BP&R Jan 2012

British Plastics

and Rubber

bp&r

THE MONTHLY MAGAZINE FOR BRITAIN’S POLYMER PROCESSORS

lee thomas, md of th plastics, gets tough on dryER costs www.thplastics.co.uk

Success on an Olympic scale

Plastic design tailored A robotic boost for UK to fit manufacturing

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bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk EDITORIAL Editor: Leanne Taylor T: +44(0)1829 770037 E: leanne@rapidnews.com Managing Editor: Sam Anson T: +44(0)1829 770037 E: sam.a@rapidnews.com

SALES Advertising Sales Manager: Lisa Montgomery T: +44(0)1829 770037 E: lisa@rapidnews.com

A new year,

a new look

ART Production & Design Manager: Samantha Hamlyn T: +44(0)1829 770037 E: sam@rapidnews.com Production: jonny jones T: +44(0)1829 770037 E: jonathan.jonesr@rapidnews.com

SUBSCRIPTIONS Welcome to the first issue of British Plastics and Rubber for 2012. As our regular readers will notice, we’ve got a brand new look for the new year.

We’ve done this to coincide with the ever-changing plastics and rubber industry; embracing the modern with a fresh new look and design, while still championing the traditional with important news and updates. In each section readers will now find content split into shorter bursts of industry news alongside longer features, with colourcoded sections designed to help you find what you’re looking for, fast.

Our digital Xtra issue has also been launched – a completely new look with exciting additional content such as videos, animations and images, in a new turn-page format that’s designed to be easy to read and easy on the eye.

The year starts on a bright note for UK manufacturers, with reports suggesting that the sector performed well in Q3 of 2011, with productivity rising and an increase in new customers.

This is backed up by positive news regarding employment, as figures from the Reed Job Index Analysis suggest job opportunities were 17 percent higher in December 2011 compared to the same period in 2010 and more than a fifth higher than two years ago in 2009.

Despite the Eurozone crisis still contributing to a feeling of uncertainty, UK manufacturers are in a prime position to succeed in the face of adversity by taking advantage of factors such as increasing export orders from overseas markets and low interest rates. British Plastics and Rubber is proud to support UK manufacturing, and this issue features a special focus on two UK success stories – Vannplastic Ltd, a small business awarded a contract to supply the Olympic games with over 3900 m2 of composite decking, and Kelly Sant, a university lecturer with a keen eye for design, who, along with her partner, has produced a new and innovative plastic product that’s ready to launch in 2012. If you are a UK manufacturer with a successful, interesting or unique story to tell, contact the editor at: leanne@rapidnews.com In the meantime, you’ll find all of the regular sections of the magazine, such as injection moulding, engineering materials and reclamation and recycling filled with the latest news from the across the plastics and rubber industries.

I hope you enjoy the issue.

Leanne Taylor - Editor

Subscriptions Manager: Tracey Nicholls T: +44(0)1829 770037 E: tracey@rapidnews.com

PUBLISHERS Christopher E Young T: +44(0)1829 770037 E: chris@rapidnews.com Mark Blezard T: +44(0)1829 770037 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (10 times/year) by Plastics Multimedia Communications Ltd, Unit 2, Chowley Court, Chowley Oak Lane, Tattenhall, CH3 9GA T: +44(0)1829 770037 F: +44(0)1829 770047 © 2012 Plastics Multimedia Communications Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.

Associated organisations

THE BIG STORY TH Plastics won’t allow its customers to settle for the energy hikes The majority of UK energy providers announced increased fuel costs in 2011, with the main reasons cited being rising wholesale prices, largely due to political unrest in the Middle East, the increasing energy needs of the Asian market and the tsunami in Japan.

As a consequence, last year 52 percent of manufacturing businesses reported a hike in energy costs, with a quarter of British manufacturers experiencing a 10 percent increase, with some firms suffering utility bill rises of up to 55 percent .

So profits are squeezed as firms are reluctant to upset client relations by passing the costs on to their customers.

In severe cases, production is being forced overseas to China and other, cheaper, large scale manufacturing bases.

Bucking the trend, by finding ways to reduce plastics manufacturers’ overheads, is innovative ancillaries solutions provider, TH Plastics. The award winning firm, well documented for increasing its clients’ profits and improving their environmental credentials, has been enhancing its customers’ ancillary solutions with its latest range of rotary wheel dryers to help them bring down their energy bills.

TH Plastics Managing Director, Lee Thomas, explains: “The energy price hike has had a detrimental impact to many plastics manufacturers and we have been looking at how we can help to bring prices down for our customers. Dryers consume more energy than most other manufacturing equipment and our new rotary wheel dryers use 40 percent less energy than standard twin tower dryers. A simple change such as this can save a company thousands.”

The energy efficient rotary dryers, another recent addition to TH Plastics’ ever-expanding product portfolio, are another way the company is saving its customers money.

Lee went on to explain: “We pride ourselves in saving cash for our customers, it’s what we’re great at.

Previously, we’ve found ways for smaller manufacturers to bring their recycling on site, saving on distribution costs – 1

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Energy efficient rotary dryers from TH Plastics

traditionally this was deemed an expensive option, especially with some of the older recycling systems using substantial amounts of electricity, but we found a way to not only make it affordable, but to make it deliver a return.

“Now we’ve brought down energy costs for the majority of our customers by installing the resourceful rotary dryers.

“At TH Plastics, we focus on developing solutions that deliver a return and which are accessible to manufacturers of all sizes. Our systems self-regulate too and are fully automated, saving significant amounts of energy and cost and in turn increasing productivity. The initial investment with us generates a great return in terms of energy cost savings.”

It’s these solutions that recently won TH Plastics the ‘Supplier Partnership: Ancillary Machinery 2011’ Plastics Industry Award. The award was won for developing a turnkey solution that enabled its client, Birkby’s Plastics, to recycle its waste product on site, while turning what was a major cost for Birkby’s into a profit centre.

Lee continues: “We have open and trusting relationships with our clients;

Birkby’s has worked with us for many years. Customer service is really key to our business model, we want to make the experience of working with us hassle-free and positive. For example, to make the setting up process as smooth as possible, we’ll test the products prior to complete installation to check they’re compatible with the client’s existing machinery. This also means that the installation itself is hassle-free, taking a minimal amount of time and saving on operational disruption. All in all, we’re offering a solution to bring down customers’ overheads while making their businesses more streamlined, productive and environmentally friendly.”

TH plastics is growing rapidly, it has doubled its turnover in the last 12 months. One of the reasons behind the company’s increased success is its high level of technical expertise and ability to provide the best advice. With a growing team and decades of experience in the plastics sector, the business has retained some of the best talent in the industry.

Lee adds: “Our people make our business. Without them we couldn’t deliver the high levels of customer service that our customers are used to seeing. All our client-facing personnel have the technical knowledge, insight and creativity to ensure each customer has the bespoke solution that’s right for them. This is part of the reason why our main customers have worked with us for several years now.”

TH Plastics also recently added robot products to its continually expanding solutions portfolio, as a result of an agreement with pioneering robot manufacturer, Yushin Automation.

For further information or to book a free consultation please call T: 01457 855514 or visit: www.thplastics.co.uk

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on the cover

bp&r BRITISH PLASTICS &RUBBER

contents January 2012

on the cover

26-27 REGULARS

Lee Thomas, MD of TH Plastics, gets tough on dryer costs.

‘Tyred’ tyres get an eco-makeover

Energy efficient rotary dryers are helping to reduce manufacturers overheads by helping to bring down energy bills.

39-40

SEE PAGE 4

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RUBBER

THERMOFORMING Multi-layer thermoforming sheet extrusion line in demand

EDITOR’S LETTER

22-25

A new year, a new look

FILM & SHEET

INJECTION MOULDING

34

ENGINEERING MATERIALS

18

RECLAMATION & RECYCLING

32

SOFTWARE

43

BUYERS’ GUIDE

44

EVENTS

41

A focus on blown film

12-17 FEATURE

FROM THE FRONTLINE

DESIGN

Protecting the packaging industry

28

A tailor-made innovation in plastic

8-11 FEATURE

18

COMPOSITES Success on an Olympic scale for UK company

29-31 ]FEATURE AUTOMATION AND ROBOTICS Robots to boost UK manufacturing

42-43 INTERNATIONAL TRADE A look forward to the currency markets in 2012

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Composite concrete forms help construction industry break new ground At Plastimagen Mexico 2011, Sabic announced the launch of one-piece, reusable concrete forms made from the company’s high-performance LNP Verton long glass fibre-reinforced composite.

The new corrosion-resistant composite forms were developed by Sabic and Meccano de Mexico, a Mexican construction supply company, to replace heavy traditional multi-piece steel forms through reducing weight by up to 40 percent, cutting cycle times from hours to minutes and helping to reduce overall construction costs for more-affordable housing.

“Sabic provided the material technology, technical expertise and local presence that allowed us to successfully develop and commercialise this breakthrough product for our customers,” said Salvador Jalife Lozano, Chief Innovation and Development Officer, Meccano de Mexico. “Using LNP Verton composite, our new concrete forms can give contractors exceptional benefits including significant time savings, easier handling and durability for repeated use.

These moulds have the potential to change the way concrete panels are formed on the job site, helping to streamline construction and provide a

Postive mood at composites conference The current outlook for the Wood Plastic Composites (WPC) industry is positive and sales figures are promising, according to a market research study.

The study, carried out by Britsol-based AMI Consulting, was presented during the eighth WPC Conference in Vienna by Jon Nash, Head of Strategic Research at AMI, who stated annual growth rates of up to 22 percent are expected until 2013.

Mr. Nash said the largest growth rates are expected for applications in the building construction and interior finishing segments, with decking remaining the most widespread WPC application in the global market.

The conference offered a practical demonstration at the premises of headline sponsor battenfeld-cincinnati of a WPC coextrusion 7-chamber decking profile at a line speed of 2.25 m/min, which is the equivalent of about 400 kg/h.

Meccano de Mexico’s New One-piece Reusable Concrete Forms Made Using SABIC’s LNP Verton Long Glass Fiber-reinforced Composites

COMPOSITES

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Meccano’s new forms are used to mould concrete panels for houses where, on average, 500 panels are required for a typical row house.

“Replacing metal forms with our LNP Verton compound material is a major step forward in building and construction because it addresses top industry demands for ing Us Concrete Wall Made better materials, greater Forms Made from speed, lower costs and Meccano’s Concrete s ite Compos SABIC’s LNP Verton improved ease of use,” said James LeGacy, General Manager, Americas, Innovative Plastics. competitive advantage for Meccano and its customers. This cooperation with Sabic Futher information reinforces our mission: ‘Building www.sabic-ip.com Innovation’.”

The conference displayed innovative applications for WPC profiles

This decking profile is said to not only be geared to the growth market, but also offers the benefit of up to 25 percent in material cost savings compared to profiles wholly made of virgin materials, thanks to its inner layer consisting of reclaim material.

Deltawood, from Rijssen in the Netherlands, simultaneously presented a

new composite exhibition home at battenfeld-cincinnati’s technical centre.

The “Simply Housing” concept, designed for do-it-yourself applications, especially in disaster areas, demonstrated an innovative field of application for WPC profiles. In addition to metal reinforcement in load-bearing elements, the structure was provided with maximum strength primarily by targeted orientation of the wood particles inside the WPC profiles. battenfeld-cincinnati stated the predominant optimism and growth rates in the WPC industry also had a positive effect on its current fiscal year. In 2011, the machine manufacturer realised its second-best result ever in the WPC segment and was said to strengthen its position of market leadership in Europe and Asia.

Futher information www.battenfeld-cincinnati.com

UK named as country of honour at forthcoming composites show Innovation, automation and recyclability have been announced as the three main topics for this year’s JEC Europe Composite Show, at which the UK has been named country of honour as “one of Europe’s most innovative composite industries.”

JEC Europe, which will be held in Paris on 27-29 March 2012, is expected to receive over 30,000 visitors and host

more than 1,150 exhibitors.

Innovation has been identified as a key theme as it acts as a driver for the composite industry’s development.

According to JEC Group President and CEO Frédérique Mutel, “The worth of the global composite market went from 38 billion Euros in 2000 to 72 billion Euros in 2011.

We are expecting growth worldwide. At an average 6percent-per-year increase, our market will be worth 91 billion Euros by 2015.”

Futher information www.jeccomposites.com

2,200mm x 1,300mm that has been customised to include inlets within the surface of the table, which are used for resin infusion and additional vacuum under the membrane.

Vacuum press tables, from Elkom, may include further inlets to provide additional heating or cooling when using more complex jigs. Temperatures of 220°C can be achieved beneath the membrane.

The NCCEF vacuum press includes the patented energy-saving Ökotherm heating/cooling platen system and is designed to its their individual needs; with requirements such as temperature, heating and cooling times, temperature uniformity and system control.

Futher information www.cdukltd.co.uk

The show will feature composites in automation as a main theme

Playing an important role within Composite Press the facility, which meets University carries out cutting Challenge edge research into composite materials The National Composites Certification to support companies and Evaluation Facility in theaerospace Elkom composite vacuum (NCCEF) at the University supply chain, is a membrane press at the NCCEF of Manchester states it range of processing composites centre. has assembled state-ofequipment for the the art equipment and fabrication of developed analytical composites; either by techniques for the testing and evaluation lamination of prepreg materials, or resin of composite technologies. infusion of dry fibre preforms.

It is said to provide expertise and For vacuum pressing the facility is evaluation techniques in the development equipped with an Elkom composite of new composite products and vacuum membrane press used for its manufacturing processes and also heating and cooling platen technology. The provides companies with an evidence system installed at the NCCEF composites base to demonstrate the quality of their centre employs thermal oil heating with products. water cooling. It has a table size of

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Over 100 tonnes worth of Ecodek decking on the

COMPOSITES FEATURE

right hand side of the stadium in this picture

Success on an Olympic scale

for UK-based Composites Company

Vannplastic Limited, based in Saltney, Wales, is a UK small business enjoying an Olympic-sized success story after being chosen to supply 3900 m2 (approx 110 tonnes) of its Ecodek composite decking for use in the VIP area of level 02 of the Olympic Stadium.

The British-made wood polymer composite was chosen due to its ecological and sustainability credentials which fit in with the ethos for the 2012 Games.

Together with the specifiers, Vannplastic designed a bespoke decking profile to meet stadia design regulations that allowed for drainage, but stopped litter falling through the gaps and therefore becoming a fire hazard.

According to the company, the decking had to undergo stringent testing for slip resistance, load testing and burn resistance before it could get approval for use on the stadium.

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The Olympic Delivery Authority (ODA), the public body responsible for developing and building the new venues and infrastructure for the Games and their use after 2012, was so impressed with the product that they sent their CEO, John Armitt, down to the Ecodek factory for a tour and presentation.

Leanne Taylor caught up with Alex Collins, Director of Vannplastic Ltd, to discover more about the project and what it means for the company as a UK small business.

BP&R: As a small business, what does it mean to you to be awarded a contract to supply the Olympic games with your composite decking material?

AC: Being approved as a supplier to the Olympic Stadium has given us even more credibility with large construction companies and architects alike. The ODA’s flooring specification for the stadium was far in-excess of any standards we have had to meet in the past and as such, we had to subject our composite decking to some very rigorous testing procedures. All the testing was done on our standard Ecodek decking product and it passed with flying colours. Passing these stringent tests has given us and our customers even more faith in the qualities of our product.

BP&R: How long was the process from initial specification to the completed project?

AC: We were first contacted by the Stadium’s specifiers in May 2009. We then had to get the product approved for visual appearance and price. The physical and slip testing started in July 2009, followed by factory inspections and audits from the ODA and its approved contractors. The profile design (mildly modified from the standard Ecodek deck board to include an overlap) was approved early 2010. After this, we had to write up installation guidelines and approve fasteners etc. The actual

The Olympic decking is a solid decking board that gives a lot of benefits over hollow composite decking

product did not commence supply until winter 2010. All 110 tonnes of Ecodek were then taken over a very short period of about eight weeks.

BP&R: Can you explain more about composite decking, what its benefits are and how it measures up against traditional decking?

AC: We never suggest the composite decking is there to replace wood, rather that it is an alternative, in the same way that stone or slabs would be. Good quality composite decking offers many advantages over timber, the most obvious ones being reduced maintenance, no painting or staining, improved slip resistance, 95 percent recycled and 100 percent recyclable, smarter appearance, no splinters, available in custom lengths and in a range of colours.

Alex Collins with John Armitt, CEO of the ODA at the Ecodek factory

BP&R: Were you up against a lot of competition to supply the material for the stadium?

AC: Initially, I naively thought that we would easily get the contract due to the lack of other UK manufacturers of composite decking.

I was soon put right on that and told that the country of manufacture was immaterial. In the end we were competing against four or five other decking manufacturers from all over Europe.

BP&R: Can you explain the material make-up of the decking and why these particular materials are used?

AC: Ecodek has full FSC & PEFC certification and is made up from reclaimed hardwood fibres and recycled HDPE. The other ingredients are the pigment system and additives that improve strength, UV resistance, durability and reduce moisture absorption. Ecodek is a solid decking board that gives a lot of benefits over hollow composite decking. We only use hardwood fibres as these give better mechanical properties, improved appearance and reduced fade when compared to softwood based composite products. Our polymer content is HDPE; we use this polymer as it is very tough, has good low temperature impact resistance, excellent screw retention and is a readily available in recycled form.

BP&R: At the end its life, is the decking recyclable?

AC: Yes, its 100 percent recyclable making it a fully sustainable construction material. We even buy off-cuts and scrap back. However, because we make to custom lengths for no extra charge, there is always minimal waste on site and the customer is not paying for material that would end up as off-cuts.

Alex Collins

BP&R: Is the Olympic decking being used for any other applications?

BP&R: How big an opportunity for UK businesses is having the Olympic games held in London?

AC: The Olympic profile has now been relabeled as our ‘Stadia’ profile, as the overlapping profile of the board prevents flammable media from falling through the gaps and building up in any enclosed areas underneath. This was required in order to meet the ODA’s fire safety requirements.

It is not a profile that we run often, as you can imagine, there aren’t that many stadiums being built, but it is also available for other projects where an overlapping board is required.

The decking p stadia regu rofile has been des ig lations th at allow fo ned to meet stops litt r drainage, er falling through th but e gaps

AC: I suspect that it is a fantastic opportunity for business based in the south of England, but the further North you go, the less of an opportunity it seems to have been. We are one of the very few companies in Wales to benefit from the games so far, and I feel that’s a shame for the Welsh economy as a whole.

Futher information www.ecodek.co.uk MAIN IMAGE: London 2012

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Winning design student undertakes placement as 2012 competition gets underway Design student, Lewis Pearson, has returned from a week-long work placement at Bayer MaterialScience in Leverkusen, Germany, his prize as winner of Design Innovation in Plastics 2011.

Lewis, from Swansea Metropolitan University, won with his entry, 'Moving Shelves for Primary Schools', an interactive library shelf system for children aged 3-6.

Lewis said: “Design Innovation in Plastics is an excellent opportunity for students to explore products and challenge our own understanding of design. We have to consider the theory as well as the practicalities of bringing a product to market.”

Lewis's design adequately matched the theme of Design Innovation in Plastics (DIP) 2011, which was ʻDesign4Funʼ. Martin Sixsmith, chairman of the DIP organising team, said: “My

2011 winner Lewis Pearson

design

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The 2011 winning design , “Moving Shelves for Primary Schools’

congratulations once again to Lewis and the other five finalists from the 2011 competition, the standard of entries was high and we are now looking forward to an equally high quality from our 2012 contestants.”

Launched in October, DIP 2012 is open to all undergraduate and postgraduate students registered at a university or college in the UK, as well as Ireland. To date nearly 280 students have registered for the competition,

whose theme is ʻUniversal Design: Designing for the Rest of Usʼ.

Students are being asked to design a product to help those with physical or cognitive impairments, but which is also appealing to the mass market.

Around 100 students who have entered the 2012 competition have attended Bayer MaterialScience sponsored roadshows held at Northumbria University and at the Institute of Materials, Minerals and Mining (IOM³) HQ in London.

Design tutor Robin Jones, of London South Bank University, attended the DIP roadshow at the IOM³. He said: “We have incorporated Design Innovation in Plastics into our coursework. We view it as an excellent motivator for our students as they get the opportunity to work alongside industry experts and have them evaluate their designs.”

Futher information www.designinnovationplastics.org

The chair comes in a range of colours and is said to have premium surface quality.

Ticona's Celstran LFT gives light weight, rigidity and

robustness to the “IC01-Chair”

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Plastic goes designer with award winning chair A designer chair made of glass fibre reinforced polypropylene from technical plastics specialist, Ticona, has won awards for its innovative design.

The ʻIC01-Chairʼ is said to be lightweight, easy to process and provide high dimensional stability and surface quality.

The contemporary model, made of Celstran PP LFT with 30 percent glass fibre, is said to weigh 5.5 kg, which

Ticona claims is a lot lighter than competing models made of other materials.

“In addition to the significant weight and cost advantages over typical materials used in similar applications, this Celstran PP LFT offers high stiffness, strength, toughness and low warpage while providing wide design latitude, colourability and a much better surface finish out of the mould”, said Simone Orosco, Development and Marketing Manager of Ticona, Brazil.

Ticona claims the benefits of using Celstran PP LFT in a chair include the materialʼs little tendency to creep, its high impact strength, enhanced notch toughness, excellent tensile strength and elongation as well as its plastic deformation response to overloading, which prevents the chair from collapsing suddenly.

The ʻIC01-Chairʼ, which retails at 400 to 500 USD, has won various contemporary design prizes focused on styling, harmony and coherence of design in the designerʼs home nation of Brazil.

Futher information www.ticona.com

design FEATURE

The product is a new style of flat-packable

polypropylene mannequin that saves space and has an environmentally sustainable design

INNOVATIVE PLASTIC DESIGN

tailored to fit

With the modern world requiring innovative and inventive designs for ergonomic, economic and aesthetic reasons, the use of plastic is being rolled out across many business sectors. Kelly Sant, a Senior Lecturer and Area leader for plastics at the Faculty of Architecture and Design at the University of Brighton, tells BP&R how plastic innovation and design is providing much needed solutions for emerging and existing businesses in the fashion industry.

Itʼs no secret that starting up a fashion label is extremely demanding, ambitious and expensive, especially with soaring premium rental costs and costs of traveling to trade fairs and fashion shows. Systematique, a UKbased design company, is combating these issues head on with design innovation by successfully craeting a new, dynamic, flat-packable plastic mannequin, called ʻZiPP Mannequinoʼ.

Zipp Mannequinos are designed to look extremely stylish, as well as being by elected been s 12 0 s 2 a h in tment equino s n e n v a in M for The London Design

cost effective. The design of the Mannequinno has been carefully engineered from sheet polypropylene; its panels are zipped together to create three-dimensional forms. The amount of polypropylene used is utterly minimal and the design utilises the materialʼs properties to the full.

These space-saving designs embrace key customer needs and fulfillments, saving retailers precious storage space. They are ideal for packing for transportation to fashion shows, trade fairs and pop-up shops and are extremely cost effective for airfreight shipping. The basic form is ideal for customisation and branding, both at mid and high ends of the market, where technological innovation and design can be used to differentiate brands.

The aesthetics of their design is seen as a key advantage to retailers, such as award wining ʻDePLOY WorkSHOPʼ, Londonʼs sustainable fashion label, who have been using ZiPP Mannequinos both for travelling events and in their retail space in Marylebone. DePLOY Founder, Bernice Pan, says that the design has added

value to their outcomes as a customer, and remarks that even though the price is affordable, the forms do not detract from the fashion products being exhibited on them.

Systematique will launch their Mannequinos in 2012, having recently been awarded investment with Design London (http://www.designlondon.net) an international centre for interdisciplinary innovation offering postgraduate teaching and executive education and research.

Systematiqueʼs vision is to become the biggest provider of quality flat packable mannequins in the world, providing customers with a professional platform to represent and market their brands affordably. Their vision is also aimed at keeping the products as environmentally sustainable as possible, aside from the obvious advantages of being lightweight, space saving devices, Systematique are looking for production systems and sheeting solutions that create additional environmental impact on their products from cradle to grave.

Futher information Systematique Ltd can be contacted at studio@ arashandkelly.com

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design FEATURE

Mould software tools can help minimise mistakes in the injection moulding process

Amidst the turbulent economic climate challenging the plastics industry, manufacturers are looking at design to drive innovation. Eric Henry, Technical Sales Manager for Autodesk, explains more about how the latest moulding software can help plastics companies stand out from the competition.

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How Plastics Manufacturers Can Use Moulding Simulation Software to Shape

a

Brighter Future As we look forward into 2012, prospects for the UK’s manufacturing sector remain bleak, with the latest figures showing a weakening in output. According to the CBI, UK manufacturers reported a further slight weakening in total order books in December 2011 while export orders remained well below their long-run average. In plastics manufacturing, the picture is a little brighter with the emergence of new polymers likely to lead to a measure of growth during 2012.

Eric Henry, Technical Sales Manager, Autodesk

Weaker customer demand means we are seeing more manufacturers prepared to take on smaller volume productions - even among those companies that had previously ignored this area. In order to win new business, manufacturers have to be more creative with their designs to drive innovation. Many of the new products that will be developed during 2012 will be specialist and involving new technologies and processes.

In line with this, we are seeing a trend to more user simulation and analysis upfront in areas like computational fluid dynamics (CFD), stress and deformation analysis and failure mode analysis. These techniques reduce the risk manufacturers face in manufacturing innovative products and help them decide what types of designs or processes will not work at all or need modifying in order to function effectively.

We are also witnessing a growing trend towards design optimisation across the industry. Before committing to a new design, manufacturers are increasingly asking themselves the questions – can the product be made lighter, and critically, can it be made to perform more effectively over the entire product lifecycle.

Inevitably with economic conditions remaining uncertain and any projected recovery in plastics manufacturing still

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design FEATURE The close egr int ation of Moldflow simulation with Autodesk Inventor allows a perfect visualisation of the resulting moulded plastic part.

fragile, companies operating in this sector continue to need tools that drive insight into the plastic injection moulding process.

There are, however, a variety of other factors at play that are fuelling the need for mould analysis. Moulds are typically very expensive. If they do not work properly because, for example, the gate has been placed incorrectly and the mould does not fill, then the mould needs to be reworked which is very expensive. Mould fill simulation can help avoid such costly mistakes.

In addition, plastic parts are generally manufactured in very large numbers.

Therefore, the cycle time between filling and ejection of the finished part is critical.

In this context, mould simulation can help in understanding the cooling process of the plastic inside the mould and in making the right decisions in placing the cooling ducts in the right locations. In this way, it can contribute to reducing the cycle time.

Plastic parts are often also key components of finished products. Imagine a car manufacturer supplier who cannot

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deliver a key part because of a mould failure. In this context, mould simulation can help reduce errors and avoid losing critical time.

Aesthetic considerations are also important here. Plastic parts often need to look polished and/or perfect. Issues like sink marks or burn marks etc. must be avoided. Again, mould injection simulation can help to eliminate these problems.

Last but not least, plastic parts need to have optimum quality. Warping needs to be minimal to ensure a good fit. Mould analysis can play a key role here also in helping to reduce warpage.

Putting a Solution in Place If the industry is to be successful in its positive push towards innovation and optimisation, it needs to make use of design software solutions capable of eliminating errors, reducing production cycle times, while improving quality and productivity and reducing cost and project development lifecycles.

In the future, we are likely to see an increasing focus on plastics manufacturers ensuring that they get things right first time. The first mould needs to work - maybe after a few minor modifications. We are seeing higher levels of investment into simulation and analysis tools that help eliminate even these minor modifications.

Aware that in this highly competitive field, it is increasingly important for manufacturers to ensure that their customers remain confident that they can take on the projects and deliver them successfully and on time, some manufacturers are insisting that companies across their supply chain are using simulation analysis and even certified in the use of it.

Validate and Optimise Manufacturers today can use the latest software tools to optimise product development across plastic parts manufacture and associated injection moulding processes. In plastic flow simulation, they can leverage the latest

solutions to simulate the flow of melted plastic to help optimise plastic part and injection mould designs, reduce potential part defects, such as weld lines, air traps and sink marks, and improve the moulding process. In the case of sophisticated, injection moulded fibre reinforced thermoplastics, for example, Autodesk Moldflow’s fibre orientation models provide a solution that allows significantly improved orientation prediction accuracy over a range of materials and fibre contents.

They can make use of feed system simulations to model and optimise hot and cold runner systems and gating configurations, improve part surfaces, minimise part warpage, and reduce cycle times.

In addition, they can use a technique known as CAE data exchange to validate and optimise plastic part designs using tools to exchange data with mechanical simulation software. This in turn enables users to analyse the strength of fibre reinforced plastic parts.

The latest design software can also provide an enhanced range of benefits in areas like thermoset flow simulation, error checking and repair and mould cooling simulation.

Hand in hand with this growing emphasis on simulation, analysis and predictive capability, we are also seeing an increasing interest demonstrated by plastics manufacturers in sustainable design. Demand is growing for tools that enable plastics manufacturers to assess environmental impact against manufacturability and cost, and shape their design approach accordingly.

Designers are increasingly getting this information at the CAD phase, helping them think about sustainability from the very outset of a project and deliver energy efficiency throughout.

Positive Prospects In what remains a difficult market with a future clouded with economic uncertainties, manufacturers urgently need to find ways to stand out from the competition. Fortunately, the latest breed of design software solutions has the capability to enable them to do this. Using such tools is allowing them to design and manufacture within a ‘right first time’ environment and to focus on reducing the time and cost of the product development cycle, thereby cutting time-to-market while increasing innovation and ultimately business advantage. further information www.autodesk.com

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engineering materials

Excellence in Nylon Distribution

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news Polymer provides a replacement for metal gears: Case study Italian-based Saroplast, desingers and producers of high-precision injection moulded plastic components, have chosen Victrex PEEK polymer for the manufacture of an agricultural tool to harvest fruit.

When designing the tool, Saroplast encountred ergonomic and practical problems in relation to its weight, which was considered too heavy for constant use, negatively impacting upon its mechanical function.

“We began to evaluate the possibility of replacing some metal components with polymers, in order to achieve a more lightweight and easy to handle tool, while enhancing the lifetime of the device,” explained Roberto Frare, Head of Technical-Commercial Operations at Saroplast.

Saroplast designers focused on the toothed gear wheel that drives the tool via a connecting rod. “We ran the first tests with a PPS-based material, but these trials failed after only 3 minutes because of

excessive wear. The problem appeared after only three minutes of use, affecting the rod as well as the gearing,” said Frare.

Victrex PEEK 450CA30 was chosen for its lightweight properties, excellent resistance to wear, fatigue and high operating temperatures. It is also said to support manufacturing to tight tolerances.

“We worked with the technical planning department at Saroplast to come up with a solution. A modification was made to a metal ring, and we also added a roller bearing that controls the movement of the rod. The key was to use our Victrex PEEK 450CA30. In the first instance it was used to overprint the component, in the second to mould it directly,” said Reinhard Veljovic, Market Development Manager for Italy, at Victrex Polymer Solutions.

According to Saroplast, Victrex PEEK 450CA30 provides a lightweight solution that enables ease of use throughout an entire day. The high thermal resistance of the polymer allows the tool to operate continuously without incurring excessive wear. The new design also runs more quietly and reduces energy consumption significantly.

“The use of PEEK 450CA30 led to a considerable reduction in weight. The new design weighed ten times less than the original model, improved the acoustic index and reduced power consumption.

The new, highly optimised device feels quite different to the user, and we expect this to result in a significant increase in production,” added Frare.

Futher information www.victrex.com of 30 t CA ol u o 450 to e t ad EK ves m PE ar r h ea X G RE live CT n o VI r a fo

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Flexible seal rings offer ductility ATO S.r.L, an Italian-based compression moulder, has chosen Solvay’s KetaSpire PEEK resin for its flexible seal rings used in oil and gas, food processing, medical and pharmaceutical applications.

KetaSpire KT-820 PEEK provides greater flexibility and elasticity than competitive PEEK grades, according to Davide Polloni, Market Development Manager for ATO. “For example, these parts can be folded or twisted in half and then twisted again into three or four small concentric rings. Compression moulded seal rings made of KetaSpire PEEK can also be softer and easily machined.”

The flexible PEEK seal rings are manufactured via standard compression moulding and with ATO’s specially designed Hot Compression Molding (HCM) process. A custom-made HCM machine produces highly elastic, high-performance semi-finished parts with 30 percent elongation, which is said to be triple that of traditional compression moulding.

The elongation test is done on samples manufactured directly from semifinished products, not from samples made via injection moulding. According to ATO, a special feature of the HCM process is the repeatability of the production cycle through computer-controlled parameters to ensure high quality and highly consistent products.

ATO manufactures compressionmoulded seals with diameters from 2.5 cm to 50 cm (1 inch to 20 inches) and thicknesses of 15 mm to 70 mm (0.6 inches to 2.8 inches).

According to Solvay, KetaSpire PEEK is produced to the industry’s highest standards and offers a combination of superlative properties that allow it to replace metal in some of the most severe end-use environments. It is claimed to be one of the industry’s most chemically resistant plastics and offers excellent strength, superior fatigue resistance and a continuous-use temperature in excess of 240°C (464°F).

KetaSpire PEEK’s low coefficient

Products get a grip with launch of new TPEs Teknor Apex has launched a new series of ʻwet-gripʼ thermoplastic elastomer (TPE) compounds for injection moulding, which are said to retain a non-slip surface and secure grip even when wet.

The Monprene Wet Grip Series of styrenic block copolymer compounds, which will be introduced by the company at NPE2012, are said to minimise or eliminate the problems encountered with many standard TPEs in soft-touch applications like grips, handles, knobs and cushions.

These products often become slippery and hard to handle when wet from rain, humidity, sweat, dishwater or other common substances. Unlike the standard TPEs, the new Monprene products are said to retain their rubberlike traction when wet, while providing the same elasticity and other key

mechanical properties. They are available in hardnesses from 10 to 45 Shore A and, according to Teknor Apex, they can be applied onto a variety of substrates by means of two-shot, coinjection, or insert moulding.

“Teknor Apex has spent more than a year perfecting Monprene Wet Grip Series TPEs so that manufacturers of housewares, appliances, personal care items, tools and sporting goods are able to make their products easier and safer to handle,” said Brian Mulvany, Senior Consumer Market Manager. “The proprietary wet-grip chemistry that we have developed addresses everyday situations in the real world, where workers must handle tools, cooks use utensils and golfers grip clubs regardless of surface conditions.”

In tests measuring the coefficient of friction of a standard styrenic TPE with a Monprene wet-grip grade, the new compound exhibited a coefficient that

a Spirit of Partnership

of linear thermal expansion (CLTE) helps to ensure strong dimensional stability and tight tolerances.

Futher information www.atoitalia.com www.solvayspecialtypolymers.com

ATO flexib le seal ring s made from Keta Spire PEEK

The new TPEs can be used on items such as golf clubs

www.ultrapolymers.co.uk

was 25 percent greater when surfaces were wet with plain water and 175 percent greater in the case of soapy water.

Futher information www.teknorapex.com

Lexan OQ PC resin, used for the visors, is said to provide excellent optical qualities and high impact resistance

of powered air purifying respirators (PAPRs) and supplied air (SA) respirator systems – are designed for protection in workplaces such as foundries, automotive refinishing facilities, chemical plants and construction sites.

“Our materials can play a key role in the development of next-generation protective gear that workers feel really good about,” said James LeGacy, North America General Manager, Performance Compounding, Innovative Plastics.

“Sabic’s versatile, lightweight resins offer designers new ways to enhance comfort, usability and aesthetics, New 3M Versaflo M-Series Safety Headgear Made

Seeing more clearly thanks to optical quality resins 3M have launched a new range of hardhats and helmets made from lightweight Xenoy and Lexan OQ optical resins from Sabic.

The new 3M Versaflo M-series respiratory headgear product line is said to use custom-coloured Xenoy polycarbonate/polybutylene terephthalate (PC/PBT) resin for headgear shells and visor frames, enabling thin-wall designs which helps reduce the headgear weight by approximately 15-20 percent compared to the company’s previous Lseries products.

Water-clear Lexan OQ PC resin, used for the visors, is said to provide excellent optical qualities and high impact resistance. Sabic states the material’s high impact resistance and crystal clarity enabled 3M to create protective visors that are thin but extremely strong.

Al Solyntjes, Lead Product Development Specialist, 3M, said the high-performance resins from Sabic had contributed to the success of the new range. “Our customers have reported immediate improvements in comfort and protection with Versaflo M-series headgear, “ he stated.

The new 3M Versaflo M-series hardhats and helmets – used as part

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with Sabic’s Lexan and Xenoy Resins

a Spirit of Partnership

encouraging consistent use and freeing workers to focus on the job – not their headgear.”

Sabic states its materials offer key performance attributes to withstand demanding work environments. Compared to glass-filled nylon, which 3M initially considered for the headgear shells, Xenoy resin is said to deliver superior lowtemperature ductility for consistent impact performance in cold weather. The material also provides low specific gravity combined with excellent flow for thin-wall parts to reduce weight.

Futher information www.sabic-ip.com

engineering materials NEWS

www.ultrapolymers.co.uk

film & sheet

news

Polyden Folien’s shrink films made

Sustainable films launched for European packaging industry Cardia Bioplastics and Polyden Folien have announced their cooperation on sustainable film products for the European packaging industry.

Flexible film manufacturer, Polyden Folien, has launched a new range of packaging films made with Cardia Biohybrid technology that are said to combine renewable thermoplastics with polyethylene material to lessen dependence on finite oil resources and to reduce carbon footprint.

The launch of the flexible films is said to be consistent with Polyden Folienʼs business development of sustainable packaging. Managing Director, Peter Moser, said: “We are excited to work with Cardia Bioplastics.

Our packaging products made from their Biohybrid resins will form an integral part of our responsible packaging offering. We are looking forward to presenting our customers the Biohybrid packaging films, in particular for shrink film applications,” he said.

Cardia Bioplastics Managing Director, Dr Frank Glatz, said: “We are delighted to be collaborating with Polyden Folien. They are one of Germanyʼs leading flexible film specialists with a strong track record of providing innovative products to the packaging industry.

with Cardia Biohybrid technology

“In addition to offering high performing packaging films and excellent service, they are clearly committed to sustainable development of their products. Our partnership with Polyden Folien will enable their film customers to purchase innovative packaging products with reduced dependence on finite oil resources and lower carbon footprint.”

Cardia Bioplastics is said to be benefiting from the trend towards sustainable packaging with applications including flexible film, injection moulding, blow moulding, foam, extrusion and coating applications.

Plastribution, the distributor of Cardia resins in the UK, has seen similar success in its territory: “It is our experience that both manufacturers and end-users see a pressing need to reduce their dependency on fossil fuels for a number of reasons, not least the pressures being exerted by a more ecoconscious consumer. The ability to do this in the most cost-effective manner, and without adversely affecting functionality, is being met by Cardia Biohybrid.”

Futher information www.cardiabioplastics.com www.polyden.de www.plastribution.co.uk

Environmentally friendly films for high-end graphics applications Derprosa has launched new products that complete its range of laminating films for the graphics sector.

Soft Touch, Soft Touch Metalized, AntiScratch and Ecofilm are some of the products that make up the family of bioriented polypropylene (BOPP) films aimed at achieving the best finishes on high-end graphic supports.

The Spanish-based company states the new products stand out for their machinability, bonding adhesion qualities and adaptability to other post-lamination finishes.

The company claims Soft Touch is the first ever BOPP film with tactile properties that endows printed matter with a unique finish and sharper images that before.

Soft Touch Metalized provides a textured visual effect and even a holographic sensation combined with the smooth and velvety Soft Touch feel.

Anti-Scratch is said to provide products with effective protection because of its scuff resistance and UV ink adhesion and hot stamping properties.

Ecofilm is Derprosa’s environmentally friendly film that is said to enable the customer to choose the Derprosa quality and guarantee while respecting the environment.

Derprosa states the idea behind this new range of laminating films is that it can now supply specialist graphic art companies with products that enable them to market supports that are of high quality with sensorial properties.

Futher information www.derprosa.es/en/home

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blown film special

The new ‘KAGE’ 5-Layer Blown Film System

Attendees at open house event blown away by film system Indian-based Kabra Gloucester Engineering unveiled its first ‘KAGE’ 5Layer Blown Film System at its open house event held at the company’s headquarters in Dunetha-Daman, India.

Over 100 attendees saw the company’s first fully loaded 5-layer line in operation at Kabra Gloucester’s new facility. KAGE is the brand name for film systems manufactured by Kabra ExtrusionTechnik (KET) Ltd. The new facility utilises engineering designs and technology from Gloucester Engineering Company

of the USA, its joint venture company.

Adam Blumenthal, Managing Partner of Blue Wolf Capital, the majority owner of Gloucester Engineering, attended the event and said, “I am extremely proud to see the equipment run so well and am gratified to observe our customers openly embrace the KAGE brand. We look forward to continuing to serve both the domestic and export market with our KET partners and expanding KAGE’s global market share.”

The company states at the open house, the 5-Layer blown film line produced 2200mm layflat barrier film at 525kg/hour, producing film for oil packaging applications. The line, which can also be used for producing

lamination films, is designed for outputs of up to 600kg/hour and has an installed capacity of 4000T/year.

Kabra Gloucester Engineering say the line has been specifically designed for Prropyl Packs Ltd. of Kerala, India, who will use the machine at its plant to manufacture film for primarily edible oil packaging applications. The barrier film is said to meet government shipping standards as well as improving the shelf life of the oil, protecting it against oxygen and moisture and ensuring its cleanliness.

Futher information www.gloucesterengineering.com

BLOWN film SPECIAL

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Advanced Internal Bubble Cooling System Introduced Addex Inc., a supplier of blown film equipment and components, has introduced an advanced internal bubble cooling (IBC) system for blown film extrusion lines.

The Digital Internal Bubble Cooling (DIBC) system is claimed to deliver the fastest reaction time in the industry to ensure precise bubble control, helping processors to speed product changeovers and significantly reduce scrap.

“We have elevated the technology to a new level, offering one of the most sophisticated bubble cooling systems on the market,” said Rick von Kraus, President of Addex Inc. “At a time when resin prices are high and scrap reduction is a major concern, the DIBC represents a major advancement that helps processors realise major raw material savings.”

According to the company, the five-sensor system features a highspeed, servo-controlled air regulation valve that performs splitsecond corrections in bubble size (up to 20 adjustments per second).

Processors have reportedly switched from a 40-in layflat to a 60-in layflat in seconds instead of the minutes it took with the previous system.

Addex also reports that at least one film processor has reduced annual waste by just over 60,000 lb of material, which equates to a 1.5 RMS (Raw Material Savings = annual percentage of raw material saved). von Kraus said the DIBC system went through several iterations in terms of software development and creation of the unique air regulation valve.

Patented split sensors are said to enable the airflow intake and exhaust to react to the slightest changes in bubble size at or below the frost line where the bubble size is not yet final. A set of two non-contact ultrasonic sensors are aimed at the bubble below the frost line where size changes, particularly with low meltstrength resins like metallocenes and LLDPEs. According to Addex this allows an immediate correction by the

intake/exhaust blowers via the AC invertercontrolled blowers. For the more critical layflats, this is done via the high-speed servo reaction control valve.

A second set of two ultrasonic sensors are aimed at the bubble above the frost line where bubble size is stable to calibrate the lower sensors to ensure the size is kept constant. The DIBC system includes a fifth ultrasonic sensor that is aimed at a fixed target in order to calibrate the other four sensors whose readings can be altered due to changes in air temperature.

The 100 percent digital circuit system is said to eliminate errors caused by interference due to electrical devices like corona treaters or ultrasonic sensor driftings. Thanks to the digital circuitry, the DIBC continues to function if one, two, or three of the four ultrasonic sensors fail.

However, in split-level set-ups, one sensor must function at each level.

Diagram of the Digital Internal Bubble Cooling (DIBC) system

Addex state the DIBC system is versatile because it can be used with 100 percent blower speed control and with the air valve control for the tightest possible layflat control. Features are said to include a limited number of buttons and switches along with operator alerts that indicate an off-center or “breathing” bubble.

Futher information www.addexinc.com.

ABOVE: Triple bubble

HT: e RIG t bubbl r a m S

New Blown Film Initiative for North American Market American Kuhne has announced a new initiative to offer Kuhne GmbH blown film technology and equipment to the North American marketplace.

All blown film equipment will be designed and manufactured in the Kuhne Group headquarters in St. Augustin, Germany. American Kuhne will provide sales, service and spare parts for the installed and commissioned equipment operating in North America, out of their headquarters in Rhode Island.

“The significant technical developments in Blown Film equipment from Kuhne GmbH perfectly complements our existing product offering,” states Bill Kramer, President of American Kuhne.

“Given American Kuhne’s growth and success over the years, we felt the time was right to bring this leading technology to the North American market,” Mr Kramer continued.

In order to drive this new initiative, American Kuhne has employed Tom Helming as Vice President of Blown Film Systems.

Peter Kuhne, President of Kuhne GmbH said: “Kuhne GmbH has been making tremendous advancements in three key growth areas of blown film; conventional co-extruded films, triple bubble systems for the production of biaxially oriented films and waterquenched, multi-layer technology specialty film systems. With our leading edge technology and our significant and growing market share in Europe, we feel this is the right time to enter the North American market.”

The blown film division of the Kuhne Group specialises in the construction of blown film lines for standard and special applications. The division’s portfolio is comprised of three line concepts called Smart Bubble, for the production of monolayer and multilayer films, CoolBubble, water quenched blown film lines for barrier packaging and thermoforming applications and Triple Bubble, biaxially oriented film lines for demanding packaging applications.

American Kuhne states these oriented films present unique opportunities for alternative packaging strategies by offering advanced shrink, barrier and optical properties and thinner gauges and lower costs.

Futher information www.americankuhne.com

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The immersed tunnel will be approximately

RUBBER

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six kilometers long and consist of 32 elements.

Latest technology to improve ‘tyred’ tyres Momentive Performance Materials Inc., a global provider of silicones and advanced materials, has announced its collaboration with Sumitomo Rubber Industries, Ltd., one of the world’s largest manufacturers of tyres and other rubberbased products, on the development of the Enasave Premium tyre, which earned the highest rating (AAA) for rolling resistance under the Japan Automobile Tyre Manufacturers Association’s (JATMA) labelling system.

Launched at the Tokyo Motor Show in December 2011, Enasave Premium is the flagship tyre in the top-selling Enasave fuel-efficient tyre series.

“Our Enasave Premium tyre proves that with the right technology, it is possible to achieve key environmental, safety and performance attributes in one product,”

said Ikuji Ikeda, President, Sumitomo Rubber Industries.

Enasave Premium is claimed to be the world’s first tyre to use Momentive’s NXT Z 45 silane, a coupling agent for silicabased tyre tread compound and an excellent candidate to consider for improved dynamic and physical properties, including rolling resistance and wet traction. The new silane is said to virtually eliminate the ethanol that is released during the manufacturing and use of silica tyres.

According to Momentive, the NXT silane technology can help save energy, increase manufacturing efficiency and improve automotive safety. Tyres with silica-based tread compounds, manufactured using NXT silane, are said to offer improved dynamic and physical properties, including reduced rolling resistance, which improves gas mileage

and reduces CO2 tailpipe emissions, and improved wet traction, which helps cars stop more quickly and safely. In addition, energy consumption can be reduced through lower silane use levels and improved processing. NXT silane is also said to be higher in renewable materials content than standard silanes.

“We have been building the NXT silane technology platform for tyre performance improvement for more than a decade,” said Mike Stout, Global Marketing Director, Tyre and Rubber, Momentive Performance Materials.

“Sumitomo Rubber’s exciting Enasave initiative brought together two leaders in their respective fields, each with a long history of innovation and market firsts and a deep commitment to sustainability.”

Futher information www.momentive.com

Did you know... you can now access a user-friendly market report looking at key factors that affect the UK polymer markets. The report, provided by Plastribution, can be downloaded from BP&R’s digital Xtra magazine.

extra

Innovative sealing products chosen for the world’s longest tunnel In October 2011, Trelleborg Infrastructure signed a contract with China Communications Construction Co. Ltd. for the supply of a sealing system for the worldʼs longest immersed tunnel. The seals were chosen due to their innovative design that will ensure water-tightness even in case of a seismic event.

Part of the prestigious Hong Kong – Zhuhai – Macau link project in China, the immersed tunnel will be approximately six kilometers long and consist of 32 elements. The joints will be sealed with a Trelleborg sealing system consisting of Gina gaskets, Omega seals and waterstops as well as other seal designs.

“A water depth of more than 40 metres makes this project challenging, as does the need for the seals to remain watertight when exposed to seismic ground movements,” said Managing Director of Trelleborg Infrastructure, Peter Stello.

“The award of this contract recognises our innovation and engineering knowledge. We have designed a sealing system that is able to meet the seismic conditions specific to this area. Safety is of paramount importance and our products are critical, especially as it is virtually impossible to make repairs when the tunnel is in place.”

First deliveries of the sealing system will be made in 2012 and continue until the end of 2013. Manufacturing of Gina seals and large-sized Omega seals will take place in Ridderkerk, the Netherlands, while the smaller Omega seals and waterstops will be produced in the Trelleborg Engineered Systems facility in Qingdao, China.

The immersed tunnel is a part of the Hong Kong – Zhuhai – Macau link

project that also includes, at a span of 29 kilometers, one of the world's longest bridges. Travelling times between Hong Kong and Zhuhai or Macau are expected to reduce to approximately 40 minutes from the four and a half hours it currently takes by road. By slashing travel times between the eastern and western banks of the Pearl River Delta, parts of less-developed southern China will gain improved access to global markets through Hong Kong.

Futher information www.trelleborg.com/news

Tire Technology Expo 2012 l Taking place in Cologne, Germany on 14, 15 & 16 February 2012 l Over 130 exhibitors showing the very latest technologies With over 130 exhibitors, Tire Technology Expo 2012 is set to deliver more speakers and more content than previous years. Two UK universities are offering optional twoday rubber short courses; Queen Mary, University of London, is running a Rubber Materials Short Course and Coventry University is running a Tyre Mathmatical Modelling Course.

The main conference will cover all the crucial industry issues such as raw materials supply, new manufacturing and energy reduction technology, sustainability and biotechnology.

The show is said to feature a range of new technology and materials including pressure sensor electronics, additives and adhesion resins, valve technology, weaving systems, x-ray inspection and testing equipment. www.tiretechnologyexpo.com

from the frontline At the start of a new year, with new challenges for recycling targets outlined by the government for recycling packaging waste, Phillip Law of the British Plastics Federation tells BP&R why we should protect one of our strongest industries.

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Plastic is used in packaging to

Protecting the packaging industry give added protection to products

A 57 percent target for plastics packaging recycling by 2017 – this is the challenge posed in a grandly titled ‘UK Government (DEFRA) Consultation on Recovery and Recycling for Packaging Waste for 2013-17’ issued just before Christmas. Naturally the industry opposes this as a grossly exaggerated target.

When will politicians learn that the plastics packaging industry is a UK national strength to be nurtured and not punished? The UK discovered Polythene in 1933 and we were one of the first to exploit the potential of stretch blown PET for bottle manufacturing in the early 80's.

Politicians fail to see that packaging is not a stand-alone product, that it is called into being to protect an item whether it’s food or a drill. Historically, there have been calls to introduce a packaging standstill, but this is tantamount to recommending a slowdown in consumer expenditure with all its ramifications for growth in a wide swathe of industrial activities.

We are certainly not against a challenge. The industry-led Plastics 2020 Challenge initiative has, in a bid to divert all plastics from landfill, proposed a plastics packaging recycling target of 50 percent by 2020. But we stressed that this was a challenging enough target by itself and only achievable if all the stakeholders in the plastics recycling chain actually worked together in a coordinated way, that is, in addition to the industry itself, Local Authorities, the waste management companies, brand owners and retailers.

Yet it is difficult to point to a forum, and certainly one where the government is involved, to provide the necessary coherence to what should be a properly coordinated national waste strategy.

It is difficult to see any solid ground on which the government figure is based. One of their assumptions is that plastics packaging will grow by 2.5 percent per annum by 2015. A straw poll of BPF members shows that none are expecting this growth. The reasons are obvious.

Lightweighting continues its onward march, receiving added momentum with each spike in material prices, and we have the increasingly cautious behavior of the UK consumer as witnessed by the chill winds blowing down Tesco’s aisles in the run up to Christmas. I wonder if someone has mentioned to DEFRA that the government is reducing expenditure and that the local authorities will have less money to play with to orchestrate collection facilities. One other thing, where is all that additional recycling capacity going to come from? Food for thought.

AUTOMATION & ROBOTICS

Members of the KraussMaffei team jointly opened the new production hall

news Packaging firm acquires robotics specialist Packaging company Multivac has announced the acquisition of Finland’s Trimaster Oy in a move to expand its product portfolio of line automation, robotics and palletising systems.

Multivac states the move will enable the company to offer complete end-to-end packaging lines right through to final palletisation as well as strengthening its presence in Scandinavia.

Trimaster Oy, which was founded in 1998, specialises in palletising systems and robotic cells as well as monitoring and conveying systems. The company currently employs around 20 staff members, who will be integrated into Mutlivac's Finnish sales and service business.

“We are delighted at the acquisition by this market leader, and we are also glad to be able to contribute our expertise in robotics and automation within the Multivac Group and to be able to develop it sustainably,” said Leo Johansson, current owner of Trimaster Oy. Multivac states the experience of the two companies in the development of robotic solutions gives rise to the opportunity of being able to offer automation for the widest range of requirements in the food-processing sector. “Our customers are increasingly faced with handling challenges, for example with loading of products into packs or with the converging of packs after packaging. With the acquisition of Trimaster Oy we are extending in particular our range of ABB robots and monitoring systems,” adds Esa Harju, Managing Director of Multivac Finland.

Trimaster Oy is a 'preferred partner' of the Swedish company ABB Robotics and will intensify this partnership, particularly in the sector of palletising systems.

KraussMaffei reaches full use of its increased production capacity for automation systems KraussMaffei has announced that the new assembly hall for its automation products is working at full capacity.

The company states that with the new production area it has substantially extended its assembly area for premium quality robots from 670 to 1,720 square metres.

“Full utilisation of our extended assembly capacities shortly after the start of production is confirmation of the high

New electric automation products help customers get a grip SAS Automation has launched a new range of electric grippers for applications that require high speeds and for those

acceptance of our products among our customers. Thanks to the extension, we can fully cover the rising demand for our ideally coordinated machine and automation solutions,” emphasised Dr. Karlheinz Bourdon, Managing Director of the Injection Moulding Machinery Division of KraussMaffei.

Robots and automation systems for injection moulding machines are being produced and assembled in the new hall. further information www.kraussmaffei.com

requiring light or moderate grip forces.

The company states that electric is cleaner than either pneumatic or hydraulic grippers, therefore, the new range of grippers are very effective for handling products such as circuit boards or other dust sensitive products.

According to SAS, another major advantage of electric powered grippers is control. It is said a microprocessor can be added to an electric gripping system, which can be made to vary clamping force and velocity. This can be done at little additional cost, making the gripper able to cope with a variety of sizes and shapes and reducing the need to change grippers to accommodate different types of parts. further information www.sas-automation.com

further information www.multivac.com The new electric gripper from SAS

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Production oriented gantry

AUTOMATION & ROBOTICS news

30

New gantry-style robot released UK-based adhesives specialist, Intertronics, has announced the launch of a new robot for dispensing operations.

The company states low cost, versatile robots are becoming increasingly popular in the manufacturing environment, therefore, the Fisnar F5200N gantry model joins a range of dispensing robots for applications including form-in-place gaskets, adhesives, potting, coating and filling.

In an exclusive interview with BP&R, Intertronics MD Peter Swanson explained: “We are seeing more and more dispensing applications coming within the range of a new generation of benchtop sized robots such as the F5200N, where their low cost and flexibility are enabling manufacturing production to exceed previous cost and quality expectations.�

According to the company, the strength of the UNITOP F5200N lies in its ability to create its own working area, enabling the system to be mounted on any work surface. The system is said to be suitable for use on any type of platform requiring a gantry type mounting with open access under the robot. Intertronics states it is ideal for conveyor fed automation or can be installed in work cells operating as a

robot from Intertronics

slave robot, allowing users to create their workstation.

The robot is said to comprise a control module, a teach-pendant and an articulated-gantry and has a working area of 200 x 200mm with a resolution accuracy of 0.001mm. The company states that using the teach pendant, the dispensing robot supports Windows compatible dispensing software and can

store and retrieve up to 100 programs (400,000 points).

Intertronics point out that reliability and accuracy feature strongly in the F5200 with resolution of 0.001mm/axis derived from its micro-stepping motor controlled via USB/RS232 interface. further information www.intertronics.co.uk

2008 manufacturing employment increased in nearly every major industrialised country, even as the use of industrialised robotics increased sharply.

This trend is now being seen in China, Brazil and other emerging markets as they rapidly increase their use of robotics. In Brazil, the number of robots almost quadrupled during the study period with both production and employment rising by over 20 percent.

The report also highlighted 3 areas of importance with respect to growth in this market, including robots carrying out work that is unsafe for humans, not viable in a high wage economy as well as work

impossible for humans to undertake.

The Government is providing, through the PPMA Group, up to £600,000 of funding to promote automation in UK manufacturing. Chief Executive Officer of the PPMA group, Chris Buxton, commented: “We are delighted that the Government has put its full weight behind a programme that recognises the importance of automation in UK industry and the positive effect this has for growth and employment.”

AUTOMATION & ROBOTICS feature

Robots can be used for increased productivity and efficiency

A

report has revealed that robots could be responsible for the creation of UK jobs through increased productivity and efficiency.

The Government-funded Automating Manufacturing Programme aims to increase the competitiveness of UK manufacturing in the hope it will create growth and in turn result in greater levels of employment.

The latest study conducted by the market research firm, Metra Martech ‘Positive Impact of Industrial Robots on Employment’, published recently by the International Federation of Robotics (IFR) in Tokyo, demonstrates that 3 million jobs have been directly created in recent years by the use of robots and a further 1 million positions are estimated globally by 2016.

Mike Wilson, Chairman of the British Automation and Robots Association (BARA), said: “This is great news for British manufacturing. The IFR study highlights the importance of robotics to the future growth of UK industry and the jobs it will create as a result. The recently launched government funded Automating Manufacturing Programme is providing assistance to companies looking to use automation to improve competitiveness and drive growth.” He concluded: “Together we can make UK manufacturing the best in the world and create the jobs that our country needs.”

The report found that between 2000-

further information www.ppmaltd.co.uk

robotic boost UK Manufacturing to get a

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RECLAMTION & RECYCLING

100% Recycled Nylon 100% Prime Properties

news Recycler starts up new postconsumer film recycling line WRZ-Hörger in Sontheim has announced the launch of a new postconsumer film recycling line enabling the plant to increase its capacity to up to 7000 tonnes per year and recycle DSD film waste into high-quality agglomerate or regrind.

The turn-key plant delivered by Herbold Meckesheim consists of a wet size-reduction step with an upstream separation device for extraneous materials, separation technology based on a hydrocyclone and a mechanical/thermal drying step. Downstream of the plant a plastcompactor operates in order to transform the film material into agglomerate with excellent flowing properties and high bulk density. It is said the end product can be used for the production of moulded parts.

WRZ-Hörger has the whole recycling chain on site, from collecting to sorting and recycling. The plant is in line with the current trend of curbside collectors and sorting companies installing their own recycling technology, and processors of recycled materials installing their own reclamation technology. This is said to add to the effectiveness of the recycling process and benefit the operator in terms of value creation from the collection of the

The end product: agglomerate with high bulk density and excellent flow properties

waste to the manufacture of the end product. further information www.Herbold.com Correction to contact details published on BP&R online October 2011: Herbold Meckesheim GmbH, c/o Motan Colortronic (U.K.) Limited

Enhanced PRS Being Loaded

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System for transforming purgings into valuable regrind now handles traditionally ‘difficult’ plastics Maguire Products, Inc. has announced it has enhanced its Purging Recovery System (PRS) for transforming purgings into regrind and has received the CE certification required to make the PRS available in Europe.

The PRS is a two-stage system that first slices or planes rock-like purgings into small pieces, and then reduces the pieces to uniform, high-quality regrind. Maguire will highlight the new capabilities of the PRS at NPE 2012 and present data demonstrating that the system quickly repays its investment cost by reclaiming material that would otherwise be put to waste (Booth 5963).

While the PRS is already used to reclaim purgings of many widely used polymers,

the new enhanced design is said to extend its applicability to flexible vinyl, which stretches when worked by cutting blades and can jam conventional granulators; and to shear-sensitive polymers like polystyrene, which can melt as frictional

Motan Colortronic (U.K.) Limited Mr. Karl Miller Matilda House, Carrwood Road Chesterfield Trading Estate GB- Chesterfield, Derbyshire S41 9QB Phone: +0044 1246 260222 Fax: +0044 1246 455420 Mobile: +0044 7887 788010 E-Mail: karl.miller@motancolortronic.co.uk / sales@colortronic.co.uk

heat builds up in standard equipment. The design improvements are said to permit reclaim of 85 Shore A vinyl, such as that commonly used in wire and cable.

“PRS systems now in use by injection moulders who make multiple colour changes consistently recover purgings at a rate of 125 pounds per hour, or 1,000 pounds [455 kg] per eight-hour shift,” said B. Patrick Smith, Maguire’s Vice President of Marketing and Sales. “If the polymer is worth one dollar per pound, the PRS pays for itself in only 30 shifts. This is accomplished with minimal energy consumption—an average of 7.5 kWh— since the PRS uses three small motors with a total horsepower of 11, as against motor sizes of 100 horsepower or greater for a standard heavy-duty granulator.” further information: www.maguire.com Video for digital: http://www.maguire.com/ page.php/prs20.htm

www.ultrapolymers.co.uk

01925 750320

Post-consumer film separation

More plastics recycling a key 2012 focus, predicts Axion Consulting Increasing UK plastics recycling tonnages will be a key focus for 2012 as the sector continues to extend pioneering work done on PET and HDPE bottles recycling, predicts Keith Freegard, Director of Axion Consulting, one of the UK’s leading resource and recovery specialists.

With UK plastic bottle recycling rates nudging 50 percent for drink and dairy bottles, Keith believes that further investment in technology and equipment to extract a wider range of materials from mixed plastic collections offers major potential for improvement.

“To get even higher bottle recycling rates, UK Plc. has to find viable technologies to deal with mixed rigid plastics, films and the inevitable residuals,” asserts Keith. “Kerbside collection data points to a huge untapped source of rigid, non-bottle packaging items becoming available as local authorities offer collections of more household plastics, as well as an often-ignored, high volume of post-consumer films.”

While full mixed plastics collections are very popular with local authorities, they can only realistically be initiated when processing infrastructure is in place, otherwise recovery of the materials that are currently targeted will actually decrease.

Greater emphasis on rigid postconsumer plastic packaging and films

Rhondda Respect logo on a carrier bag used for the scheme

could also lead to more ‘co-ordinated’ approaches in overcoming challenges presented by these more difficult-torecycle waste streams.

“Today’s primary sorting Material Recovery Facilities (MRFs) and bottlesorting Plastic Recovery Facilities (PRFs) were developed in response to PET and HDPE recyclate demand,” continues Keith.

“Next-generation infrastructure must be capable of extracting value from other rigid plastics and films if we are to achieve higher overall plastic packaging recycling targets.”

New investments must complement continued growth in annual bottle recovery and be capacity-matched to the inevitable rise in other rigid and flexible plastics

Bag it then bin it says council Rhondda Cynon Taf County Borough Council (RCT) has launched a scheme aimed at encouraging local youngsters to recycle their lunchtime litter, while also reducing the volume of such litter on the routes to and from school.

The Respect project is the brainchild of the Streetcare Cleansing team, which noted an increase in the amount of litter in the town centre, where students eat their lunch. In a bid to encourage them to take their litter away, the students are being provided with free plastic carrier bags, while specially liveried recycling bins have been placed in five comprehensives.

The multi compartment containers allow students to recycle plastics; cans, food waste and general litter, including the degradable plastic carrier bags, supplied

by Leeds-based Cromwell Polythene.

“The vest-style carrier bags, normally

a Spirit of Partnership

generated from existing plastic recycling infrastructure.

“People are realising we need to tackle more difficult waste streams. One solution would be to build more integrated ‘resource parks’ where varied and mixed waste streams can be processed in complementary ways,” explains Keith. “For example, residual materials from sorting commingled waste streams can be used as an energy source to provide local heat and power for adjacent washing and reprocessing units.”

However, such novel ways of dealing with plastic and other waste streams would require fundamental changes to how Materials Recovery Facilities (MRFs) assess and handle their infeed and output waste streams.

Keith adds: “2012 will see increasing importance placed on MRF optimisation, including the use of sophisticated modelling, sampling and analysis services like those provided by Axion. Accurate and representative measurement of inputs and outputs is vital to highlight where plant control responses are needed to optimise operational efficiency, maximise profits and ultimately recover the valuable resources that would otherwise be discarded.”

Axion Consulting, part of the Axion Group, develops and optimises processing and collection methods to recover value from waste resources for a wide range of clients within the recycling and process industries. further information www.axionconsulting.co.uk.

supplied for retail use, are printed in bold primary colours to give them a more ‘cool’ appearance and avoid the students feeling self-conscious about using them,” said Paul Fleetwood of Cromwell Polythene, which has supplied an initial 100,000 bags to kick start the Respect programme.

“We take waste and litter seriously in Rhondda Cynon Taf and continue to invest heavily in ensuring that we educate people to think greener and recycle everything that we can,” said Councillor Anthony Christopher, deputy leader and cabinet member for front line services.

Students are being encouraged to form their own eco groups to monitor and motivate their peers, with the incentive of a cash reward, linked to the volume of recyclate that they collect, to the school that tops the Respect league table at the end of the year. further information www.cromwellpolythene.co.uk

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Injection Moulding

The above image shows the DMLS (Direct Metal Laser Sintering) process from CRDM. A 3D version of the wording was produced in CAD, which was then built using metal additive layer manufacturing. The image shows the build in progress.

The DMLS process is used by CRDM to produce metal tools for plastic injection moulding machines.

Image: Chris Bocking

Engineering Passion

Engel UK headquarters ‘packed’ for open day A packaging day held at Engel UK’s headquarters in Warwick attracted more than 80 people from across the industry.

The day, which was held as part of the Engel Moulders’ Group series of events, covered the latest trends in packaging injection moulding and demonstrated a number of innovative processes on a range of Engel machines.

Graeme Herlihy, Managing Director of Engel UK, said of the number of visitors in attendance: “It’s fantastic. We are delighted and it makes it worth while putting these things on if people are going to respond like this.”

Demonstrations included the production of a 2k thin-wall ice cream lid with in-mould labelling on an all-electric emotion machine, IBMP blow-moulding technology in collaboration with Cantoni of Italy, as well as a 72 cavity closure mould from Portola producing sports bottle caps on a 5.5s cycle.

Also running was a state of the art test mould from Agentdraw, which featured conformal cooling for faster cycle times, Engel Flomo water flow control, electric

A positive start to 2012 sees increase in production facility In response to demand for its large machines, Wittmann Battenfeld has announced it will increase production capacity at its Kottingbrunn facility in 2012.

The MacroPower, the company’s largest machine model, is said to be receiving positive response from the market due to its compactness, modularity and high speed.

Wittmann Battenfeld states that the Kottingbrunn facility reached full capacity in 2011, and, with a promising start to 2012, the company has decided to extend the production and warehouse areas at the production site by 3000 m².

According to the company, the assembly capacity will be increased by roughly 1,600 m² with a new building, with the pre-assembly and warehouse capacity already having been expanded by approximately 1,400 m² through remodeling existing buildings.

Warwick staged the open day

injection moulding

news

Engel headquarters in

www.kraussmaffei.co.uk

Engel injection mould ing machines demonstrated some of the latest trends in plastic packaging app lications

needle valve gate technology from Ewikon and mould instrumentation technology from Kistler.

In a speech Mr Herlihy said that he could confidently predict that the 2011/12 financial year was going to be a success story for the group, with the

current figure of around £24.5 million in machine deliveries beating their existing record by approximately 50 percent. further information www.engelglobal.com/uk

The production facility at Kottingbrunn

The extension of the assembly space will be implemented by adding a new bay to the existing assembly hall. The company states the equipment in the new bay will be laid out for producing large machines and, therefore, will complement the current assembly area. The planning

phase has already been initiated and construction will start in spring, with the new hall due to be completed by the end of September 2012.

FURTHER INFORMATION www.wittmann-group.com

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injection moulding

Engineering Passion

FOAMS SPECIAL Foamy technology said to be softer than TPEs Technology for injecting a heat cure sealant that has been mechanically foamed into single shot mould tools has become widely used by leading DEMs, particularly in the automotive sector.

Soft-Foam Injection Technology (S-FIT) is said to effectively convert a single shot injection mould machine into a twin shot, using material that is claimed to be much softer than normal TPE. The Penguin foam sealing material, produced by adhesive and sealant manufacturers, Sunstar Engineering Inc., is said to have unique properties and performance when combined with the machine technology.

According to S-Fit creators, CeraCon, the ‘rapidly cross-linking curing properties of Penguin Foam materials and the physical foaming process ensure the injection of foamed gaskets inside the injection moulding tool.’

The company states the S-FIT technology ensures for the first time that injection moulding can produce soft foamed

gaskets of thermosetting PUR material. In order to utilise the S-FIT technology, users are said to require a single-component injection moulding machine, an injection mould tool and a ‘Foamply’ machine from CeraCon as an additional unit.

CeraCon states in contrast to all tools that are injecting thermoplastic elastomers as second component, ‘S-FIT tools inject the PUR material through a cold-runner needle valve nozzle so that it directly adheres to the part.’

According to Ceracon, advantages of the Penguin Foam as a thermosetting material in comparison to thermoplastic elastomers include good elasticity up to –40°C, as well as low compressive deformation behaviour up to +80°C. CeraCon state S-FIT is not limited to the production of gaskets, but can also be used for automotive, electronic and construction applications. It is said the technology can be used for elastomer technology such as rubber/PUR compounds and coextrusion. further information http://www.ceracon.com/en/ http://www.sunstarengineering.de

S-FIT tool equipped with core-back technology.

After moulding the thermoplastic part (in this case aback panel of a picture frame) an additional cavity is opened by the core-back technology, which letsin the duroplastic PUR-foam.

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Image: L-R: Representatives from Mürdter, KraussMaffei and Trexel present the first test results from the MuCell system

Foam comparison between MuCell and injection moulding The world's largest injection moulding machine using MuCell foaming technology has started operation in Mutlangen, Germany.

The machine, which is running as part of a collaborative project between Mürdter, Trexel and KraussMaffei, is producing large components in a bid to make direct comparisons between standard injection moulded parts and parts using the MuCell system.

“MuCell technology is an excellent solution for very large components because, apart from the general advantages, such as minimal deformation, shorter cycle times and lower clamping force, the material savings, above all, and weight reduction of the component play an important role,” explains Andreas Handschke, MuCell Product Manager at KraussMaffei.

The large MC 5400 – 17200 injection moulding machine from KraussMaffei is equipped with 5400 tonnes clamping force for physical foaming in order to cope with the trend towards large components in MuCell technology.

The technology permits initial compact injection of large components, for example, instrument panel carriers, followed directly by a comparison with the MuCell process. “Our target can often only be reached by means of trials with direct comparison between standard injection moulding and MuCell,” explained Handschke.

Further information www.kraussmaffei.com

www.kraussmaffei.co.uk

Foam technology helps Ford win Gold at industry awards An instrument panel made using MuCell Microcellular foaming technology has helped Ford Motor Company bring home gold from the Society of Plastics Engineers’ Automotive Innovation Awards.

By creating the instrument panel for the new Ford Escape in microcellular foam, it is claimed its weight is reduced by more than 1lb, mechanical properties are improved, moulding cycle time is reduced by 15 percent and moulding clamp tonnage is reduced by 45 percent, saving an estimated £1.85 per vehicle versus solid injection moulding processes.

“Ford is focused on leveraging innovations in materials that help save weight and boost fuel economy, helping our vehicles travel further on less gas,” said Derrick Kuzak, Vice President of Global Product Development.

The instrument panel of the Ford Escape is the first to be moulded using the MuCell process, and is the largest part to date produced using this technology.

The process has already been used successfully in Ford vehicles in Europe for valve covers, along with heating,

e Less holding pressur ive sit po y has a ver cy effect on the tenden y all eci of parts, esp large ones, to warp

especially large ones, to warp. Warping occurs when stress points freeze during the cooling process. Less holding pressure means fewer stress points in the molten plastic, meaning the existing stresses have the chance to relax because of the lower pressure, and that happens before the melt solidifies. The result is parts with little or even no warping.

Chemical foaming agents also positively influence the flow properties of a polymer melt. Once the foaming agent decomposes, the gases released within

The instrument panel is the largest

More effective injection moulding with chemical foaming agents When most people think of chemical foaming agents they only think of polymer foams and lightweight plastic parts. But that's only part of it.

Chemical foaming agents have various properties that can be very beneficial for injection moulding processes. They can minimise sink marks, improve flow properties and reduce warping, sometimes even at shortened cycle times.

Since polymer melts containing foaming agents create an internal pressure in the injection mould, which counters the thermal volume reduction, parts created in this way exhibit fewer or even no sink marks. This significantly lessens or completely eliminates the need of the holding pressure, enabling the processor to use smaller machines and produce with shorter cycle times.

Less holding pressure has a very positive effect on the tendency of parts,

the melt act as an internal lubricant and reduce the melt viscosity. Depending on the requirements of the individual process, this allows injection moulding to be done at either a higher speed or a lower temperature. In the area of thermoplastic injection moulding, chemical foaming agents can therefore justifiably be designated as processing agents as well.

FURTHER INFORMATION www.tramaco.de/en

automotive part to date produced using MuCell technology.

ventilating and air conditioning systems.

“We are pleased that Ford recognises the immense potential MuCell holds for vehicle cost and weight savings,” said Steve Braig, President and CEO of Trexel.

“We’re now working with Ford to apply the MuCell process in a strategic way for many more applications as they incorporate MuCell into their design guidelines.”

By utilising microcellular foaming technology, petroleum is saved as well as

reduced overhead and energy costs by decreasing the amount of time it takes to produce plastic parts.

The MuCell process is scheduled for use in the production of instrument panels, along with other applications, in future Ford vehicles beginning next year following its debut in the new Escape.

FURTHER INFORMATION www.trexel.com

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thermoforming

news HYTAC end mills

Thermoforming machines for high productivity to be displayed at NPE 2012 Illig, global supplier of equipment and tooling for thermoforming plastic materials, will present its current RDK series model at NPE 2012.

The machine will make hinged packages of different shapes and sizes from the most common packing materials – from PS via PP and PET to bio plastic materials like PLA trays.

The machine is said to have a high productivity of up to 55 cycles per minute, which is achieved by servo-drives and process controlled machine sequences.

The Illig ThermoLineControl and the control module sas-up (self-adaptive startup) are said to simplify the machine operation and accelerate the start-up of new tools, serve for process optimisation and thus increase process continuity.

Through special HTS heater elements and compensation control, the energy consumption of the thermoforming machine is said to be considerably lowered and the product quality increased. further information www.illig.de The RDK 80 machine from Illig

New plug-assist tools and techniques for thermoforming CMT Materials Inc., a supplier of plugassist materials for the thermoforming industry, has announced it will demonstrate new technology and techniques that allow thermoformers to reduce sheet thickness when forming heavy-gauge materials at NPE 2012.

In addition, the company will show new tools that reduce machining and processing time of HYTAC syntactic foam plug-assist materials. Also featured will be CMT Material’s new reformulated HYVAC hold-down fixture material for rapid, lowcost production of vacuum hold-down trim fixtures.

“Our customer base continues to be pushed for higher quality – attributes like more even material distribution, improved transparency with less scratching and more demanding part geometries – all at a time when plastics and other production costs are on the rise,” said Terrence Woldorf, General Manager of CMT Materials. “Along with innovative new products to meet these needs, we’ve developed new ways to use HYTAC syntactic foam materials to reduce startup time, cycle faster and often reduce heating time/temperatures for significant cost savings.”

At NPE, CMT states it will demonstrate new techniques to optimise material distribution in heavy-gauge applications, thus reducing material use and cutting cost. To reduce machining and processing time of HYTAC syntactic foam, the company will show new developments in tool geometries, plus corresponding feed, speed and depth of cut details to ensure long tool life and high-quality surface finish straight from the machining centre.

Meanwhile, the company will demonstrate the use of its HYVAC material that can be used to create a quick and easy hold-down fixture for trimming and quality control inspection simply by using an existing formed part as a casting mould. further information www.cmtmaterials.com.

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thermoforming

news Multi-layer thermoforming for food packaging battenfeld-cincinnati has received a second order this year for its multi-layer thermoforming sheet extrusion line from an Asian packaging manufacturer.

With a total of six multi-layer lines in three years, the machine manufacturer states it has taken on a leading role in the growth segment of PP and PS barrier sheet for food packaging.

Benefits to processors are said to include the high output and the process technology design of the core components, such as the extruder, feedblock, die and polishing stack, which are all said to be geared to ensure consistent high product quality.

Acording to battenfeld-cincinnati, the new order is for a 7-layer PP/PS sheet extrusion line equipped with five

extruders, an output of up to 1,200 kg/h and is laid out for sheet thicknesses ranging from 350 to 2,500 Âľm.

The core components of battenfeldcincinnati’s multi-layer thermoforming sheet extrusion lines are said to include high-speed single-screw extruders. Here, the company claims it has extended its product portfolio and now offers a 45 mm high-speed extruder model in addition to the 75 mm screw size.

In the multi-layer lines, the 75 mm extruders take care of plasticising the main layers with an output between 300 and 1,000 kg/h, while the 45 mm extruders produce the functional layers such as bonding adhesives and barrier materials, as well as surface covers and high-gloss finish. The feedblock-die combination ensures an even distribution of all layers both across the width of the sheet and in the direction of extrusion. battenfeld-cincinnati states the feedblock and die also feature an edgeencapsulating system to ensure resource-

n line 9-layer sheet extrusio innati inc d-c fel ten bat m fro

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saving processing of the barrier material as well as all other materials. This includes direct, in-production reclaim of the mono-sheet edge trim generated.

Finally, the polishing stack, with polishing rolls and post-cooling rolls arranged extremely close to each other, favours optimal sheet properties and transparency.

Barrier sheet is in strong demand on the Asian market, demand driven by climatic conditions, transport over long distances as well as the products to be packaged, which require packaging for a long shelf life time. further information www.battenfeld-cincinnati.com

events

02

03

04

February

March

APRIL

BP&R takes a look ahead at the upcoming conferences and exhibitions of 2012.

Elastomers Latex and Synthetic Polymer Dispersions

13 – 14 March 2012 Kuala Lumpur, Malaysia Description iSmithers conference on trends and developments in natural rubber latex, aqueous synthetic polymer latices, processing chemicals and additives, latex-based products and relevant legislation.

NPE International Plastics and Rubber Exhibitions

Materials PVC Formulation

1 – 5 April 2012 Orlando, Florida

20 – 22 March 2012 Dusseldorf, Germany Description AMI conference covering materials and equipment for producing PVC compounds.

Materials Silicone Elastomers Conference

27 – 28 March 2012 Berlin, Germany Description This conference aims to cover the whole range of silicone elastomer materials, including high temperature vulcanised (HTV), room temperature vulcanised (RTV) and liquid silicone rubber (LSR). Aimed at manufacturers, processors, designers and researchers with a common interest in silicone elastomer materials, applications and processing, to inform them of current developments.

Description Largest US exhibition, organised by the Society of the Plastics Industry will feature emerging technologies and new applications from 2,000 suppliers, educational sessions led by industry experts and networking discussions among 75,000 professionals from 120 countries.

upcoming International Plastics and Rubber Exhibitions Plast Italia

8 – 12 May 2012 International Plastics and Rubber Exhibitions Chinaplas

18 – 21 April 2012 Shanghai, China Description The largest plastics and rubber fair in Asia accompanying the growth of China’s plastic and rubber industries. Incorporating injection moulding, extrusion, ancillary equipment, blow moulding machines, CAD/CAM, recycling and in-mould decoration.

Milan, Italy Description Held in Milan every three years, the range of products represented covers the whole plastics and rubber industry.

Including injection moulding, extrusion, blow moulding, thermoforming, moulds and dies, test equipment and ancillary equipment for plastics and rubber processing.

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A challenge ahead for plastics and rubber traders 2011 was a challenging year for plastics and rubber businesses engaged in international trade – and 2012 promises to be no different.

Charles Purdy, Director of Smart Currency Exchange, looks at what the New Year might bring and the implications for currency markets.

42 bp&r

Towards the end of September 2011 it was widely reported in the media that there were just six weeks left to save the euro. Well, that deadline has come and gone and we are now embracing a new year. The euro crisis rumbles on and the idea that it will somehow be solved with one piece of decisive action is, to say the least, far-fetched.

What can we expect, then, in 2012 and, more pertinently, what are the implications for currency markets? We work with many businesses that trade internationally in plastics and rubber industries. Whether they are importing raw materials from abroad or selling in international markets, or a combination of both, all have been impacted upon by currency fluctuations during 2011. I don’t expect that situation to change during the next 12 months.

Recent changes in the prices of raw materials within the plastics industry have seen Borealis, a leading provider of chemical and innovative plastics solutions, increase all polyethylene and polypropylene prices by EUR 100/tonne.

Gerd Löbbert, Borealis Executive Vice President, Polyolefins, said: “This decision to increase prices reflects our assumptions on the economic development and it's necessary for the implementation of our Value Creation through Innovation strategy”.

With many businesses across the international plastics and rubber markets forced to absorb higher raw material costs as a consequence of increases in crude oil

prices, companies are resorting to raising their selling prices.

As far as the €/£ exchange rate is concerned, in 2011 we saw a high close to 1.20 and a low at 1.10. This volatility looks set to continue – in the first few weeks of 2012 we’ve already seen the euro go above €1.21/£1 and reach its highest rate for eighteen months. For the US$/£ the range has been quite narrow - a low of 1.55 and a high of 1.65.

The paradox is that, against the backdrop of the euro zone crisis, currency volatility was less in 2011 than in 2010.

One might conceivably have expected a significant decrease in the value of the euro due to the clear weaknesses of some of its member states – notably, Greece, Italy, Portugal, Ireland and Spain. The reason the euro has held up relatively well, however, is that the markets clearly recognise that the possible fallout of the euro would be global with contagion spreading far and wide from the euro zone.

It is also worth pointing out here that, while volatility may have fallen in 2011, the range that the exchange rates are moving between are still large and could still have a very significant affect on importers and exporters. As any international trader will tell you, small currency movements can have a seismic financial impact on large orders.

As far as the euro zone is concerned, then, I am not anticipating that the problems we are currently witnessing will go away anytime soon. The debt crisis in the euro zone is likely to lead to recessions in the UK and across EU member states. Any economist will tell you that, as far as debt is concerned, there is only so long you can kick the can down the road.

The US has similar problems to the EU. Debt is a huge issue there. Moreover,

of crude oil is The increasing price many businesses on having an affect

unemployment across the pond is stuck stubbornly – and worryingly – at the ten million level.

The implications of all this on interest rates are that they are likely to remain historically low in both the US and UK. Don’t expect any rate rises in either country in 2012. The euro zone may actually reduce rates having unwisely increased them in mid 2011.

In terms of how things might actually pan out in the euro zone, we may see it completely unravel. A Greek or Italian withdrawal is not out of the question. This would see these former member countries returning to their pre-euro currency – the Greek drachma and Italian lira respectively. As weak economies, both currencies would be extremely weak – and volatile – emphasising the need for great care with regards to currency strategy amongst UK plastics and rubber firms doing business in either.

Could we see a German withdrawal from the euro? Interestingly, while Germany is commonly recognised as one of the two lynchpins of the euro zone – along with France – many see its withdrawal as the least painful way forward. The reason is that Germany’s withdrawal would – all other things being equal – see a devaluation of the euro. And this devaluation, in trading terms, would greatly benefit remaining members and

software directory manufacturing management directory DESIGN & PROCESS SIMULATION

The Euro hit its highest rate in 18 months in January 2012

may bring some respite to the beleaguered Italy, Greece, Portugal et al.

In the meantime, the German deutschmark would be greatly valued – a reflection of the country’s relative strength right now.

The message in all of this is clear for plastics and rubber businesses trading internationally. There is no easy way forward for the euro zone and, indeed, global economy. Currency fluctuations and uncertainty are with us for the foreseeable future. Consequently, having in place a robust currency strategy is not just useful right now – it is an absolute prerequisite.

further information www.smartcurrencybusiness.com/bpr 0207 898 0500

Autodesk® Moldflow® Wilde Analysis Ltd T: 0161 474 7479 E: moldflow@WildeAnalysis.co.uk W: www.WildeAnalysis.co.uk Plastics Made Perfect Autodesk® Moldflow® Plastics Simulation Software allows Designers, Toolmakers and Engineers to validate and optimise the design and manufacturability of plastic parts.

Autodesk® Moldflow® helps users to identify, communicate and resolve problems earlier within the development cycle, meaning innovative designs get to market faster, with the confidence that tooling and part quality will be right first time.

Autodesk® Moldflow® has the largest available polymer database, and offers the tools to troubleshoot existing issues or to improve the manufacturability of new design projects.

Supported by Wilde, with over 30 years experience in FEA, CFD and Reliability Engineering.

ENTERPRISE RESOURCE PLANNING Solarsoft Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Solarsoft Business Systems MEI Division (Europe) T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Modules: Production Monitoring, “Drag and Drop”, Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts, Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/Tannoy Alerts, Stand-alone, “Drag and Drop” Scheduler, Stand-alone, SPC “Machine Analyzer”, Machine Energy, Monitoring, KPI Dash-boards, Visual Manufacturing (Large LED/LCD Displays), Automatic Data Import/Export Functions (for Integration to Manufacturing Systems &Other Software Packages).

Solarsoft iVP ERP SAAS Manufacturing Software (for Plastics’ Processors) Solarsoft Business Systems T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Solarsoft’s iVP ERP (SAAS) software for the plastics’ converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution. It seamlessly integrates with Solarsoft-Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’ industry.

A listing in the Software Directory costs £140 per programme per year.

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ intouchmonitoring.com Real-time production monitoring systems.

Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages).

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

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

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

SYSCON-PlantStar MTec Services Ltd T: 0114 2476267 F: 0114 2476267 E: mt@mtec-services.co.uk W: www.mtec-services.co.uk W: www.syscon-intl.com PlantStar systems provide customised, scalable applications that deliver realtime plant floor data from any machine, shift, and plant anywhere in your business. Affordable systems available for all size of processor.

Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more.

With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.

Call Lisa on 01829 770037 for details.

43 bp&r

BP&R buyer’s guide services

plasma surface treatment

mouldmaking

fastenings and fixings

acquisition

materials for sale and wanted

injection moulding masterbatch printers printers of plastic mouldings

WANTED

Injection Moulding businesses Are you looking to retire and/or sell out of your injection moulding business? We may well be interested, if you are not tied in to a long lease. If you're located in the West Midlands, we may well want to take on your key employees as part of the deal.

If interested, please contact, in confidence: Greg McDonald Goodfish Limited greg@goodfishltd.com (01543) 505 323

extrusion flow analysis Fleming Polymer Testing & Consultancy Unit 326, Hartlebury Trading Estate, Kidderminster, Worcestershire, DY10 4JB T: 01299 253300 E: enquiries@flemingptc.co.uk W: www.flemingptc.co.uk Compuplast bureau service & distributor

mouldflow analysis

TAMPO.SCREEN.FOIL Contour Marking Co Ltd Albert House, Gledrid Industrial Park, Gledrid, Chirk, Wrexham LL14 5DG T: 01691 770093 F: 01691 770023 E: sales@contourmarking.com W: www.contourmarking.com

pad

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

materials

additive masterbatch

polymer distributors

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

mould release colour masterbatch

conductive plastics and coatings TBA Electro Conductive Products

Fleming Polymer Testing & Consultancy Unit 326, Hartlebury Trading Estate, Kidderminster, Worcestershire, DY10 4JB T: 01299 253300 E: enquiries@flemingptc.co.uk W: www.flemingptc.co.uk Rheometry,TGA,DSC,MFI/MVR Impact

bp&r

engineering plastics

tool making

Eclipse Colours Ltd

design and manufacture of blow moulds

Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service.

1 mm Easysperse MicroPellets to 4 mm MaxiPellets.

Standards second to none.

Beaubury Precision Moulds Ltd

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PO Box 56, Rochdale, Lancs OL12 7EY T: 01706 647718 F: 01706 646170 E: info@tbaecp.co.uk W: www.tbaecp.co.uk

4 Telford Close, Aylesbury, Buckinghamshire HP19 8DS T: 01296 434311 F: 01296 433276 E: blowmoulds@ beaubury.co.uk W: www.beaubury.co.uk

ultrasonic welding

equipment ancillary

InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 816507 F: 01509 816774 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

control systems and equipment quality monitoring control Kistler Instruments Ltd T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.

thermocouples co-extrusion die heads and systems Ridgeway Co-Extrusion Technology Ltd

assembly hot plate welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransonplasticsjoin.com

Machines Automation Robotic Systems Ltd T: +44(0)1904 489 888 E: sales@mars.gb.net W: www.hotplatewelding.co.uk An innovative specialist in plastic welding solutions providing standard and bespoke plastic welding machines and equipment, tooling and training.

Machine Techniques Ltd Units 3-5, Sutton Court, Bath Street, Market Harborough, Leicestershire LE16 9EW T: 01858 434059 F: 01858 433638 E: davidchatterton@ymail.com W: www.mactec.co.uk

plastic assembly Machines Automation Robotic Systems Ltd T: +44(0)1904 489 888 E: sales@mars.gb.net W: www.plasticassembly.co.uk

Telsonic UK Ltd Units 14 & 15 Birch Copse, Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: sales@uk.telsonic.com W: www.telsonic.com

vibration welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransonplasticsjoin.com

chillers/ temperature controllers

Elmatic (Cardiff) Ltd Wentloog Road, Rumney, Cardiff CF3 1XH T: 029 20 778727 F: 029 20 792297 E: sales@elmatic.co.uk W: www.elmatic.co.uk

dryers/ dehumidifiers

film blowing

Colortronic (UK) Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@colortronic.co.uk W: www.colortronic.co.uk

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

induction heating for platens and tools MF Induction Heating Unit 5, Martindale, Hawks Green, Cannock, Staffs WS11 7XN Replacement Coils New platens T: 01543 570642 F: 01543 574460 E: sales@mfinduction.com W: www.mfinduction.com BS EN ISO9001: 2000 registered.

BS EN ISO9001:2008

hot runner systems

Colortronic (UK) Ltd

hot runner controllers

extrusion systems

granulators

An innovative specialist in plastic assembly solutions providing standard and bespoke plastic assembly machines and equipment, jigs, fixtures and training.

Colortronic (UK) Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@colortronic.co.uk W: www.colortronic.co.uk

spin welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransonplasticsjoin.com

ultrasonic plastics assembly systems

Unit 22, W & G Estate, Challow, nr Wantage, Oxfordshire OX12 9TF T: 01235 760435 F: 01235 763021 E: frankh@ridgewaycoex.co.uk W: www.ridgewaycoex.co.uk Optimised monolayer die heads, coating die heads up to 4 layers, multi-layer die heads up to 7 layers, for pipe/tube sizes from 1 mm O/D up to 200 mm O/D; multiple tube die heads for mono and multi-layer products; multi-layer, multi-parison blow moulding die heads up to 7 layers; multi-layer sheet and profile dies up to 5 layers. R & D and product development projects; line conversions; turnkey system installations.

extruders and downstream equipment

heating equipment

infra red systems

Cooper Plastics Machinery

CNC ASSEMBLY MACHINES

Branson Ultrasonics

Cannon ShelleyUK agents for Belotti CNC Machining Centres

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

32 Roman Way Business Park, Godmanchester, Huntindon, Cambridgeshire PE29 2LN T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com

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

Repairs, servicing or rebuilds.

UK agent for Lyons Electronics

45 bp&r

BP&R buyer’s guide hopper loaders

nozzles & nozzle tips

screws and barrels

Colortronic (UK) Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@colortronic.co.uk W: www.colortronic.co.uk

injection moulding

printing machines pad

Technical Welding Services (Rochdale) Ltd Corporation Road, Sparth Bottoms, