator in the early 1990s. The separation technology has evolved with design optimisation and Bunting-Redditch is widely regarded as a world-leading supplier. A recent project involves the recovery of aluminium from crushed dross.

Coleman added: “The ElectroMax is one of our most successful and innovative new products […] We took the design of our traditional Electro Overband Magnet and reconfigured the coil and the cooling system to develop a lighter and stronger Overband. This has proven exceptionally popular in mining and recycling applications.”

ElectroMax Magnets sit suspended over conveyors, either across the belt or over the head pulley, and separate ferrous metal from transported nonmagnetic materials.

The ‘Overband’ design includes a self-cleaning belt to transfer captured metal into a collection area, whilst the ‘Suspension’ model features only the magnet block and requires manual cleaning. Overband and Suspension Magnets are the most commonly used magnetic separators in the world, with BuntingRedditch manufacturing and supplying since the foundation of the company.

Coleman concluded: “During the past two challenging years, our focus has been on investing in our manufacturing facilities and developing our separation technology. This has stimulated our sales growth in 2021 and provides the perfect platform for sustained growth in 2022.”

Cygnet Texkimp builds thermoplastic lab line to support innovation in plastics technology Cheshire-based fibre handling and converting technology specialist Cygnet Texkimp has installed a lab-scale version of its thermoplastic processing equipment at its Innovation Centre to enable faster development of plastics technology through dedicated customer trials.

The company is making its Direct Melt Impregnation Thermoplastic Composite Line available to help companies develop new materials and material combinations to manufacture thermoplastic prepregs and tapes.

Research and Development Specialist Ben Lloyd said: “We’re enabling manufacturers to explore a new and novel technology, prove out their concepts, and carry out innovative product development before choosing to invest. The fast-moving composites sector needs this kind of dedicated environment to speed up adoption of new technology and support innovation. The response from the market has been phenomenal and we’re completing trials on a wide range of different materials.”

At 5m long and 1m wide, the lab-scale machine is half the size of the full-scale line launched in 2020.

It is applicable for polymers ranging from polypropylene to PEEK and can process a range of fibres including carbon fibre, glass fibre and

hybrid fibres.

The company is working with organisations from the automotive, aerospace, construction and energy sectors, many of which want to produce their own materials to fulfil their exact needs.

Lloyd added: “This collaborative approach enables both parties to refine and advance the technology to achieve a solution that is tailored to the application and proven in its effectiveness.”

The technology combines standard polymer pellets with a polymer and fibre matrix extrusion methodology to simplify and shorten the process of manufacturing thermoplastic prepreg materials while maintaining the quality of the end product.

It was designed to transform the way highgrade thermoplastic composites are manufactured and make them more easily accessible to highvolume markets.

Thermoplastic parts in automotive applications enable manufacturers to make vehivcles more easily reparable and recyclable as well as cleaner and less expensive to manufacture.

Cygnet Texkimp is also a leading manufacturer of thermoset prepreg machines and began developing its thermoplastic technology as interest in the methodology has grown in line with the expansion of the composites market.

The repsonse from the market has been phenomenal and we're completing trials on a wide range of different materials

www.britishPLASTICS.co.uk

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feature

S STÄUBLI’S SIMON JENKINS LOOKS AT THE NEED TO ENSURE AN AUTOMATION DIVIDEND FOR EMPLOYEES IF BUSINESSES ARE TO MAXIMISE THE BENEFITS OF THEIR INVESTMENT IN ROBOTICS AND AUTOMATION, THROUGH THE RETENTION AND UPSKILLING OF THEIR WORKFORCE.

This collaboration between the operator and the robot is a benefit to both parties, with the operator generally being removed from the mundane tasks.

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DELIVERING THE AUTOMATION DIVIDEND FOR EMPLOYEES

E

ver since robots started to become a significant part of our manufacturing processes, the benefits of the technology, in terms of performing heavy, dirty, repetitive, and sometimes dangerous tasks have been extolled. Clearly for businesses, the automation dividend is seen in improved performance, productivity, quality, and often lower manufacturing costs. However, alleviating humans from these activities is just one part of the story. Today, with labour shortages blighting many businesses, employee retention has never been more important.

The perception of a clear dividing line between tasks for robots and tasks for humans started to become blurred when collaborative robots entered the workplace. Clearly, risk assessments need to be carried out to ensure safe and true collaboration, but the continued uptake of these systems confirms that they do have a place in our manufacturing environments.

This collaboration between the operator and the robot is a benefit to both parties, with the operator generally being removed from the mundane tasks to add value through human flexibility and dexterity.

This represents one level of improving an operators’ working environment and giving them a more interesting role.

The continued shortage of labour in many of our manufacturing sectors has sparked a new and higher level of interest in robots and automation, and perhaps for the first time, businesses are looking even more closely at how they can re-deploy, retrain and upskill their existing workforce alongside their investment in automation to futureproof their production.

The often-voiced mantra of ‘robots cost jobs’ has over the years proven to be largely false. It has now become clear that in many cases robots and automation are the route to not only saving jobs, but the means of providing employees who were once restricted to mundane tasks the opportunity to obtain new skills and develop as individuals.

ENSURING AN EMPLOYEE AUTOMATION DIVIDEND So how can one individual’s role change as a result of the introduction of robotics and automation? It is true that many of the tasks once deemed to be the domain of the operator are now being performed by a robot. However, despite the common perception of 24/7 unmanned running, robots and automation do at times require support. This is especially true in applications where multiple product variants are being produced. Although it is sometimes possible to automate many changeover tasks, in some cases there is still the need for human intervention to perform set-up tasks such as swapping over grippers, fixtures and organising product for assembly or processing. The role of the operator here is now more akin to that of a technician.

The once mundane tasks are now replaced with interesting operations which require increased skills and deliver a greater level of responsibility. Taken a step further, with the company investing in additional training, this one employee could also take responsibility for robot programming and performing initial diagnostics on the robot cell should problems arise.

There are also other opportunities for businesses to entice existing employees to think about upskilling through additional training in some maintenance tasks. For those individuals who show yet more potential, further training and education to obtain formal qualifications will be greatly appreciated by the individual and the business will have grown their skill base in-house as opposed to spending often large sums on ongoing recruitment to replace disillusioned employees. Investing in the existing workforce will not only increase the overall skill levels within the business, but also foster greater loyalty from employees who will have been able to realise a tangible dividend for themselves from the company’s investment in robotics and automation.

www.britishPLASTICS.co.uk

FEATURE

SPOTLIGHT

DR DR BEGOÑA GALINDO, SUSTAINABLE AND FUTURE MOBILITY GROUP LEADER AND CO-ORDINATOR OF THE EXCELLENCE SCIENCE GROUP AT AIMPLAS, SPECIALISES IN MATERIALS RESEARCH IN NANOCOMPOSITES, FLAME-RETARDANTS, LONG-FIBRE REINFORCED THERMOPLASTICS AND CONDUCTIVE COMPOSITES, AMONGST OTHERS. HERE SHE DISCUSSES HER EXPERTISE AND ROLE IN THE AIMPLAS-LED VETERIA21 PROJECT.

DRIVING FORCE

How is your expertise helping drive the mobility sector towards greener materials and therefore greener vehicles?

One of the main current social challenges related to global warming is the reduction of emissions and polluting gases related to transport. Polluting gas emissions can be reduced by optimising the fuel consumption of combustion vehicles and increasing the use of electric vehicles. From the manufacturing point of view, modifications can be made considering material selection. Materials have a direct impact on fuel consumption and battery distance range. The two main research lines are Sustainable Materials and Lightweight Structures.

Is it surprising that the transport industry has taken this long to replace metal components with lightweight thermoset composites?

No, it is not. Decreasing the vehicle weight by 10 per cent will reduce 6-7% gas emissions in combustion vehicles. In electric vehicles, a weight reduction strongly increases the battery distance range. Composites can decrease weight by 50-70% compared to metal. Nevertheless, it must be pointed out that, to achieve high reduction, a redesign of the metal part must be implemented.

Traditionally, thermoset composites were proposed as an alternative, but their low production rate and mechanical recyclability promoted the development of greener solutions. Thermoplastic composites are presented as an industrial alternative to thermoset composites due to their reduced weight, high mechanical resistance with no loss of ductility, adaptability to different manufacturing processes and short manufacturing cycle times, and their abililty to form hybrid materials, as well as their circularity and reduced waste.

