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Incorporating Polymer Age and Rubber and Plastics Age.
From the snow and the freezing temperatures to the (problematically slow) recovery from the Christmas calories, kickstarting 2025 has not been easy. But here I am, back at my desk with a generous cup of coffee, excited to be bringing you some (hopefully) great content.
I hope you had a relaxing festive break indulging in all your favourite treats – as we say in Italy, ‘A tavola non si invecchia!’ (At the table, one never gets old!).
Our cover star for this year’s first issue is Summit Systems, with Robert Last taking centre stage as the new Managing Director. He discusses the company’s top priorities for 2025 to offer even more sustainable, innovative and cost-efficient solutions to his customers. The keyword? Support. The bonus? Fun! Summit’s focus lies on helping clients be the best they can be while enjoying the process and the people because let’s be honest – a smile makes everything better.
Which swiftly takes me to Luxus’ 60th anniversary party. A fun time was had, which is the only suitable way to celebrate such a milestone. As recycling and sustainability lead the way in 2025, honouring remarkable achievements like this can inspire others to do the same. Condale Platics and TM Robotics also shed light on the importance of sustainable practices within the industry, both pushing the boundaries of what’s possible in construction, robotics and injection moulding.
AI and automation are another recurring topic, and it’s no wonder why. Nextek takes us through how they transitioned from traditional markers to AI to successfully separate food contact from non-food-contact packaging.
Our regular columnists Philip Law and Dave Raine offer a glimpse into the Trump Presidency and its potential consequences, posing the following question: will the UK benefit from it or be penalised by it? Polymerman also touches upon the American President’s second term with an overview of exchange rates as the USD is expected to strengthen. He offers a thorough analysis of 2024 polymer prices and an
is our oyster “2025 may have started with uncertainty and a touch of low morale but the show must go on because the possibilities in the plastics industry are endless and ours to make.”
outlook for 2025, citing inflation, the ongoing geopolitical conflicts and last year’s Houthi terrorist action against commercial shipping as leading causes of a global economic slowdown.
2025 means one step closer (than ever) to Interplas 2026. We’re bursting with excitement and can’t wait to catch up with familiar faces and hopefully see many new ones! In the meantime, make sure you sign up for our Med-Tec Innovation Expo and TCT 3Sixty for free.
This year may have started with uncertainty and a touch of low morale due to the rise of National Insurance costs, higher rates and lower thresholds. But the show must go on – pardon the cliché – because the possibilities in the plastics industry are endless and ours to make!
I hope you enjoy this issue and continue to stay with us through many more.
EDITOR
Recycled compound specialist Luxus celebrates 60 years of recycling excellence. The UK business is a high-performing thermoplastics provider, playing an integral part in a sustainable supply chain for customers in sectors like automotive, construction, packaging and horticulture.
Now a £36.5-million turnover operation with dedicated processing, innovation and quality testing facilities at its headquarters in Louth, Lincolnshire, Luxus employs 140 people in the area and 30 at a specialist subsidiary in South Wales.
Ron Tonn established the company in 1965 to provide waste solutions for the burgeoning plastics industry, which has prided itself on a pioneering approach to compound production ever since. The US Army veteran arrived in the UK in the late 50s to launch the European arm of an American
operation. He was joined by current Managing Director Peter Atterby, who has been at Luxus for 55 of the 60 years celebrated. They established the first dedicated compounding facility in Louth, attracted by the existing industry and export potential offered by the Humber ports.
The early 80s saw the development of a dedicated laboratory to foster innovation, with a stateof-the-art technical centre added in 2014. This significant investment enhanced the ability to re-engineer materials and drive polymer technology and analysis capability in one of today’s largest and most advanced facilities in the UK. Colour Tone Masterbatch launched in Caerphilly in 2017 and won the Queen’s Award for Enterprise in Innovation in 2022 for its work in hard-torecycle black plastics.
Mr Atterby said: “Celebrating our 60th anniversary is a real opportunity for us to reflect on
what has been achieved, and underlines our commitment to quality, our clients and the environment. Recycling has rightly become part of everyone’s daily life, but we were well into our journey by the time household targets were introduced in the early Noughties.”
He continues, “We’re incredibly proud of the leading industry role Luxus plays and the importance our work has. Our unstinting sustainability efforts, innovative technical compounds, and successful projects showcase our dedication. A long, strong
track record of delivery allows us to speak with authority, share expertise and provide credibility in a competitive sector as we look towards future milestones.”
The company now produces 30,000 tonnes of recycled plastic compounds annually from an initial 600 tonnes, then going into the formation of coat hangers and films.
End uses include automotive internal components (A-surface materials), with a key strand being the lightweight car parts to aid fuel efficiency and the electric vehicle transition. The company also produces specialist materials for waterless washing machines.
Luxus’ seventh decade will see it continue to lead the industry as it pushes the boundaries of sustainability in plastic recycling and customer service. It will also launch an exciting brand, offering safe and traceable multi-life solutions. Deodorised polymers are also under development for potential use in FDA applications.
The company has delivered a Department for Energy Security and Net Zero partfunded project to develop cleaner recycling processes. The representatives look forward to attending the Plastics Recycling Show Europe (PRSE) 2025 in Luxus’ celebratory year.
“Celebrating our 60th anniversary is a real opportunity for us to reflect on what has been achieved, and underlines our commitment to quality, our clients and the environment.”
[GD] Could you explain how the idea came about and your first thoughts?
[AH] I started working with Netstal when I was 25, and within four years they joined KraussMaffei, although they were running them as two separate companies. This is the first time I met Richard Mumford.
While at Netstal I spent a year working on a project in Dun Laoghaire for Becton Dickinson (BD). The management team asked me if I would be interested in moving to Ireland, so I did
BP&R Editor Giulia Daniele caught up with Andrew Hitchcox, Director at Invotek Polymer Solutions. The conversation highlights the benefits and hurdles of transitioning from a fulltime employee to a self-employed sales agent representing KraussMaffei and Motan Colortronic in Ireland.
and spent about seven years in the medical device industry.
BD was split into different business units, and the one I was involved with was diabetes care. It was spun off to be run as a separate company, which is known as Embecta.
About six months ago, we
discovered that Liam Shortt from Bray Engineering Services was retiring. He had the agency for KraussMaffei and Motan Colortronic before me. Richard approached me explaining that they would normally ask an established Irish-based company to take over, but they already have
other priorities. They wanted someone whose sole priority was them and their product range. They told me they would have supported me at the start so I could promote their brands in the Irish market.
This is a one-in-a-lifetime opportunity and I couldn’t turn it down. I’ve never owned a business before, but I was lucky to have a great mentor, Connor Slater, who at the time was the Engineering Manager at Embecta. I have huge trust in Connor and he gave me the confidence to accept. I was shocked to be asked
The event for us is a must in the plastics industry, and an opportunity to meet with both old and new clients. See you in 2026!
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Continued from page 8 >
but also equally pleased and honoured.
[GD] How did KraussMaffei and Motan Colortronic support you?
[AH] They’ve allowed me to go out and do my job without worrying financially for the first two years. I can travel, meet old and new customers and re-establish relationships I may have lost. I wouldn’t have had the capital to do it, so their support is extremely important.
My priority is to represent KraussMaffei and Motan Colortronic, helping their customers overcome issues and providing them with innovative solutions. I think having a market presence in Ireland is essential. Many great companies need and want to be supported from a sales, projects and service perspective. It’s a unique position to be in and I feel fortunate to have been offered it.
[GD] How was transitioning from being a full-time employee to a self-employed agent?
[AH] It was strange, and it still is in some ways. Since we were young, we have had a tight schedule and a cut-off time. There’s no cut-off now. This lack of structure took some getting used to. I always like to be busy and help people, and I feel guilty when I have a quieter day. Being an engineer, I love solving problems and being involved, and I struggled with having some downtime, although it’s becoming less frequent now.
I have worked full-time for a company for the past six years, meaning I didn’t travel much. During that time, my network within the injection moulding industry shrank, and I had to get it going again when I became self-employed. I think it was the biggest challenge and still is. Some people don’t know me and others haven’t seen me in a long time, so I am focused on building these relationships back up again.
This job is all about trust. It involves replying to emails punctually and keeping your word. If you say you’re going to do something, you need to prove to them that you’re ready to go out and do it. It’s about keeping the line of communication open and being honest with your customers. If you don’t know the answer to a question, show them you’re actively looking for ways to find it. Some people may be sceptical, especially if they don’t know me, so I want to prove that they can trust me, my skillsets and my expertise.
[GD] What are some of the projects you’re most proud of since stepping into this role?
[AH] I was involved in a project with BD, known as the ‘Nano PRO’ project. It’s a pen needle device, and I was tasked with the selection, installation, integration and validation of capital equipment. There were 192 cavity moulds and I had to build these injection moulding cells. Many of these moulds run sub four seconds and each one produces a billion parts every year. This is the first time I’ve seen something like this in the industry.
I carried out the validation of the Nano PRO moulding cell to medical device standards. It’s the project I am most proud of.
[GD] How do you see your role evolving in the future?
[AH] My priority for the next six to 12 months is to re-establish older relationships and foster new ones. I want to add value to my customers and the projects I am involved with. I am lucky to travel and explore different realities, so I can bring fresh ideas
“I think having a market presence in Ireland is essential. Many great companies need and want to be supported from a sales, projects and service perspective. It’s a unique position to be in and I feel fortunate to have been offered it.”
to each project. I also plan to get the business settled and introduce a routine.
I am extremely grateful for the opportunity that KraussMaffei and Motan Colortronic have given me. I am also thankful for the help from Liam Shortt. He came to visit clients with me, and we have a few more trips planned in 2025, so his support has also been invaluable.
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Robert Last, Summit Systems’ Managing Director, speaks with BP&R to discuss the company’s focus and priorities for 2025 while striving to maintain a competitive edge and strong working relationships.
[GD] How does it feel to be stepping into the role of Managing Director at Summit Systems?
[RL] Stepping into the role of Managing Director at Summit Systems is an incredible opportunity. I am truly honoured to take over from Mike Jordan as he steps up to Group CEO in continuing to grow the business and maintain our position as the go-to supplier of ancillaries for the plastics industry.
Mike has built a remarkable legacy since founding the company in 1989, introducing world-renowned suppliers to the UK plastics industry. A major milestone in our journey was the acquisition of Total Process Cooling in 2017, which became the Process Cooling division of Summit Systems. Process cooling remains a key growth area for us, and we see great potential in it over the next 5 years. Mike will continue to work closely with our suppliers on the development of new products and services.
Becoming a Managing Director has always been a
BACK FROM LEFT TO RIGHT: Paul Perry, Matt Ross, Ian Lowe, Nigel Baker
FRONT FROM LEFT TO RIGHT: Mike Jordan and Robert Last
personal ambition. When I joined Summit Systems in 2022—a company where the passion and dedication of the staff are palpable—I knew I could play a role in shaping the future of the business. So, when the opportunity arose, I was ready to take the ‘bull by the horns’ and make a significant impact on the future of Summit Systems.
[GD] How does your vision align with Summit Systems’?
[RL] My vision aligns closely with Summit Systems’ commitment to placing customers at the heart of everything we do. I’ve come to understand that our people are often the first point of contact for customers, and this approach is something I truly value.
Many of our customer and supplier relationships span years and some decades, and their voices are genuinely valued and listened to across the business. These collaborative partnerships ensure we work together as one entity, striving to help our customers make and save money.
Ultimately, my vision is to continue fostering these strong, long-term relationships, ensuring our customers and suppliers feel
supported and empowered to achieve their goals.
[GD] How do you plan to drive the company into the next phase of growth?
[RL] We are proud to work with over 1,500 companies in the UK plastics industry, supporting their production with the latest technologies and innovations. Our plan for the next growth phase is to broaden and deepen our penetration into the UK and Ireland.
Summit Systems will continue to provide comprehensive aftercare services. These will be supported by a dedicated after-sales team of knowledgeable engineers who offer ongoing service and support to our customers, building on Mike’s first-to-market 24/7 service support.
In 2024, we hosted our first Process Cooling Open Day, inviting customers to learn more about the advanced technologies we offer. The event was well received, and it opened their eyes to the potential cost savings and the latest technologies available such as Adiabatic Cooling which provides Free Cooling. We’re planning the next open day for March 2025.
“Our focus remains on optimising productivity and reducing energy consumption, helping our customers make and save money, whilst driving sustainability.”
We cherish our longstanding relationships with multiple world-class suppliers in both plastics and cooling. We have bolstered our sales and service teams to allow us to deliver our long-term strategy.
[GD] Have you seen any trends in terms of customer demands and requirements during your time at Summit?
[RL] We’re committed to supporting each of the markets we work in, whether it’s automotive, technical, medical, packaging or construction, and the different challenges they face.
A good example is energy efficiency, which we find to be a key focus for our customers. One of them reported an annual energy saving of 357,667kWh with their new adiabatic cooling system, representing an impressive 90% reduction in energy consumption compared to their original system.
Additionally, the Maguire Vacuum Dryers can help reduce energy usage by up to 70%, with one of our customers reporting a 6-hour reduction in their start-up times, allowing them an additional 6-hour production time whilst also cutting energy usage during that period.
Another example of significant savings comes from the Microgel Temperature Controllers by Frigel. In a recent trial on a customer’s injection moulding machine, the controllers reduced the cycle time to under 9 seconds. This efficiency boost increased production so dramatically that the customer ran out of packaging materials,
having never achieved such productivity levels before. They have since ordered three more units.
Our focus remains on optimising productivity and reducing energy consumption, helping our customers make and save money, whilst driving sustainability.
[GD] What are the company’s top three priorities for 2025?
[RL] In 2025, we are exploring acquisitions to expand our products and services range to support our customers.
We significantly invested in our IT systems to enhance efficiency across all departments. These improvements enable us to work more effectively with our customers, ensuring quicker turnaround times for quotes, and prompt technical and service responses.
We understand that every minute of downtime impacts operations, so we have focussed on strengthening our After-Sales Customer Support. We have recently appointed an Engineering Director to reinforce our technical and engineering departments. To support him, we have introduced a Customer Response Manager and a Customer Support Manager to maintain high-quality service as we grow.
[GD] If there’s one thing you’d wish to achieve as Managing Director at Summit, what would it be?
[RL] Mike established the business 35 years ago and I intend to build on it with the support of the team I am really fortunate to have while maintaining that number one position in the marketplace.
The economy in 2024 continued to be dominated by the effects of the global economic slowdown. General inflation was moderate throughout the year, although it stayed above the Bank of England target of 2%. On this basis, the base interest rate was only reduced once in the period by 0.25% to 4.75%. In addition to the ongoing conflict between Russia and Ukraine, the clash between Hamas and Israel continued while geopolitical tensions in the Middle East remained a global concern. At the beginning of 2024, Houthi terrorist action against commercial shipping in the Red Sea raised concerns about supply chain security, delayed the arrival of goods from Asia and increased shipping costs as vessels diverted from the shorter Suez Canal route and sailed around the Cape of Good Hope.
After a small upswing from the shipping issues at the start of the year, the polymer market prices continued to trend lower. All sectors witnessed supply exceeding demand, exacerbated by producer capacity increases for many materials. A small price upswing for volume polymers occurred in autumn but was not sustained as producers fought hard to win available volumes. Prices remain at the level described as the ‘bottom of cycle economics’ by polymer producers, leading to the idling and closure of plants where the financial performance is no longer viable. This effect was more pronounced in Western Europe due to the higher cost of operating polymer plants, and further polymerisation plant closures will cause an increased dependence on imports.
As in the polymer market, the risk of global recession weighed heavily in the energy sector. It continues to overtake geopolitical concerns that could affect oil and gas supply, with prices remaining depressed throughout the year.
Following a challenging 2023, polymer converters often struggled in 2024, with factors such as low demand in the automotive sector and further substitution of single-use plastic packaging with wood fibre alternatives impacting demand. Low polymer prices provided some relief towards achieving adequate levels of financial performance.
Crude oil
Brent Crude traded in a relatively tight range of 73 - 89 USD per barrel. Prices increased steadily until April and fell away until October when prices blipped on the back of fears of a wider conflict in the Middle East before stabilising at the end of the year.
The Euro trended weaker against the GBP through most of 2024, with a gain of 5 cents over the 12 months. The GBP: USD was more volatile with the dollar weakening in the run-up to the US elections but recovered its losses by the year-end. The average monthly value ranged from 1.25 to 1.32 during 2024.
The volatility of aromatic feedstock continued in 2024, with Benzene and Styrene monomers recording significant swings, often independent of Brent Crude and Naphtha.
The olefin situation was dominated by over-supply, with spot prices trading at a considerable discount to the contract values. In the case of C2 high-import penetration of competitively priced PE suppressed demand. Despite C3 being typically a co-product of Naphtha cracking from C2 production, any associated reduction was insufficient to avoid a glut of C3, leading to large discounts for spot purchases
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It is interesting to note that all monomers recorded a moderate net gain in contract pricing.
Such was the demand for polymer raw materials that producers were typically forced to pass through monomer discounts in full, with polymer converters resisting full
monomer increases. They were often able to achieve discounts greater than monomers as competition for available volumes was intense.
The graph below confirms the oversupply of C2 and C3, with spot volumes selling at discounts versus Naphtha for at least part of
2024. Overall, the economics of monomer production in 2024 improved from 2023.
The graph below illustrates the relative volatility of aromatic feedstocks, with periods of discount and significant premium. The economics towards the end of 2024 became very marginal.
https://www.getecha.de
The disruption to shipping caused by the Hothi attacks in The Red Sea resulted in prices increasing from February to May. Then, prices moderated until July when a very modest recovery took place before prices fell away through to the end of the year.
After close tracking of PE and PP price levels in 2023, 2024 saw PP pricing dropping below PE for the first time since late 2018. This was mainly due to the weak demand for PP in the consumable durables market with automotive and white goods markets suppressed by low consumer confidence levels.
2024 was an interesting year in terms of styrenic polymer pricing. The increasing price in the January-April period and the falling input pricing reflect the influence of imports from the Far East when shipping was being disrupted following the Houthi attacks in the Red Sea. Not only did shipping times increase as vessels diverted around the Cape of Good Hope, but some ships had to take on additional bunker fuel, leading to delays and vessels returning to their port of origin. This led to prices falling away, until they briefly increased in the late summer, before receding again.
The supply of PE from the USA that resumed in 2022 continued to be a dominant factor in 2024, with a strong flow of materials for film extrusion and blow moulding arriving at competitive prices. UK converters have become accustomed to the longer lead times and the consequent need to make forward price commitments to secure supply
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Engineering polymers
The engineering polymers market reflected the global economic situation, with prices continuing to slide throughout the year. The high level of competition for available volumes eroded producer margins. Profitability stabilised from mid-year onwards.
UK Economic outlook
The recently elected Labour Government is seeking growth for the UK economy. However, both consumer and business confidence are subdued. In particular, employers are concerned about the hike in National Insurance costs, with a double whammy of increased rates and lower thresholds adding significant costs to wage bills. The aspiration to build more than 1 million new homes during the lifespan of this government is unlikely to be realised due to planning and labour resource restrictions.
The amendments to UK REACH, particularly the ATRM process, will help ensure that the cost of compliance for UK businesses is significantly lower, reducing the risk that some substances become unavailable due to prohibitive registration expenses.
Global geopolitical issues
The second Trump Presidency will likely have a major impact on global politics. Attempts to resolve issues such as the Israeli conflict with Gaza, the Russian invasion of Ukraine and Houthi rebels from Yemen disrupting shipping will contrast with increased taxation on goods imported into the US, from which retaliations risk escalating into a broader trade war.
In 2024, European and UK PVC producers successfully applied for imposing anti-
dumping duty on US-origin products. While this action benefits PVC producers, PVC converters will likely suffer following an increased penetration by imports of semi-finished and finished goods.
Logistics
The combination of relatively low polymer prices and volatile container shipping rates could cause significant disruption in polymer supply. East-West routes will likely be the most volatile. European polymer converters’ greater resilience on polymer imports will add to the vulnerability of supply chains, highlighting the importance of resilience.
Exchange rates
The USD is likely to strengthen as the Trump presidency gets underway. This will place inflationary pressure on imported PE from the US and imports of materials from outside of Europe. Bank of England interest rates will remain higher than those in the Eurozone, maintaining the GBP stronger than the Euro.
Crude oil
The likely scenario is that Brent Crude will continue to trade in the 70 – 90 USD per barrel range, with energy companies trying to manage supply in an economic environment that will tend towards falling prices. Traditional energy companies heavily reliant on Crude Oil sales and derivatives have increasingly diversified their revenue sources, with many turning to renewables for sustainability both for the planet and their business models.
Feedstock
C2 (Ethylene)
Ethylene pricing is likely to be heavily influenced by PE import levels from the USA, which are expected to increase in 2025 and keep C2 pricing at relatively low levels.
C3 (Propylene)
C3 has a double reliance on crude oil refining in which C3 is a significant cooutput of Naphtha cracking for ethylene and a bi-product of the FCC (Fluidised Catalytic Cracking) process. This is 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, meaning low C2 demand and refinery output rates will impact C3 availability. Demand for petroleum is likely to decrease following the increased use of EVs. Recovery in C3 demand to make polypropylene required for consumer durables could tip supply/ demand back for producers. This could lead to some cross-subsidy of C2 derived from Naphtha cracking.
This important aromatic hydrocarbon compound is the basis for the following intermediates, including Ethylbenzene, Cumene, Cyclohexane, Nitrobenzene, Linear Alkylbenzene, Maleic Anhydride and others. 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 aromatic petrochemical compound.
The fortunes of SM are closely related to Ethylbenzene and Benzene. An important characteristic of SM and the Benzene family is their relative ease of being shipped worldwide in tanker vessels. 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 – an important component of polyurethane manufacturing used in automotive and furniture.
2024 will continue to be challenging for Polyolefins as more new capacity for all grades comes on stream, with demand likely unable to match it. Highly commoditised grades such as PPHP, HDPE for blow moulding and LLDPE C4/ C6 for film applications will be under the most pressure. Oversupply in these sectors will push producers to increase the output of more specialised grades which will decrease price pressure on these more premium products.
The situation for 2025 starts with some uncertainty. Polystyrene prices are likely to closely follow the volatility of SM (Styrene Monomer). Towards the end of 2024, several European ABS producers called for the imposition of anti-dumping duties on imports from Asia. However, no similar application has been made to the UK authorities so far, probably because there is no domestic ABS production.
2025 started much the same as 2024 finished with downward pressure on prices and plentiful supply from producers across the board. It is expected that notations for most engineering polymers will continue to soften throughout the year, as competitive pressures continue.
Taxes PPT and Corporation Tax
The UK Plastics Packaging Tax that came into effect in April 2022 saw a rate of £200 per tonne for plastics packaging that contains less than 30% recycled content. It was increased to £217.85 in April 2024 and is likely to be adjusted by the inflation rate in 2025. In the case of plastic raw materials, this typically costs about £1.00 per tonne due to the liability incurred on plastic valve sacks. The more significant impact relates to the supply of plastic packaging where the liability applies to each tonne of packaging produced, with the last entity undertaking a ‘significant transformation’ picking up this tax liability. The opportunity to use chemical recycling and adopt a mass balance approach is likely to be approved following detailed discussions with HM Treasury.
The state of the UK Government’s finances is unlikely to afford any opportunity for tax concessions for either companies or individuals. However, there is a commitment not to increase the rate of Corporation Tax in the lifetime of this parliament.
Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution.co.uk
The construction industry is a major contributor to global carbon emissions, accounting for approximately 39% of all emissions worldwide, according to the World Green Building Council. 28% of this stems from operational emissions, such as energy usage for heating and lighting, while 11% is due to embodied carbon in construction materials like timber, steel and concrete. Temporary structures like hoarding have traditionally relied on materials like plywood and timber, which come with high environmental costs.
Not only are they resourceintensive, but they also create waste and pollution when discarded after use. Timber’s contribution to deforestation exacerbates biodiversity loss and climate change, while plywood production often generates chemical pollutants. Temporary structures made from these materials have short lifespans and often end up in landfills, leading to waste generation and environmental degradation. The disposal of timber hoarding adds to
Daniel Foster, Technical Sales Engineer at Condale Plastics Ltd, explores how a successful partnership with Panthera Group redefined sustainable solutions for the construction industry.
“The construction industry now stands at the forefront of a global push towards sustainability and is uniquely positioned to drive change due to its significant environmental impact and expansive reach.”
landfill volumes and results in the release of stored carbon back into the atmosphere as the wood decomposes.
Panthera Group recognised these challenges and made sustainability a central tenet of their operations. In 2021, they launched EnviroHoard, the UK’s first net-zero verified hoarding system to undergo a cradle-to-grave Life Cycle Assessment. This innovative product eliminated the use of
traditional materials in favour of sustainable alternatives. The company needed a reliable partner to supply ecofriendly materials that met sustainability and performance requirements and found one in Condale Plastics.
By using recycled uPVC sourced from end-of-life window frames and doors,
Condale provided Panthera with a material that could meet the durability demands of construction sites while significantly reducing the product’s environmental footprint. This can be reused up to 10 times through a closed-loop process, ensuring long-term sustainability and minimal resource wastage. One of Condale’s contributions was their ability to extrude 500mm-wide profiles for the EnviroHoard panels. This allowed Panthera to create hoarding systems that were durable and capable of withstanding harsh construction environments. The result set a new industry standard, seamlessly combining resilience with ecofriendliness.
CUSTOMISATION AND COLLABORATION
Beyond sustainability, modern construction projects demand customisation to meet specific branding and aesthetic requirements. Panthera’s clients often request bespoke hoarding in unique colours, such as Cobalt Blue. Condale’s extrusion capabilities and expertise in colour matching allowed them to deliver high-quality panels tailored to these needs, ensuring that each project aligned with the client’s branding.
Condale’s commitment to collaboration extended to the design and tooling process. The team worked with their partner to develop a bespoke tool for extruding wide panels, enhancing the hoarding systems’ structural integrity and visual appeal. This facilitated seamless panel connections, ensuring that EnviroHoard was not only robust but also aesthetically
pleasing. This product has significantly reduced carbon emissions, helping Panthera advance its commitment to achieving net zero by 2045.
Neal James, Managing Director of Panthera Group, highlighted the importance of Condale’s expertise and collaborative approach: “Condale has proven to be highly cooperative, their extensive technical expertise has been invaluable throughout the process. They take the time to explain the extrusion process and its difficulties, helping us grasp what can and cannot be accomplished about new profiles, colours, etc. Thanks to Condale’s expertise and support, we have emerged as a leader in delivering sustainable, net-zero products, helping our clients meet their own sustainability goals,” said James.
The construction industry now stands at the forefront of a global push towards sustainability and is uniquely positioned to drive change due to its significant environmental impact and expansive reach.
By investing in emerging technologies such as 3D printing, infrastructure digital-twin simulations, carbon-capture materials and smart energy systems, the sector can reduce emissions and enhance efficiency.
EnviroHoard serves as a blueprint for how innovative materials and processes can address environmental challenges while meeting the industry’s practical needs. As the demand for eco-friendly construction solutions scales exponentially, these partnerships will play a pivotal role in shaping the future of the industry.
Chairman of DIP, Martin Sixsmith, said that with increased focus on the self-care agenda, the 2025 theme offers an exciting opportunity for creating a product which can seamlessly integrate into daily life and help all age groups.
“This is a subject which resonates with many people, and it therefore offers a huge amount of scope for students to showcase their creative talents for the benefit of others,” he said. “We are very much looking forward to seeing their end product!”
Students must submit their entries by March 14th, when DIP’s panel of industry judges will whittle the submissions down to a final six. Final judging will take place in London on May 9th, with the award ceremony on June 20th.
Design Innovation in Plastics is the longest-
UK and Ireland-based university undergraduates will take part in the DIP competition to design a plastics-made product to promote or monitor either physical or mental health.
running plastics competition of its kind in Europe, having been established in 1985. It is supported by the Institute of Materials, Minerals and Mining, the Worshipful Company of Horners, and sponsored by leading design and plastics organisations, including Covestro.
Sustainability is one of the key considerations applied by the DIP judges when critiquing the many designs submitted. Students entering the competition are asked to show evidence that a clear understanding of sustainability principles has been applied to their design.
DIP works in harmony with the British Plastics Federation which, via its member groups and expert committees, is championing several sustainability initiatives at different stages of the supply chain - including design - to achieve a circular plastics economy.
“This is a subject which resonates with many people, and it therefore offers a huge amount of scope for students to showcase their creative talents for the benefit of others.”
In a world that has had to rapidly adapt to on screen education there has never been a better time to invest in a British Plastics and Rubber webinar.
We will help you with the whole process, with a dedicated project manager, content consultation and a multi-channel marketing campaign to drive attendance and views.
Webinars offer a multi-layered marketing outcome, enabling you to tell your story to a global audience, define your organisation as a thought leader and simultaneously deliver a healthy number of leads for your sales team to get to work on. To discuss how you can leverage our audience and marketing channels with a Webinar contact our Sales team:
As NEXTLOOPP approaches its fourth anniversary, it is time to take a closer look at the multi-participant progress in closing the loop on postconsumer, food-grade recycled Polypropylene (FGrPP).
Nextek’s project benefits from four years of trials and learnings that have fasttracked the polyolefin sector’s understanding of how to maximise PP’s lifecycle.
Some milestones are the challenge tests for HDPE and PP that avoid the limitations of the PET style challenge tests, quantification of the background contamination in post-consumer PP, highperformance cleaning steps, ink separation, including ILMs, and multiple decontamination technologies. One of the main breakthroughs is food-grade sorting using AI.
TIME IS RUNNING OUT FOR PP
The European Commission’s Packaging and Packaging Waste Regulation (PPWR) is pushing for more stringent recycling and reuse standards by 2030, which could spell the end of PP if there’s no pathway for its sustainable recycling. This would leave a yawning gap in the postconsumer food-contact packaging sector.
Professor Edward Kosior at Nextek discusses recent trials during which TOMRA’s GAINnext sorted 5 tons an hour at 97% purity. He explains how AI can successfully separate food contact from non-food-contact packaging, boosting sorting capacity and sustainability in packaging design.
HDPE (milk bottles) and recycled PP (most of our pots, tubs and food trays) have a 25% lower carbon footprint than recycled PET.
Some might argue that PET should fill this gap. However, Plastics Europe has conducted a life cycle assessment that compares the carbon footprint of different recycled plastics. This revealed that recycled
THE SORTING DILEMMA NEXTLOOPP’s fluorescent marker technology, PolyPPRISM, competed with several contenders to differentiate food-grade plastic packaging from the waste stream. The issue is that changes to the labels or the packaging are required. One of NEXTLOOPP’s initial
focuses was to separate food from non-food packaging. The team trialled UV markers with NEXTLOOPP participant, TOMRA. This seemed the most effective spectroscopic sorting technology at the time. It separated the same polymer into food and nonfood fractions by adding a fully integrated, coded sorting dimension to the standard NIR/ VIS sorting systems.
Even before NEXTLOOPP launched, TOMRA had introduced the industry’s
“As traditional markers become obsolete for rigid packaging, sustainability and circularity will soon be incorporated into packaging design, delivering both environmental and economic advantages.”
first AI-based deep-learning sorting solution to separate silicone cartridges from PE streams and later for wood sorting. In 2024, the company introduced the food-grade application to address the industry-wide challenge of food-grade separation.
NEXTLOOPP supported the PP field validations conducted by TOMRA to test GAINnext’s capabilities in industrial conditions.
By early 2024, TOMRA had accelerated its GAINnext deep learning technology to separate food and nonfood plastics and was using it to identify PP packaging. They quickly realised it was a game-changer, as it correctly identified over 97% of prior food packaging content.
Since then, TOMRA and NEXTLOOPP have conducted ground-breaking trials using the former’s near-infrared, visual spectrometry system AUTOSOR. This, combined with their latest deep-learning technology GAINnext, shows how deep learning, a subset of AI, could supersede markers for rigid packaging and resolve the food-grade PP sorting hurdle.
During the latest full-scale trials, AUTOSOR and GAINnext sorted 5 tons per hour of mixed PP plastic packaging and exceeded 97% of food-grade content in the sorted output.
By providing a sorted foodgrade PP PCR stream, AUTOSOR and GAINnext can accelerate the supply of food-grade rPP via the NEXTLOOPP decontamination process in many recycling operations without any delays associated with new label or marker requirements.
Less than 12 months ago, NEXTLOOPP focused on packaging design guidelines to facilitate sorting packaging into single-polymer fractions using markers.
TOMRA’s latest innovation has turned this upside down. Instead of a system that relies on labels featuring specific markers, the neural network of the AI system is trained to identify a wide range of shapes and packaging attributes. Through structured training, it learns to separate food contact from non-foodcontact packaging.
The next step is to revise current design guidelines to understand how AI ‘thinks’. This way, we can continuously enhance GAINnext and other existing sorting solutions’ capacity.
The principles by which GAINnext recognises a package are based on object recognition. Segmenting different design factors helps AI gather different triggers to build its contextual memory of every pack.
Using the road sign analogy, AI is trained on food package shapes, sizes, dimensions or other criteria that occur frequently. Transparency, opacity, print, shapes and colours alert the system that is designed to aim for accurate recognition of the sorted PP packaging.
The more stereotypical the pack shape and inclusive of readily identified attributes, the higher the identification rate. PP food trays are predominantly unpigmented or white and rectangular, making them easy to pick. However, items like ice cream tubs, often solid and white,
are likely to be rejected from the food packaging stream as they could be identified as non-food dishwasher capsule packs. This is where design attributes and deeper learning can boost the correct recovery.
Using colour or design features to identify a pack’s former use can enhance AI capacity to define the pack’s destination. Easily identifiable packages can help brand owners signal their recycling identity without relying on a label. This has huge implications for data collection during sorting. It also provides an opportunity for Extended Producer Responsibility reporting and recovery of discrete packaging streams
via novel PRF configurations. GAINnext is trained to learn enough attribute points of differentiation to make an effective sorting decision in a split second, even if the package is crushed, torn or damaged.
This breakthrough in highspeed and precise AI sorting, exemplified by TOMRA’s AUTOSORT featuring GAINnext Deep Learning Technology, is already making a significant impact on the recycling industry. As traditional markers become obsolete for rigid packaging, sustainability and circularity will soon be incorporated into packaging design, delivering both environmental and economic advantages.
The chemical industry is poised for growth in the coming year, according to Deloitte’s 2025 Chemical Industry Outlook. Following these developments and increasing energy costs and sustainability pressures, adopting energy-efficient solutions is critical for plastics manufacturers.
Traditional injection moulding methods are energy-intensive, especially those that rely on hydraulicpowered machines. These often consume electricity even when not in use, resulting in inefficiency. Allelectric injection moulding machines offer a significant improvement, using energy only when necessary and contributing to substantial reductions in electricity consumption.
Deloitte forecasts a 3.5% rise in global chemical production by 2025, driven by automation’s role in boosting efficiency and sustainability. Nigel Smith, CEO of Shibaura Machine’s UK and Ireland partner and distributor TM Robotics, explains how industrial robots and all-electric injection moulding machines can help companies more than halve their energy consumption while enhancing productivity.
Performance tests by Shibaura Machine found that switching to all-electric
“Integrating allelectric injection moulding machines and industrial robots offers a practical path, reducing energy consumption, cutting costs and boosting productivity.”
injection moulding machines — specifically the Shibaura Machine
EC650SX-61B IMM with a clamping force of 650 tons — delivered a 51% energy reduction versus using a hydraulic servo machine. These savings are extremely important, as manufacturers strive to balance increased demand for plastics with the need to minimise their environmental footprint.
ENHANCED PRODUCTIVITY AND SUSTAINABILITY
Robotics can also play a crucial role in amplifying the benefits of all-electric injection moulding machines. SCARA robots boast high-speed performance and repeatability, making them ideal for packaging, medical device manufacturing and automotive applications.
Robots like Shibaura Machine’s THE400 SCARA
offer great adaptability and improved throughput. They are designed to handle larger payloads and have an extended reach, meaning they can be integrated with larger injection moulding machines.
Another key development is ceiling-mounted SCARA robots, which optimise available space in production environments. For instance, in a plastics factory, such robots could swiftly pick and place newly moulded plastic parts from an injection moulding machine onto a conveyor, without taking up valuable floor space.
They can unload parts from moulding machines and provide additional functions such as product inspection, assembly or packaging while maintaining high-speed operation and precision. With automation becoming more affordable, manufacturers can reduce labour costs and improve production efficiency, making these investments highly cost-effective.
Lotan, a UK-based manufacturer of plastic containers, had relied on hydraulic injection moulding machines but found these too energy-intensive. Instead, the manufacturer opted for Shibaura Machine’s all-electric injection moulding machines by TM Robotics. The company cut its running costs by 20 to 40% and shortened its cycle times by 35%, with a lower cost-per-mould.
These benefits, along with flexible clamping force and faster production, have led Lotan to invest in more Shibaura injection moulding machines — specifically the SXIII range. As an all-electric machine, the SXIII helps reduce running costs and cycle times while maintaining precise clamping force control.
As highlighted in Deloitte’s 2025 Chemical Industry Outlook, the UK plastics sector must adopt energyefficient solutions to stay competitive. Integrating allelectric injection moulding machines and industrial robots offers a practical path, reducing energy consumption, cutting costs and boosting productivity. These innovations support sustainability goals and help manufacturers thrive in a rapidly evolving market.
Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com
Maximum availability and minimum service costs
They guarantee a long service life and minimal costs thanks to their robust design. The travel axles have a new profile geometry and are made of crash-resistant aluminium or steel. This reduces unplanned downtime to a minimum and enables cost-effective maintenance, making them ideal for long-term use in industrial production.
User-friendliness at the highest level
One of LRXplus’ key innovations is the new MC7 control. It boasts an intuitive user interface and freely configurable operating buttons, making it simpler than ever. The enhanced teaching function enables the desired motion sequences to be implemented quickly, saving valuable time during
Switching to Borche means enjoying better performance, reliability and energy-efficiency at excellent values.
More and more moulders are switching to Borche. They’re taking advantage of the machines’ high performance, reliability, energy efficiency and value.
KraussMaffei’s new LRXplus linear robots boast various functions, making production more flexible and cost-effective. They can be combined with most systems thanks to their compatible interfaces, enhancing user-friendliness, performance and efficiency for several automation tasks.
set-up and operation. The 10inch multi-touch display also ensures an optimised user experience.
Proven performance further developed
The new LRXplus retains the strengths of KraussMaffei’s
previous LRX series and combines them with new features to achieve higher performances. These include great precision thanks to highperformance rack and pinion drives on the axes and a high residual load capacity of the robots.
Borche UK now has over 100 individual customers in the UK and Ireland. These range from multi-national groups that have chosen the company as their preferred supplier to small, independent family businesses.
Borche machines can stand alongside any European machinery brands and deliver equal, and often better, productivity and reliability.
They provide the same technology level at a fraction of the initial capital investment. Discover why larger moulders have switched to Borche. You can get three machines instead of two from the traditional European brands for the same capital investment, the latest technology and a three-year warranty. And you’re guaranteed an equally excellent service with little price difference.
The powerful servomotors continue to ensure fast acceleration while the synchronous movements reduce cycle times. In addition, the absolute encoder (multiturn) eliminates the need for time-consuming referencing when starting the robot. This speeds up the robot’s start-up of the robot and production.
Marekt debut at Fakuma 2024 Interested trade fair visitors had the opportunity to experience the new LRXplus in action at Fakuma 2024. The robot demonstrated its versatility in a multi-component application on an all-electric PXZ 121 and as a stand-alone version in combination with a popcorn machine. This underlines the LRXplus’ great flexibility for many automation tasks.
With the new LRXplus linear robot, KraussMaffei offers a solution that redefines flexibility, user-friendliness and automation efficiency. Whether used on an injection moulding machine from KraussMaffei, from a third-party manufacturer or for any other automation task - the LRXplus simply always fits.
“Borche machines have proven to be reliable and energy efficient, being able to stand alongside any European machinery brands and deliver equal, and often better, productivity and reliability.”
Hi-Class Machinery has recently started working with Nova Frigo, an Italian-based supplier of chillers and temperature controllers. This collaboration aims to foster new, successful working relationships.
“The continuous development of products with low energy consumption and zero ecological impact has always been their main goal. Their mission is to provide the best to their customers.”
Hi-Class Machinery Ltd are pleased to announce they now supply highquality chillers and temperature controllers, working closely with Nova Frigo.
The Italian company has successfully supplied their equipment across Europe and Africa since 1976. Now, it’s represented once more by UK-based HiClass Machinery Ltd, who offer an extensive range of highperformance water heaters and chillers at affordable prices.
From the beginning, Nova Frigo has developed machinery dedicated to refrigeration and thermoregulation They have supported
customers and guided them towards the best choices to ensure their production process is optimal and efficient, accruing a crucial knowledge of all different industries. The continuous development of products with low energy consumption and zero ecological impact has always been their main goal. Their mission is to provide the best to their customers.
For existing Nova Frigo customers in the UK, spare parts are available and more accessible than before.
Hi-Class Machinery Ltd looks to build on the after-sales service offered and looks forward to establishing new working relationships with these companies.
global large-part powerhouse in a compact footprint
The Milacron C-Series largetonnage injection molding platform is designed to deliver the highest performance, precision, power, and flexibility for the global market.
“Globally
launched in 2007, the MOSAIC platform’s evolution meets today’s manufacturing performance needs with adaptability and precision.”
The Milacron C-Series expands on the company’s vast machine technology through a largetonnage (1500-8,000 US / 1,300-6,100 metric) and two-platen press powered by an energyefficient servo-motor hydraulic system that
is geared towards versatility. This is designed to exceed the global demands of automotive, appliance, pallet and other large, moulded parts applications.
Powered by a reliable and energy-efficient hydraulic servo motor that operates with a high degree of reliability, the C-Series is tailored to demanding and diverse applications. Benefits include improved cycle precision and repeatability through a closedloop system, lower maintenance costs and reduced energy consumption (as compared with conventional hydraulic systems).
The machine platform comes with predefined configurations that can increase the speed, accuracy and capability in the large-part market. Milacron’s integrated lock nut/tonnage system uniformly distributes clamp force and reduces mould wear while offering advanced control and improved parallelism.
Enhanced machine specifications delivered with the C-Series offer improved reliability, higher max mould weights, and faster clamp speeds. The compact two-platen clamp technology features a rigid platen that matches centre tonnage deflection and can accept increased max mould weights per platens. The twin-cylinder injection unit distributes force evenly across the screw centerline, while the standard injection unit swivel for easy screw removal.
Featuring a configurable layout, the C-Series MOSAIC+ multi-touch controller delivers fast processing, extensive data collection and automation integration. Additionally, the solution’s remote camera interface, Windows OS, self-diagnostic capabilities and multi-level data protection enhance manufacturing reliability and adaptability. Globally launched in 2007, the MOSAIC platform’s evolution meets today’s manufacturing performance needs with adaptability and precision.
Good or bad for the UK?
Dave Raine discusses the potential opportunities and challenges that may impact the UK and Ireland’s economies during Trump’s second term as the US President.
As this article heads to the publisher, I’m just catching up on events in the US.
The potential effects of Trump’s second presidency on the UK and Ireland’s economies will depend on his policies on trade, tariffs, foreign relations and global markets.
His first term focused on bilateral trade agreements, including a potential free trade deal between the UK and the US post-Brexit. A second term could see a more aggressive pursuit of these, potentially benefiting the UK through increased exports to the US.
However, his protectionist tendencies (such as his tariff use) could lead to trade tensions, disrupting UK industries that rely on US trade. With the UK out of the EU, a second term could lead to closer economic ties between the UK and the US, which might give the former leverage in negotiating with other nations, potentially improving its trade prospects. Trump’s “America First” approach might limit the overall growth of global trade, hurting the UK if this restricts access to key markets.
Trump’s previous policies contributed to market volatility, and his second term could
exacerbate that, particularly in global financial markets. His stance on climate change, energy and international agreements could affect international commodity prices, trade routes and supply chains. Ireland boasts many multinational corporations, especially in the tech and pharmaceutical sectors. If he continues tax cuts for corporations and reduces regulations, he could encourage more American companies to invest in Ireland. However, changes to international tax rules could challenge Ireland’s businessfriendly environment if global tax reforms (such as the OECD’s global minimum tax rate) are implemented. Trump has shown support for Brexit and the UK’s sovereignty, but his policies could be tricky in Northern Ireland, given the delicate peace process and the potential for trade disruptions. While the US has historically played a key role in the peace process, Trump could ease tensions or create challenges, depending on his stand on
Northern Ireland’s relationship with the UK and the EU.
In summary, Trump’s second term will almost certainly have a mixed bag of impacts on the UK and Ireland’s economies. Trump’s volatile style of governance and unpredictable foreign policy decisions might introduce uncertainty, particularly in sectors that heavily rely on stable international relations. While trade deals, investment opportunities and closer US-UK ties might benefit the economies, political volatility, potential global trade disruptions and shifts in foreign policy could introduce challenges.
The long-term effects largely depend on how Trump and our leaders navigate these complex issues and relationships. The next three to six months will be a nervous and interesting time for the UK and Ireland. We can only wait and see how leaders on both sides react.
Dave Raine Chairman, PMMDA
“While trade deals, investment opportunities and closer US-UK ties might benefit the economies, political volatility, potential global trade disruptions and shifts in foreign policy could introduce uncertainty and challenges.”
Philip Law, BPF’s Director-General, touches upon the potential impact of Trump’s presidency on the UK plastics industry while offering a glimpse into some provisional readings of recent results.
We all know that business planners need stability to chart the optimal future for their companies. Stability assists confidence, and confidence brings investment. However, the world is currently carrying along like a roller coaster.
Those who watched President Trump’s inauguration with a heavy heart will find little reassurance in his most stable feature: consistent unpredictability. In his first administration, his team included fewer wild cards. From a plastics industry’s standpoint, the Commerce Secretary, Wilbur Ross – a controversial figure who dabbled in tariffs – provided a sympathetic ear. Among his private investments was a major international plastics distributor. It isn’t the case with the current proposed Commerce Secretary, Howard Lutnick – a billionaire financier who appears to fully back tariffs, regardless of costs. How these will apply to the UK and affect our business is still unknown.
Back on home ground, there are few signs that the industry is among the government’s priorities, with the administration diverted by foreign policy issues, budget consequences and social unrest. While there has been some movement on packaging legislation, we still await a response to the government consultation on Industrial Policy and guidance on how it intends
to interface with businesses at large.
The responses to our latest Business Conditions Survey clearly shows that the BPF’s membership was unimpressed by the budget announcements, particularly the National Insurance increases and the costs of the employment law package.
A provisional reading of the results demonstrates that sales are down by 3.5% in January 2025 compared with January 2024. Sentiment about general business conditions in June 2024 illustrated that 57% of companies were optimistic about their outcome. Today, this falls to 22%, with the proportion of pessimists rising to 26% from just 8%. We also saw that 43% of firms wanted to increase staff levels in June 2024. This has now decreased to 31%, with many considering the NI increase as the leading cause. 45% of companies struggle to recruit staff.
Our Parliamentary Reception in Westminster on March 4th will provide the ideal platform to communicate these impacts to the government. We now have 20 MPs and two peers in attendance, which is an impressive strike rate. We will reinforce the importance of plastics for the UK’s security in terms of defence, food and freshwater distribution, transportation, healthcare and energy and digital infrastructure.
We are pleased that our Recycling Roadmap is gaining
traction among politicians. Today 21st of January, my colleague Helen Jordan, BPF’s Sustainability Manager, presented it to the Industry Parliament Trust, of which the BPF is a member. She gave context to the loss of 260K tonnes of recycling capacity in the UK over the last 18 months.
Overall, the plastics industry marches on. We increased our UK turnover from £29.7 billion in 2021 to £32.8 billion in 2022, which is the latest year for which ONC figures are available. It’s worth noting that Inflation influences these figures.
“Overall, the plastics industry marches on. We increased our UK turnover from £29.7 billion in 2021 to £32.8 billion in 2022, which is the latest year for which ONC figures are available.”
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