Which industry and academic players are collaborating with AIMPLAS in the VETERIA21 Project, and what are its targets?

VETERIA21 is a project carried out by AIMPLAS and funded by the Valencian Regional Government

Monitoring the progress toward gender equality in science has become a well-established activity of the European Union.

aiming to increase the knowledge on lightweight material development and processing. AIMPLAS is designing and optimising a UD-tapes and LFT pellets processing line to introduce new functionalities in the final material. The case study is focused on LI battery cases. Therefore, the material requirements include EMI shielding and fire-retardant properties. Matrix materials explored are polyamides, recycled polyethylene terephthalate and polypropylene. The project received support letters from Faurecia, ITERA Engineering and Industrias Alegre.

How can inclusivity in industrial research help generate further innovations? Particularly from women?

Industry must be aware of the importance of their research activities to increase their competitiveness. Usually, research is marketdriven. There is a social or industrial need, and the scientific community looks for solutions. Research from academia needs the collaboration of industry to increase the maturity of a technology. Industrial research involvement at low TRL steps increases the research effectiveness by setting the technical and economic specifications. Nevertheless, sometimes it’s the basic research that discovers new solutions, which can create new business models. Anyway, industrial research is key to upscaling the results to industry and, as a result, to society.

Fortunately, research lines carried out by many companies and research centres are gender independent. Monitoring the progress toward gender equality in science has become a well-established activity of the European Union research policy (Directive 2002/73/EC), which focuses on the implementation of the principle of equal treatment for men and women.

In which other sectors can your expertise be applied in order to drive further sustainability and innovation?

Lightweight materials are needed in many mobility sectors due to the electrification of transport.

Aeronautics, naval, railway, defence and space are also interested in these developments. Moreover, construction and energy are two other markets to be explored. Reinforced thermoplastic pipers for CO2 transport, pultruded thermoplastic profiles, hydrogen tanks reinforcement is some of the areas where AIMPLAS is applying the VETERIA21developed technology.

www.britishPLASTICS.co.uk

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26-28 SEPTEMBER 2023

Exhibitt with Exhibi wit ith hu uss Interplas is back in 2023, bringing with it the opportunity for you to experience the UK’s largest plastics industry exhibition showcasing the full spectrum of plastics processing machinery, materials, software, services and ancillaries in one place.

It’s also the only plastics event in the UK where visitors can see working machinery LIVE on the show floor and where they’ll come to compare, contrast and buy.

With an expected 12,000+ attendees across the three-day event, as well as new features and an expanded floorplan, now is the time to position yourself as a company that can offer solutions, showcase innovation and offer expertise to an audience known for its quality and purchasing power.

@InterplasUK #InterplasUK www.interplasuk.com +44 (0) 1244 952 519

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FEATURE

T THE PARTNERSHIP BETWEEN HCL FASTENERS AND SUMITOMO (SHI) DEMAG HAS ACCELERATED PRODUCTIVITY AND CARBON NEUTRALITY.

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pioneering plastics

FASTEN UP

ath-based strap, clip and clamp manufacturer HCL Fasteners continues to demonstrate its commitment to the sustainability agenda. With three of its injection moulding machines now all-electric IntElects from Sumitomo (SHI) Demag, powered by 500 roof top solar panels, the company’s deliberate environmental stewardship is a shining example of the role SMEs can play in attaining carbon neutrality.

Despite having fewer resources to throw at the sustainability mission than larger corporates, the family-owned business, which has expanded into the US by opening a distribution hub in Houston, is fostering a ‘can do’ sustainability culture with its latest technology investments.

A long-term Demag advocate, this year the manufacturer of high-strength hose clamps, non-corrosive offshore strapping, and renewable energy farm bandings upgraded its production line by installing two 75 tonne and one 50 tonne IntElect machines. Another 75 tonne machine is being delivered in February 2022.

Previously, HCL commissioned three Systec 50 tonne hydraulic legacy systems. Managing Director David Coles said: “As a worldwide supplier of robust polymer clamping solutions and tension tools serving such a diverse international client base, we need to balance resilience and agility alongside constantly innovating ways in which we can lessen our environmental impact. This is especially important given the collective action being taken and the pressures being placed on supply chain transparency.

Consequently, we are always seeking more ways to address the climate crisis and accelerate our decarbonisation efforts.”

PRODUCING MORE, USING LESS With energy consumption responsible for approximately two thirds of greenhouse gas emissions, the precision and energy efficient IntElect’s are predominately powered by a 130kW solar-panel system.

Comparative tests performed by Sumitomo (SHI) Demag on the new 75 tonne IntElect’s has resulted in a minimum 42 per cent energy saving.

Precision moulding is equally critical for safety, with HCL manufacturing tensioning tools to install high-strength cable clamps and sea straps in extreme conditions.

Even with a bigger machine and the addition of robotics.

In addition to improving HCL’s energy consumption metrics, the three machines have collectively boosted productivity by up to 30 per cent. For an SME and ‘climate positive’ business, this helps tackle the misnomer that all-electric efficiency is purely linked to reducing your emissions.

Coles added: “Equipped with robotic sprue separators, our new IntElect’s have proven that it is possible to significantly optimise our resources and increase commercial productivity without having a detrimental environmental impact.”

Precision moulding is equally critical for safety, with HCL manufacturing tensioning tools to install high-strength cable clamps and sea straps in extreme conditions, including submerged marine environments, offshore oil and gas rigs, wind farms and underground mines.

Maintaining an incredibly consistent melt cushion and stable process has noticeably improved moulding accuracy, Coles continued, aided by the in-built hot runner and non-return activeLock valve. The addition of cartesian robots on all three IntElect machines supports HCL’s self-sustaining manufacturing approach and eliminates parts getting stuck at source: “Production consistency for a lights out operation like ours is critical to operational efficiency. I’m now confident that I won’t come into the factory the next day to encounter 12 hours of lost production time.”

As well as being markedly more hygienic and easier to maintain, Coles claimed that the automatic resetting of clamp forces and intuitive control panel made the transition to the IntElect machines seamless: “Switching from the NC4 to the NC5+ control panel could not have been easier. Even the page numbers on the control system are the same. From everyone’s perspective, our new IntElect’s are even easier to use.”

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feature

W WITTMANN BATTENFELD DISCUSSES THE BENEFITS OF ITS SHOWCASE SMARTPLUS INJECTION MOULDING RANGE.

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State-of-the Smart

he highlight of the WITTMANN BATTENFELD exhibition at last Autumn’s Fakuma 2021 show in Southern Germany was the company’s new SmartPlus injection moulding machine.

The outstanding features of this servo-hydraulic machine are its high level of cost efficiency, energy efficiency and repeatability. Global interest has been high since its unveiling.

The SmartPlus 180 is the first model that builds on the proven concept of the SmartPower series from WITTMANN BATTENFELD. The name given to the SmartPlus machine series derives from its large number of “smart” attributes, from the compact design of its machine body, its intelligent, energy-saving drive system and simple, central hydraulic clamping system, right up to injection control via a highly dynamic servo drive.

Use of proven technologies and carefully selected options have made it possible to offer the SmartPlus with short delivery times and an excellent price/ performance ratio.

The SmartPlus comes with the proven UNILOG B8 control system logic and the high-performance B8X hardware. These enable a higher clock frequency, shorter response times and higher repeatability in parts production, with user friendliness and the familiar visualisation concept remaining unchanged. Like all other machines from WITTMANN BATTENFELD, the SmartPlus fully supports the integration of robots and auxiliaries under WITTMANN 4.0.

The SmartPlus is also equipped with the KERS energy recovery technology originally designed for the company’s range of EcoPower machines.

To enable processing of regrind without any problems in the interest of sustainable production, this machine is also offered with the HiQ Flow® application software, a program to offset the viscosity fluctuations which often occur whenever this type of material is being processed.

All SmartPlus plasticising/injection units are freely accessible, compact and swivel-mounted. The machines are all equipped as standard with a wearresistant plasticising unit.

Another special feature of the SmartPlus is its further improved “Drive-on-Demand 2.0” drive technology.

It increases the machine’s response speed even more by a booster unit specially developed inhouse, which enables a higher clock frequency. This drive unit is only activated as long as required for movements and pressure generation. During cooling times or cycle breaks for parts handling, the servo drive remains switched off and consumes no energy.

In operation, “Drive-on-Demand 2.0” is the basis for highly dynamically controlled machine movements and short cycle times.

Like the SmartPower, the SmartPlus is also available as an Insider production cell version with an integrated parts handling system, conveyor belt and protective housing permanently connected with the machine, furthermore as an Ingrinder model with an integrated sprue picker, vacuum conveyor and granulator.

The machines are all equipped as standard with a wear-resistant plasticising unit.

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FEATURE

E ERIN MOUSSIAUX, VP TECHNOLOGY AT EXEL COMPOSITES, EXPLAINS HOW FIRE CONSIDERATIONS INFLUENCE COMPOSITE DESIGN.

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he mechanical properties of composites are normally the primary considerations in the design process. However, in applications where the risk of fire is a factor, such as in transportation and construction, this becomes the primary consideration when specifying composite solutions.

With the use of composites in such applications, improving knowledge of their fire performance is becoming a safety-critical issue. Generally, there are three main fire performance considerations for manufacturers. These are how difficult it is for the material to ignite, how fast the fire spreads, and how much heat it generates. How much smoke will develop and how quickly, and how toxic the smoke is are also considered.

These considerations are typically referred to as FST, fire smoke and toxicity, properties.

It is thus common for composites manufacturers to incorporate flame-retardant additives into the materials, reducing or delaying the combustion process. The nature of these varies depending on the application and any relevant regulatory requirements.

TRADITIONAL APPROACH Halogenated compounds are a broad category of flame-retardant additives that were traditionally seen as the first choice for composites manufacturers because of their high efficiency and relatively low cost. Halogenated additives work by eliminating the highly reactive free radicals generated in the thermal decomposition of polymers during combustion. By hampering oxidation reactions in the combustion process, they can effectively kill the flames.

Brominated and chlorinated additives are still used in heavily corrosive environments. However, they are becoming increasingly banned for use in many common applications. Several halogenated substances present health hazards, the produced smokes are toxic, and waste is classified as hazardous, making it costly to dispose of.

MODERN APPROACH New trends in adding flame-retardant properties to composites are based on the use of nonhalogenated substances such as aluminium trihydrate (ATH) and metal hydroxides, including

A balance must be struck between the desired mechanical properties and meeting the relevant FSTs.

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magnesium and phosphorus-based compounds.

ATH additives are now the most widely used nonhalogenated flame retardants because, despite being less effective than halogens, they are far less toxic. They operate by releasing water molecules in an endothermic reaction during the combustion process. These quench the surface of the surrounding materials, providing flame retardancy and smoke suppression. Furthermore, unlike halogenated products, ATH additives do not give off toxic smoke when burned.

The downside of ATH, being much less effective in hampering the fire, is that higher quantities are needed to meet the stringent fire requirements in many applications. Very high filler loadings negatively affect mechanical performance because there is less room for reinforcing fibres, and they influence long-term behaviour in difficult environments. Very high resin viscosities, changed reactivities and important pultrusion pulling forces require narrow process windows and tight process controls. Special consideration needs to be given to geometrical product details and the highest level of tooling quality is required to successfully produce such parts.

Ultimately, when specifying composites for applications where fire must be considered, a balance must be struck between the desired mechanical properties and meeting the relevant FSTs. While this might seem like a daunting prospect, it can be overcome by working with a knowledgeable partner who understands these considerations and can propose the most suitable solution.

This is particularly crucial in transportation applications where fire requirements vary. In Europe, trains have three hazard levels and, as we move up through them, the level of FST requirements increases.

This is just one example where we regularly hear from our clients that navigating all the necessary fire requirements and knowing what tests to apply can be extremely complicated. As FST demands will affect most other properties and have considerable effects on processing, they should be discussed in the early stages of each new enquiry. Exel Composites has the expertise and manufacturing capabilities to guide customers through it and produce the most suitable composite solution for a given application.

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EXCLUSIVE

Price Knowhow:

2021 Review and 2022 Outlook

F FOLLOWING ANOTHER TURBULENT YEAR FOR THE UK PLASTICS INDUSTRY, REGULAR CONTRIBUTOR MIKE BOSWELL REFLECTS ON THE CHALLENGES OF 2021 AND ANTICIPATES WHAT THE MARKET CAN EXPECT FOR 2022 IN HIS ANNUAL MATERIALS REVIEW.

Who is ‘Polymerman’?

Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. He has a broad knowledge of both materials and the issues affecting the wider industry, with over 20 years’ experience in the field.

2021 REVIEW

2021 turned out to be a challenging year, in which prices and availability were significant issues. Not only was price volatility a cause for concern, but for many materials, prices were inflated to record highs. A crisis in the global container shipping industry not only illustrated the dependence of the polymer industry upon the free movement of goods, but also the need for this to take place at an economic cost so that goods can move freely to the point of demand. Natural phenomena, including extreme weather events in the US and the Coronavirus pandemic, brought further supply disruption. Finally, the world faced a shortage of IC Chips, which significantly curtailed automotive production as motor manufacturers struggled to secure supply of these essential components.

Despite these significant challenges, the UK plastics industry has performed well – in many cases responding to changed demands for products necessary to deal with the pandemic. In contrast to 2020, the important automotive and construction markets did not stutter despite further lockdowns. Many of the Government’s Covid-19 related support programmes came to an end in the second half of 2021 – thus far, with no serious drama in the plastics processing sector.

2021 was a very challenging year in Polyolefins with several factors combining to create a ‘Perfect Storm’. Following a slow end to 2020, European producers exported excess stock to higher netback parts of the world, leading to local shortages.

The unexpected polar storm hit the US Gulf Coast in February, significantly affecting all polyolefin availability. Unexpected increases in demand, as economies recovered from Covid-19, and consumer spending changed from services to goods and all grades saw record prices in 2021 with buyers scrambling to secure the limited supplies.

STYRENICS

2021 proved to be a very challenging year for all styrenic polymers, with negative impacts resulting from the Brexit situation, shipping/ port issues and the availability of key raw materials. This, combined with large cost increases, meant that the year finished with market prices much higher than at the start of the year.

ABS was particularly hard hit with allocations in place for much of the period, coupled with lengthy delays in shipping. The PS market generally was more volatile than for other styrenic materials, but all polymer types had

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two distinct price increase periods – one at the start of the year due to the issues listed above and a second late in the year that was principally due to increases in energy and freight costs, as well as further raw material price rises.

It has been many years since the engineering polymers market was as volatile as it was during 2021.

ENGINEERING POLYMERS

It has been many years since the engineering polymers market was as volatile as it was during 2021. Almost every polymer type suffered with poor availability, allocations, long lead-times, and much higher prices. The effects were mainly due to raw material cost increases, Brexit, and freight issues. As evidenced from the graphs, the price increases were sustained over the whole of the year as producers struggled to keep up with raw material cost rises and demand from the market. Nylon, POM, PC, PMMA and PBT were particularly hard hit. As the year drew to a close, further large price increases were implemented on the back of much higher energy costs, as well as large price increase for key additives such as glass fibre and flame retardants.

2022 OUTLOOK

BREXIT The UK economy performed better than expected following the departure from the EU at the very end of 2020. Whilst some matters remain troublesome, including fishing rights and trade with Northern Ireland, it is thought that the worst is now over. Although the movement of goods to and from the EU27 will be subject to more stringent application of the rules and this will no doubt be the cause of further disruption to supply chains and increasing costs.

More recently, the UK Government has reviewed the UK REACh legislation and has extended the deadlines for the full registration deadline. The Government has also announced that it will enter into discussion with regards to the need to closely follow EU REACh, or to take a different approach.

LOGISTICS In December there was some evidence that shipping rates will fall with the rate for a 40ft container from China to the EU falling from a peak of $18,000 to $8,000. This is still a long way off the pre-crisis rate of $2,000, but

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there is an expectation that container shipping rates will continue to fall through the first half of 2022, as shipping lines start to cut price in order to secure volume. At some point, the economics of shipping polymer from Asia to Europe will become workable and this will bring the liquidity to the international polymer market that is not feasible at current shipping costs.

On the domestic front, Brexit exaggerated the existing HGV driver shortage and also emphasised the fragility of supply chains, resulting in domestic warehouse utilisation increasing to a level at which logistics companies were confident enough to hike rates. Along with general inflation, these logistics cost pressures will be passed through the supply chain as they represent a macroeconomic factor affecting the whole polymer supply sector.

EXCHANGE RATES The main factors of influence will be the prosperity of the UK economy coupled with base rates of lending. A key aspect of the economy will be the ability to stave off the impact of Coronavirus and, in this regard, the high vaccination rates coupled with a less severe than anticipated impact from the Omicron variant bodes well. It is also apparent that travel restrictions have resulted in amendments to lifestyles, with domestic spending increases and (whilst it is possible that travel restrictions may be lifted, at least in part) it is likely that some of these economic changes may be sustained.

With regard to exchange rates, the Bank of England uplift of 0.15% on the previous rate of 0.10%, sets the stage for subsequent 0.25% increases, as the bank starts to use this as a countermeasure to control inflation. The timing of the next move will depend upon the impact that Omicron has on both the UK and Global economies.

CRUDE OIL The pariah status of fossil fuels is likely to have interesting consequences. In early 2022, output and demand are closely matched with crude oil prices trending steadily higher, and many pundits expecting prices to breach the $100 per barrel mark in the coming months.

The dilemma for NGOs campaigning for lower carbon emissions is whether higher crude

oil prices suppress consumption, or if higher profitability will lead to increased output and investment in future production. Over the long term, there is a strong corelation between the price of crude oil and volume polymer prices, with the likelihood that any recent distortions being reduced over time.

FEEDSTOCK C2 (Ethylene) Ethylene pricing is likely to be heavily influenced by the level of PE imports from the US, which were for the most part absent in 2021. With the expectation that US imports will exceed pre-2021 levels as new capacities come on stream, it is likely that local demand for C2 within Europe will be suppressed. If this proves to be the case, the likelihood is that ethylene prices will decline, which, along with competitively priced PE, US imports will apply deflationary pressure to PE. C3 (Propylene) C3 has a double reliance on crude oil refining in which C3 is a significant co-output of Naphtha cracking for ethylene and a biproduct of the FCC (Fluidised Catalytic Cracking) process used to upgrade the petroleum fraction of crude oil distillate to the required environmental standards. Whilst the ratio of C2 to C3 in the Naphtha cracking process can be adjusted, this is within a relatively narrow window and therefore low C2 demand is likely to result in low C3 availability. The supply of C3 from the process of refining crude oil into petrol is going to depend upon the demand, and here factors including the restriction of Coronavirus on free movement and the proliferation of EVs are likely to restrict demand and push C3 towards a position of short supply. This situation is likely to enhance the premium of C3 over C2 and subsequently the relative pricing of PP over PE. It should be noted that the opportunities for PP substitution

by PE are quite limited and on this basis PP supply may be quite tight.

BENZENE This important aromatic hydrocarbon compound is the basis for the following intermediates, including: • • • •

Ethylbenzene Cumene Cyclohexane Nitrobenzene

The main factors of influence will be the prosperity of the UK economy coupled with base rates of lending.

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POLYOLEFINS 2022 will be challenging in a very different way for Polyolefins as new capacity for all grades comes on stream and demand is not expected to match it.

Of which Ethylbenzene, Cumene and Cyclohexane are precursors to key monomers, including SM (Styrene-based polymers), Bisphenol A (PC) and HMXDA (PA66).

Price volatility is expected to continue, particularly as petrochemical producers seek to improve the economics of this important aromatic petrochemical compound.

Globally, PE and PP will be in oversupply and prices are expected to drop quite significantly in 2022. PE will be affected more, and prices will start to fall early in 2022. PP is expected to hold on to prices for longer and not fall as sharply.

Highly commoditised grades such as HDPE and LLDPE C4 will be under the most pressure.

Global shipping issues will continue to be a factor and some challenges on speciality grades will remain.

The situation for 2022 starts with a great deal of uncertainty surrounding the imapct of higher energy, freight, and raw material costs.

STYRENE MONOMER (SM) The fortunes of SM are closely related to Ethylbenzene and, in turn, Benzene. An important characteristic of SM and the Benzene family is the relative ease with which these products can be shipped around the world in tanker vessels, and this tends to increase volatility as the material is either distressed in the case of surplus and exported or imported in the case of shortage.

SM is also a derivative of Propylene Oxide synthesis which is an important component of polyurethane manufacture, demand for which is currently curtailed by suppressed demand from the automotive sector, which is a key market for polyurethane.

STYRENICS The situation for 2022 starts with a great deal of uncertainty surrounding the impact of higher energy, freight, and raw material costs.

This is likely to be focused on more volatile materials such as PS. That said, for most of the styrenic polymers, it is unclear what will happen during this year. The most likely scenario is that prices will remain high and material tight until at least the mid-point of the year due to the relatively low current supply position, even with the lower demand from the automotive market. There is a possibility that prices may soften as supply improves during the second half of the year.

ENGINEERING POLYMERS 2022 starts much the same as 2021 finished – with upward pressure on prices and lower supply from producers across the board. For some polymer types, the UK market is heavily dependent on imports from outside the EU and these are still lagging behind the demand from the market, which is also having an impact and leading to prices moving higher still. It is expected that notations for most engineering polymers will remain high until at least the middle of the year, but perhaps for almost all of 2022. The ongoing very low demand from the automotive sector is expected to have little or no impact on this situation.

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This report is produced based upon the following fundamentals: • EURO based pricing for feedstock and polymer pricing • Conversion of Euro and USD based prices at prevailing exchange rates • Product baskets weighted according to UK consumption Acknowledgements Thanks to the following organisations: - PIE (Plastics Information Europe) www.pieweb.com HM Treasury www.hmtreasury.gov.uk Disclaimers The information provided in this report are based upon data available from both external and internal sources, and whilst care is exercised in producing this report we give no guarantee of accuracy.

Furthermore Plastribution and British Plastics and Rubber accepts no liability for purchasing decisions based upon the information provided, as the petrochemical market is complex and volatile.

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Your Sustainable Solutions Provider from Design to Production

PACKAGING | NEWS Lighter Cap from Berry Contributes to a More Circular Pack Solution A new closure from Berry Global, specifically created for sauces, demonstrates the company’s circular design capabilities in devising a lightweight and recyclable solution while continuing to deliver consumer convenience benefits.

Berry has utilised its technical skills to create a closure that is lighter than other versions currently available, offering valuable material savings without compromising its strength and durability to ensure a consistently reliable performance.

The closure is 100 per cent polypropylene.

The closure design features an extended narrow spout that provides controlled and accurate dispensing of product for the end user. It can be specified in snap-on or screw-on

versions and is suitable for bottles with a 38mm neck finish, including Berry’s extensive range of standard sauce bottles, enabling the company to offer customers a complete bottle and closure solution.

Matthias Hammersen, Sales Director, Food Market, Berry Global, said: “Our new closure has been designed to be extremely versatile to meet the many different needs of the food sector, while delivering a reliable performance and helping food manufacturers to improve the sustainability of their packaging.

We look forward to continuing to support our customers in achieving their lightweighting objectives and developing packaging solutions that help them become even more sustainable.”

A special mention in TIME’s Best Inventions 2021 is awarded to Garçon Wines’ flat wine bottles The annual release of the prestigious TIME Best Inventions has seen Garçon Wines awarded with a special mention for their sustainable, flat wine bottles.

The list evaluates inventions based on originality, creativity, ambition and impact, highlighting those that are making the world better, smarter and even a bit more fun.

Garçon Wines’ space-saving recycled PET bottles help make the world of wine better by targeting the wine industry’s carbon footprint hotspot of round, glass bottles. Described by journalist Jared Lindzon for TIME as ‘an emission-cutting container’, their invention saves space, weight and energy to 26

New Danish packaging made from local recycled plastic delivers significant strides in sustainable development Danish households’ efforts to sort plastic waste are now producing positive results, where they can see their recycled packaging used to make more protective packaging.

A visionary collaboration between four Danish companies has resulted in the launch of new plastic packaging made from Danish householdsorted plastic waste; a true circular loop where discarded plastic is turned into new plastic bottles.

Through this partnership, the four companies are driving increased recycling of household plastic waste, using it as valuable raw material for new protective plastic packaging.

The companies are Nopa Nordic A/S, Schela Plast A/S, Aage Vestergaard Larsen A/S and Dansk Affald A/S. This partnership to create real environmental progress started more than a year ago when Nopa Nordic requested packaging in recycled material

This partnership to create real environmental progress started more then a year ago.

using domestic Danish household-sorted plastic.

Consumer demands for new packaging sparked more development work between the partners, which has now resulted in the development of the new packaging, meeting a great need at a time when everyone is looking for sustainable solutions.

All four companies reinforced that an open and innovative collaboration between them, each bringing their own expertise,

is the way forward for the development of more environmentally sustainable Danish products.

Schela Plast, who produced the packaging, has been an important partner in the project due to their extensive knowledge of blow moulded packaging made from imported household-sorted plastic waste. They expect the production of local recycled plastics from Denmark to increase significantly.

significantly slash carbon emissions throughout the supply chain.

Santiago Navarro, CEO and co-founder at Garçon Wines, said: “We are deeply honoured that our flat wine bottle has been recognised with a special mention in TIME’s Best Inventions of 2021 – arguably one of the most prestigious product-based lists for global innovation from one of the most highlyesteemed publications.

“The list and special mentions have showcased some truly inspirational and ground-breaking inventions, so it is a very proud and humbling moment to see ours included. The special mention makes us more motivated than ever to continue our mission of making more climate- and planet-friendly packaging, especially as we look ahead to launch in both the USA and Australia next year.”

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Your Sustainable Solutions Provider from Design to Production

FEATURE

From the waterways to better days

B BELL PACKAGING INTRODUCES REUSED OCEAN PLASTIC TO ITS 2022 PORTFOLIO

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ne of the most exciting new developments in the plastic packaging industry is the ability to access and reprocess the postconsumer waste found on our beaches, riverbanks and along the perimeters of our oceans.

Unfortunately, plastic is now seen as a bad product – yet out of sight, beneath the surface of our oceans, there are millions of tonnes of other waste packaging made from glass, paperboard and metal that do not float and therefore cannot be seen.

Plastic has become a key focus on social media and in television documentaries, with politicians and supermarkets looking for ways to enhance their green credentials and promote a greener world.

NO EXCUSE FOR WASTE There can be no excuse for rubbish being discarded into the environment and Bell Packaging is counted amongst the first companies in Europe to endorse and support the collection and recycling of these materials.

In 2019, Bell launched Retran – a polyester-based material containing a minimum 70 per cent recycled content. The credentials of this material are so high they are suitable for pharmaceutical and food grade applications, with excellent clarity and full certification. The product has been hugely successful and nearly 80 per cent of Bell Packaging’s global customer base has switched to using this environmentally protective and innovative new product.

We are taking a significant step forward towards a circular economy and a better global environment.

Furthermore, the 70 per cent recycled content meets the requirements of the plastic packaging tax being introduced in April 2022. However, Bell recognised the need to keep moving forward and, in 2021, introduced its Biojet range. In simple terms, this is Retran with an additive that stimulates and accelerates the biodegrading process.

PRODUCTIVE EVEN IN A PANDEMIC Whilst both products have been hugely successful, Bell recognised that even more needed to be done. Thus the company has continued to work throughout the pandemic in order to identify reliable sources of plastic derived from the ocean.

In simple terms, this is ‘Reused Ocean Plastic’.

The polymer used to produce the new packaging is being sourced from companies that organise and mobilise local communities to collect plastic waste from beaches, riverbanks and ocean perimeters.

Generally, these are communities who do not have the infrastructure for waste management but, by paying local people to collect the plastic and deliver it to recycling facilities, the problem is reduced.

A SIGNIFICANT STEP As we have all seen, there are large quantities of plastic waste floating in the sea. If we can help to collect and reuse some of this waste, and turn it back into useful products, we are taking a significant step forward towards a circular economy and a better global environment.

The new material has been extensively tested and meets the minimum strength requirements of Bell’s processes. It has excellent optical qualities and testing to date reports that there has been no difference in performance compared to Retran, Jetran or Biojet packaging.

Bell Packaging has started converting Reused Ocean Plastic for its forming and insert divisions, with tubing and boxes to follow in 2022. Samples and more information are available from the company’s headquarters in Luton.

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Your Sustainable Solutions Provider from Design to Production

FEATURE

reduce

Z ZOTEFOAMS WAS AWARDED THE BEST NEW CONCEPT AWARD FOR REZORCE CIRCULAR PACKAGING AT THE UK PACKAGING AWARDS 2021 IN NOVEMBER.

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reuse

ReZorce

panel of industry experts, encompassing retailers, brand-owners and industry bodies, considered a shortlist of 12 projects in the Best New Concept category, with two being highly commended and the winner announced as ReZorce, presented as an alternative to composite materials for beverage cartons.

The award recognises a new invention, not yet commercially available, which represents a significant technological step forward by using new materials and/or innovative pack prototypes and which has been designed and developed by a UK company.

Compère Alan Dedicoat said: “[The] judges loved seeing development of mono-materials and felt the pack facilitates recycling, and simplified the actions required by the consumer to do so.”

The judges added that ReZorce is “a future for liquid board that tackles the big player alternatives.

Making it easy for the consumer to dispose of and use recycled content. We love seeing the development of mono materials. A very exciting project and results.”

ReZorce Circular Packaging meets or exceeds industry standards for food safety and barrier properties. Zotefoams is currently nearing the commercial launch of ReZorce beverage cartons produced from HDPE ReZorce sheet: due to the layered structure of the material, recycled polymer (currently up to 70 per cent) can be incorporated within the core layers. ReZorce is fully recyclable via post-consumer household waste collection, offering a circular solution – in contrast to current composite materials that can only be downcycled.

Neil Court-Johnston, VP Strategy EMEA at Zotefoams, said: “I was very happy to accept the Best New Concept Award on behalf of Zotefoams

It’s inspiring when technology makes a difference and the ReZorce conceptto-reality has huge potential

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recycle

(L-R): Philip Chadwick (Packaging News); Phil Buttress (Heidelberg Graphic Equipment); Luke Rust; Neil CourtJohnston (Zotefoams); Stephen Edge; Paul Turner; and Jon Culshaw.

and our ReZorce Circular Packaging technology.

This is a huge achievement and one of which we are very proud.

“Many thanks to Packaging News for a fantastic event, to category sponsor Heidelberg and to our colleagues and industry partners who joined us on the night to celebrate. It’s an exciting time for ReZorce as we have a number of customer trials taking place over the next few months, so it’s fantastic to get this recognition from the UK Packaging Awards.”

David Stirling, Group CEO at Zotefoams, added: “I’m very pleased to see ReZorce Circular Packaging being recognised. It’s inspiring when technology makes a difference and the ReZorce conceptto-reality has huge potential to address a huge problem, reducing waste and the CO2 footprint of barrier packaging.”

In 2021, the ReZorce range of materials from Zotefoams also saw success in winning the BPF and Horners Bottlemaker’s Award during Interplas in September, as well as a Green Apple Environment Award and being shortlisted for several innovation, recycling and environmental awards.

Stirling concluded: “We’re delighted that the entire industry, from polymer producers to recyclers, is endorsing this ground breaking technology as we approach its commercial launch.”

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Refurbishment of main flight available in 7-10 days.

Barrels •

Stock of bimetallic barrel blanks up to 50mm bore allows for new bimetallic barrels to be manufactured in 7-10 days. Barrels up to 305mm bore will take slightly longer.

•

Partial re-sleeves within 7-10 days.

Tie Bars • •

Tie bar repairs within 7-10 days.

New chromed or non-chromed tie bars available.

Call our sales line for expert assistance -

Ask for Hugh or Pete on 01536 206653

sales@nickersoneurope.com Ring us on 01536 403886 • Email sales@nickersoneurope.com or visit our online store www.pmseurope.com Nickerson_A5_Flyer_CMYK.indd 1

01/12/2021 12:37

AUTOMATE YOUR TESTING

•

•

Productivity Reliability Traceability 24/7 operation, rapid ROI

Contact us now to discuss your needs www.tiniusolsen.com sales@tiniusolsen.co.uk

Your Sustainable Solutions Provider from Design to Production

FEATURE

P PLASTICS RECYCLING AND RESOURCES CHARITY RECOUP HAS CONDUCTED A PLEDGE2RECYLE CITIZEN PLASTICS RECYCLING BEHAVIOURS INSIGHTS STUDY HOSTED ON THE PLEDGE2RECYLE WEBSITE RECEIVING OVER 6,500 RESPONSES FROM ACROSS THE UK.

T

IN CIRCULARITY

he results indicate that 95% of citizens claim they recycle plastic drinks bottles every time. This drops to 83% with shampoo and conditioner bottles and 80% for cleaning products and sauce bottles. Claimed recycling rates drop considerably once the packs become more complicated. For example, when the packs are more difficult to clean or less likely to be collected kerbside. Only 52% of citizens claimed to recycle trays that had previously contained cooked food or ready meals. 62% of citizens claim to recycle fresh meat trays every time. This rose to 73% for clear fruit and veg clear trays.

Anne Hitch, Head of Citizen and Stakeholder Strategy at RECOUP, said: “The picture painted of citizen plastics recycling behaviours is a complex one. Simplicity is the key to citizen engagement both in pack design and recycling messaging.

Recycling needs to be intuitive both in terms of collection consistency, service provision, and pre-preparation of the pack. Convenience is paramount to unlocking the potential for higher plastics recycling rates.”

The work further indicates that there is confusion when a pack claims to be ‘recyclable’ when it is a non-target material for kerbside collection schemes. For example, the move towards mono polymer toothpaste tubes has led to the tube being declared ‘recyclable’ when it is not collected

by Local Authorities kerbside. There is a need for synergy across the value chain for items where technical recyclability claims cannot be matched by infrastructure, sorting, and capture capabilities.

Work is needed to agree as to how this can be accurately relayed to citizens without causing even more confusion.

30

Recycling needs to be intuitive both in terms of collection consistency, service provision, and prepreparation of the pack.

Even the simplest plastic pack (the drinks bottle) challenges remain in ensuring that citizens preprepare the pack in line with industry guidelines of empty, rinse, and lid on. Less than half of citizens on the survey claim to recycle bottles this way (43%). This represents key losses to the industry in terms of recyclate that could easily be recycled with existing infrastructure if citizens understood the importance of the preparation instructions.

Whilst the full report is available to RECOUP members only and will be released into the open domain in early May 2022, an executive summary is available on the RECOUP website.

RECOUP’S Pledge2Recycle Plastics team is currently working with the 13 Kent Councils as a ‘Live Lab’ delivering and investigating how plastics recycling communications can result in the desired outcomes in terms of plastics recycling behaviour change.

The results of this project are due in the open domain in July 2022 with further activations scheduled to follow elsewhere in the UK.

www.britishPLASTICS.co.uk

MASTERBATCH & ADDITIVES | NEWS Taiwanese thermoformer partners with Milliken

© South Plastic 2021

South Plastic Industry Co. Ltd. (SPI), a leading Asian manufacturer of thermoformed plastic food packaging, has been striving for years to develop a clear, anti-fogging polypropylene (PP) lid for its microwaveable food packaging.

The aim has been to replace oriented polystyrene (OPS) in this key application, but it wasn’t easy to find a way to get the highly recyclable PP to meet all the necessary performance requirements whilst retaining the clarity and non-yellowing aesthetics that are vital to appealing to consumers on the grocery store shelves.

Until now.

SPI has leveraged its close relationship with Milliken & Company to finally achieve its goals.

Using Milliken’s Millad NX 8000 clarifier, the two parties have produced an UltraClear PP resin that delivers

These additives allow SPI to produce a thinner PP liquid without affecting rigidity on all the performance promises for readymeal packaging, while also offering additional processing benefits. SPI also recently began using Milliken’s Hyperform HPN performance additives in its PP formulations, as well.

SPI President Tosho Wang said: “By using Milliken’s additives, we are able to thermoform our products at a lower processing temperature, which allows us to reduce our energy use.

At the same time, these additives allow SPI to produce a thinner PP lid without affecting rigidity.”

Many suppliers use oriented PS resin for their ready-meal packaging lids, but those can only withstand 85°C temperatures

and are not suitable for microwaveable products. With UltraClear PP, such packaged foods can go straight from the refrigerator to the microwave while retaining the necessary clarity and aesthetics.

SPI, which now uses Milliken clarifiers in all its UltraClear PP packaging products, says it plans in the future to also explore using the material to expand the use of PP in more food applications, including some that currently use PET. When it comes to thermoformed polypropylene food packaging for South Plastic Industry, the way forward is clear and involves further close collaboration with Milliken.

LyondellBasell’s Polybatch 73641 NIR Black obtains COTREP Certification LyondellBasell’s black colour masterbatch Polybatch 73641 NIR has obtained the COTREP certification, which demonstrates that plastics containing these masterbatches can be separated using conventional NearInfrared (NIR) sorting equipment.

Black and darkcoloured plastics are difficult to sort in post-consumer waste because they are not visible to the optical or NIR detectors which are widely used in material recycling facilities. When black and dark plastics cannot be sorted by colour or polymer type, they will enter the waste stream destined for landfill or incineration, or reduce the value and opportunities for re-use of the sorted plastic material.

COTREP, the French Technical Committee for the Recycling of Plastic Packaging, established by Citeo, Elipso and Valorplast, assists manufacturers in the development of recyclable plastic

packaging solutions to support the circular economy.Núria Vallespí, Marketing Manager, Color Concentrates at LyondellBasell, said: “We are very pleased to offer Polybatch 73641 NIR with a COTREP certification which is designed for circularity.

When customers and brand owners choose Polybatch73641 NIR, they create the possibility to support the circular economy by enabling existing sorting technology to effectively separate and avoid plastic waste.”

LyondellBasell’s Polybatch 73641 NIR is part of the company’s NIR detectable black masterbatch range that enables the sorting of black plastic articles in post-consumer waste streams.

Different products are recommended depending on the customer needs and polymer base. Besides the NIR sortable black series, LyondellBasell offers a range of NIR sortable colours covering a broad colour palette.

Polybatch 73641 NIR is part of the company's NIR detectable black masterbatch range

www.britishPLASTICS.co.uk

31

feature

Polymer pricing requires a

L

ast year, the polymer industry experienced complex material supply conditions. Although most British processors were anticipating some turbulence at the end of the Brexit transition period, the added global challenges of raw materials sourcing and price hikes, amplified by the pandemic, created the perfect pricing storm.

J JO DAVIS, MANAGING DIRECTOR OF BRITISH TECHNICAL MOULDER BROANMAIN PLASTICS, SUMMARISES THE IMPACT OF COUNTLESS PROCUREMENT CHALLENGES AND HOW BROANMAIN CONTINUES TO NAVIGATE THE ONGOING PRICING INSTABILITIES.

Severe shortages of raw materials have threatened the survival of SME plastic manufacturers and OEMS across Europe. No production plant has been immune to the effects. Absorbing rising prices as they reached a six-year high while simultaneously overcoming the technical hurdles without compromising production quality has been immensely challenging.

As with many supply chains, there are several months’ worth of lag before higher prices and supply bottlenecks really start to bite. The ripple effects of COVID-19, rising energy costs, plant shutdowns, US winter storms, the Suez Canal blockage, suppliers declaring force majeure, and countless other logistical problems continue to leave lingering PE production and supply chain volatility issues.

Given that raw material costs account for approximately 60 per cent of a finished product cost, increasing spot raw material by 150 per cent will naturally push the finished product cost up by 90 per cent.

The tipping point for most processors and their customers came during the 2021 periodic negotiations of future material contracts. Although analysts were optimistic that the issues might be resolved in early 2022, the fallout of price increases and materials shortages still plagues most European injection moulding firms.

As of December 2021, Plastics Information Europe reported little price movement amid weak demand.

Simultaneously, compound prices have soared.

These can be attributed to the increased cost of titanium dioxide, flame retardants, stabilisers and other additives used widely by technical moulders such as Broanmain.

Standard thermoplastics showed little price movement amid weak demand in December 2021 (Source: Plastics Information Europe)

The tipping point for most processors and their customers came during the 2021 periodic negotiations of future material contracts.

For domestic manufacturing SMEs, creating this better balance and rebuilding the equilibrium is very dependent on all parties working collaboratively together. To help offset these trade imbalances, Broanmain has put its energy into maintaining longer-term partnerships with trusted material suppliers. The company is also continuing to invest in technology that increases its production agility and supports its sustainability missive.

Our most recent IntElect investment helps to ensure that valuable material is not wasted. By targeting zero defects, we can help to ensure that every single pellet is treated with respect and moulded into a high-quality part.

The current situation has highlighted structural flaws. Yet, as an SME manufacturer of technical plastic components, it really demonstrates to us the importance of building out better supply chain resilience. Navigating these instabilities requires a paradigm shift towards better value and risk mitigation.

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www.britishPLASTICS.co.uk

comment

T

M MARK VICTORY, SENIOR RECYCLING EDITOR AT ICIS, DISCUSSES WHY SINGLE-MATERIAL BALE PRICES HAVE SURGED AND MIXED-POLYOLEFIN BALE SUPPLY CONTINUES TO TIGHTEN.

EUROPE MIXED PLASTIC WASTE SUPPLY TO FURTHER TIGHTEN

he European mixed plastic waste market is expected to further tighten in 2022 amid growing use of mixed-polyolefins grades by mechanical recyclers and increased use of refuse derived fuel (RDF)-suitable reject bales by pyrolysisbased chemical recyclers.

Mechanical recyclers are increasingly exploring the use of mixed-polyolefins waste as a feedstock, amid record high recycled polyethylene (R-PE) and recycled polypropylene (R-PP) pellet prices and structural shortages of mono-sorted R-PE and R-PP waste.

New sorting capacity from waste managers and recyclers targeting the use of mixed-polyolefins waste, is due to come on stream in 2022.

This is not the first time that mechanical recyclers have explored mixed plastic waste as a feedstock, with previous attempts unsuccessful because low yields and the complexity of sorting material made the process economically unviable.

Nevertheless, ongoing tight supply of monomaterial bales and growing demand for recycled material have shifted the economic feasibility of using mixed plastic waste significantly.

SINGLE-MATERIAL BALE PRICES SURGE With sharp increases in single-material bale prices across 2021, ongoing structural shortages, developments in sorting technologies, and firm recycled high-density polyethylene (R-HDPE) and R-PP pellet values (currently at record highs in Europe), using mixed polyolefins waste as an input has become economically viable.

Northwest Europe (NWE) post-consumer mixed coloured high density polyethylene (HDPE) bale prices increased by 393% on average in 2021. NWE PP post-consumer mixed-coloured bale increased by 182% on average in 2021. NWE colourless postconsumer polyethylene terephthalate (PET) bottle bale values increased by 131% on average in 2021.

With a number of new packaging projects scheduled for 2022 – driven by the ongoing sustainability pressure on fast moving consumer goods (FMCG) brands – mono-sorted HDPE and PP bale availability is expected to remain low throughout 2022.

Increasingly, waste managers and mechanical recyclers are looking to extract the usable polyolefins from mixed-polyolefins bales, leaving an RDF-suitable reject bale that can then potentially be sold onwards into the chemical recycling or RDF sector. RDF reject bales are currently selling at positive values.

MIXED-POLYOLEFINS BALE SUPPLY TO TIGHTEN Mixed-polyolefins bale availability is expected to further tighten in 2022, particularly in France as a result of new mechanical recycling sorting and treatment capacity expected to come on stream in the first quarter of 2022.

High prices for mixed-polyolefins fractions and the desire to avoid competing with mechanical recyclers has meant that pyrolysis-based chemical recyclers are increasingly switching away from rigid and mixed-rigid/flexible grades of mixed polyolefins.

Historically, mixed polyolefins have been the preferred feedstock choice for pyrolysis-based chemical recyclers because of the need to limit PET (which oxidises, and does not depolymerise via pyrolysis), chlorine (which is corrosive), nylon and flame retardants content in its input material.

At the same time, high energy costs are making burn for energy more attractive and the RDF market is growing – particularly from the cement industry.

While most pyrolysis-based chemical recyclers are eager to avoid competition with mechanical recyclers for ideological reasons, this is placing t hem in direct competition with the RDF sector because of a lack of sufficient infrastructure to meet expected demand.

Although 2021 saw northwest Europeean RDF reject bales trading in positive territory for the first time, in some other European territories, such as Scandinavia and the Netherlands, prices continue to trade in negative territory, although this is expected to change as chemical recycling demand scales up in 2022.

There is currently 364,000 tonnes/year of operational chemical recycling capacity in Europe, of which 218,000 tonnes/year (or 60%) is pyrolysis based, data from the ICIS Chemical Recycling Supply tracker shows.

With new chemical recycling plant volumes frequently being announced, this volume is expected to increase in the coming years, even as the majority of plants remain at pilot or lab scale.

ICIS has launched a new mixed plastic waste pricing service covering European prices for mixedpolyolefins waste bales, reject refuse-derived fuel (RDF) bales and reject materials recovery facility (MRF) bales. Along with this, the new service covers emerging trends in the chemical and mechanical recycling markets, as well as the burn-for-energy sector.

www.britishPLASTICS.co.uk

33

PLASTIC WELDING SOLUTIONS Design

A C TI O N I S O UR TISF SA GO R U A O

Development

L

INGENIOUSLY SIMPLE EXTRUSION WELDING

Y

FUSION 1

Mould Tooling

Compact and slimline:

Thanks to integrated air guide

Injection Moulding

Suspension device:

Beyond the Mould

Effortlessly weld longer by suspending the device

Controlled:

Automatically controlled air temperature

Pistol Grip Handle:

Can be mounted for onehanded welding

Rod shape

Reduced design for increased maneuverability in small spaces

Double-sided wire intake For more flexibility when welding

LED Light

To illuminate the welding area

Your technical experts for Toolmaking and Plastics Injection Moulding www.pentagonplastics.co.uk

Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com

websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 |

Tel: +44 (0)1793 827666 Email: sales@transxl.co.uk Web: www.transxl.co.uk www.magog.co.uk

Screws, Barrels and Precision Components for the Plastics and Rubber Industries • Screws: Single, Parallel and Conical Twin. Multi Start & Mixing.

SHEET LINES

Specialist Abrasion & Corrosion Resistant screw coatings.

Designs and specifications to suit your specific processing and production requirements.

PIPE/PROFILE

250mm Wide EP Edge Trim Granulator

1000mm Amut PVC Sheet/film Extrusion Line

Small Tube Line

900mm wide Simplas flex lip sheet die model L4-AS

90mm Welex extruder with screen changer

1220mm wide Sheet Downstream

• Barrels: Bimetallic, Through Hardened & Nitride Specifications. Water Cooled, Plain and Pin Barrels for Rubber.

• Feed Sections and Liners: Smooth and Grooved bores, Nitride and Bimetallic Specifications.

THERMOFORMING

• Refurbishment: Screw Flight Rebuild and Barrel bore Honing. Fast track repair service.

• Co-Rotating Extruders: Screw shafts, Elements, and Barrel sections for a wide range of machines and sizes.

• On site Services and Technical Support: Wear check surveys, measure and record for manufacture, installation.

PELLETISING

GRANULATORS

To discover more about our products and services, contact us: Magog Industries Ltd, T: +44(0)1920 465201 E: enquiries@magog.co.uk

EXTRUDERS

Process Experience Manufacturing Expertise Engineering Excellence

34

ial Be Soc

0 Ovesr t3o0view Video

MORE MACHINERY, MORE PHOTOS ON THE WEB WWW.TRANSXL.CO.UK

www.britishPLASTICS.co.uk

BP&R BUYER’S GUIDE MATERIALS MOULD RELEASE

MASTERBATCH

HAMPTON COLOURS LIMITED

C

M

Y

CM

CY

CMY

THE PERFECT MATCH • Polymer Specific and Multi-polymer Colour & Additive Masterbatches • Fastmatch matching service • 1mm Easysperse Micropellets to 4mm Maxipellets

+44 1274 731 552 sales@eclipsecolours.com www.masterbatch.co.uk

K

infrared welding

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

Tel: +44 (0)1453 731555 Fax: +44 (0)1453 731234 sales@hamptoncolours.co.uk POLYMER SPECIFIC AND UNIVERSAL MASTERBATCH, SMALL LOT SPECIALITY COMPOUNDS PLUS MATCHING SERVICE

ULTRASONIC WELDING InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

Super Bluish Titanium Dioxide

cleaning materials

HIGH TECH AND HIGH PASSION.

   

Infrared Welding Ultrasonic Welding Hot Plate Welding Heat Staking

JOINING

MY

Find your perfect joining method.

www.frimo.com

ASSEMBLY

PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk W: www.incontrolultrasonics. co.uk

Telsonic UK Ltd

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

Purging Compounds Release Agents Mould Maintenance

VIBRATION WELDING Branson Ultrasonics

CHEMTREND.COM MACHINERY & EQUIPMENT

BP&R SOFTWARE GUIDE

CONTROL SYSTEMS AND EQUIPMENT

PROCESS OPTIMISATION SOFTWARE

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

RJG TECHNOLOGIES LTD Moulding Technology

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

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

Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag and drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts.

• • • •

QUALITY MONITORING CONTROL

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

INTOUCH T: 01604 537100 E: enquiries@ intouchmonitoring.com www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

Zero Defect Moulding – What’s your target?

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

PRO-OP™ software provides a step-bystep procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time.

PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection.The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result.

PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture.

PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.

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

Kistler Instruments Ltd

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

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.

MACHINERY & EQUIPMENT

SILICONE MOULDINGS Technical Mouldings in

Silicone, FKM, EPDM, Neoprene, NBR Contact

WWW.MEADEX.CO.UK

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

35

BP&R BUYER’S GUIDE MACHINERY & EQUIPMENT HOT RUNNER SYSTEMS

CONTROL SYSTEMS AND EQUIPMENT QUALITY MONITORING CONTROL Kistler Instruments Ltd

Cavity pressure measurement systems and sensors for control of the injection moulding process and automatic hot-runner balancing, provides zero-defect production with 100% quality control.

T: F: E: W:

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

01256 741550 01256 741551 sales.uk@kistler.com www.kistler.com

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

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.

METAL DETECTION and dosing

HEATING EQUIPMENT Metal Detection

Magnetic Separation

INDUCTION HEATING FOR PLATENS AND TOOLS MF Induction Heating

MASTERMAGNETS.COM

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

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

Permanent Electrostatic Magnets Separation BOOK YOUR FREE SITE VISIT TODAY

+44(0)1527 65858

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

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

www.quick-mould-change.com

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

SCREWS & BARRELS

DRYERS

Wanted

www.magog.co.uk

Rubber Manufacturing Company

Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries.

• Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks

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

Contact us to find out how we can help you

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

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

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

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

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

FILTRATION ALUMINIUM MATERIAL STORAGE BINS Off the shelf or made to order with very competitive pricing!

Standard sizes available: 80l, 200l, 420l, 830l.

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

Contact us today on 01827 265800 or visit www.summitsystems.co.uk Prices start from £428 10% reduction with offer code:

BPR18

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

Exhibiting at Interplas on stand DD10 Hall 3A

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 36

www.britishPLASTICS.co.uk

SECONDHAND AND RECONDITIONED Cooper Plastics Machinery

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

UK agent for Lyons Electronics.

DTL Machinery UK

- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment.

- We also buy redundant, nonrunners & faulty machinery.

- Machinery repair and maintenance services available.

T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com

TransXL International Ltd

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

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

BUSINESS FOR SALE

TESTING EQUIPMENT Gammadot Rheology Testing & Consultancy Services

Buying, Selling, Merging?

Whatever your business needs, Richmond Capital Partners are the industry experts with a proven track record of guiding acquirers or sellers through the process of buying, selling and merging.

Contact Paul Holohan in complete confidence on 07798 530684

Refurbished machines with fault and leak free guarantee.

We buy & sell all manner of plasscs equipment.

Visit our workshop in Wellingborough, Northants.

01933 272747

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

richmondcapitalpartners.com

‘USED INJECTION MOULDING MACHINERY DEALERS’

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

Ultrasonic Plastic Welders New & Used

Tel; 07730 413197 Tel; 01258 459257

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

MAPRA Technik Co — BAREISS

INSPECTION & MEASUREMENT

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

HARDNESS - IRHD AND SHORE For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers.

T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

new & used

Branson-Mecasonic-Telsonic

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

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

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

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

MAPRA Technik Co – DOSS

MARCEL AUBERT – KAFER

For DOSS visual solution of Italy –Inspection & sorting machines for O’rings, Seals, Gaskets.

T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

PRINTERS

SERVICES TESTING/CONSULTANCY

TRAINING

PRINTERS OF PLASTIC MOULDINGS Total Print Ltd

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

PRINTERS OF INJECTION MOULDED PRODUCTS & COMPONENT PARTS

MONITORING

MOULDFLOW ANALYSIS

SOFTWARE

Looking To Outsource Your Branding? – We Can Help.

Specialist Sub-contract Pad, Screen, Digital and Laser Engraving Services.

Premier Impressions Ltd Units 10-11, E.Plan Estate, New Road, Newhaven, East Sussex, BN9 0EX T: 01273 512512 E: sales@premierimpressions.co.uk W: www.premierimpressions.co.uk

COMPONENT PRINTERS TAMPO.SCREEN.FOIL

Improve OEE Reduce downtime Increase throughput Reduce scrap

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

60 Day Free Trial www.intouchmonitoring.com

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

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comment

NEWS FROM THE FRONTLINE

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DIRECTORGENERAL OF THE BPF, PHILIP LAW: ACCORDING TO THE PRELIMINARY RESULTS OF OUR LATEST BPF BUSINESS CONDITIONS SURVEY, THE PLASTICS INDUSTRY ENTERED THE NEW YEAR WITH A HIGH LEVEL OF ACTIVITY, MATCHING THE HEIGHTS OF THE RECOVERY PHASE LAST YEAR.

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usiness is currently impeded by Covid absences which are now running at 7.7% and about one third of firms are saying this is serious enough to disturb their production. Profitability is being undermined by the familiar litany of supply chain issues, logistics and energy price escalation, but a significant proportion of the industry reports the easing of difficulties in sourcing raw materials.

One potential alleviation on the energy front is the re-opening of the BPF’s Climate Change Agreement to new participants. Our scheme is called BPF Energy. Companies who sign up to it and agree to strive towards percentage reductions in their energy usage qualify for exemptions in the Climate Change Levy added to energy bills. This can amount to 92% of the levy for electricity and 83% for Natural Gas. Across the sector, average savings equate to £56,000 per year for electricity and £7,500 for gas.

Normally, we say that to make participation worthwhile, a company’s expenditure on electricity should be in excess of £100,000 per annum (at 10p per kWh). To be eligible, companies must be a plastics processor of semi-finished or finished products. For more details on eligibility you can go to www. bpf.co.uk/cca, but the window of time is short. The scheme reopened in December 2021 and the deadline for applications is 31 March 2022. You are advised to get your applications in by late February.

Companies not currently in our Climate Change Agreement should seriously look at this as energy efficiency has taken on renewed importance with the introduction of the government’s Net Zero Carbon targets. Energy use is at the heart of this and our progress in reaching these challenging targets will be a major factor in our competitiveness against other materials.

The BPF is now making available a Net Zero Hub, a concentration of resources to assist companies on their journey towards

attaining Net Zero emissions. This includes the recently published https://www.bpf. co.uk/netzero/training-and-resources.aspx.

BPF had a rousing end to 2021 with three of its online resources nominated for Awards. PolymerCourses.com became a finalist in the Plastics Industry Awards ‘Best Training and Development Programme’ category. To date, some 800 people have enrolled on its courses. Packscore, an easyto-use tool facilitating the design of plastics packaging for recycling, was nominated for an Innovation Award at the National Recycling Awards. Our EcoDesign Hub, well-populated with online tools, guides, websites and carbon calculators from around the world, was also nominated for a Circular Economy Award at the same event.

Being nominated was an achievement in itself, and a great motivator for the BPF team.

Our political contact developed with a very successful Parliamentary Reception held on 30 November in the House of Commons where BPF members invited their local MPs. The gathering of over 100, including 27 MPs, Peers and Government officials, was addressed by myself and by Lee Rowley, the Parliamentary Under-Secretary of State for Business and Industry. I was able to communicate the economic importance of the industry and its sustainability credentials – especially its potential contribution to net zero carbon targets. I placed some emphasis on the need for sound science in decision making saying ‘greenwash’ can lead to the use of alternative materials which are more burdensome to the environment. I also stressed the need for a plastics-friendly investment climate.

Plastics have a major role to play in infrastructure renewal, particularly in those areas targeted for ‘levelling up’. We will be holding a further Parliamentary Reception in November of this year.

Plastics have a major role to play in infrastructure renewal, particularly in those areas targeted for ‘levelling up’.

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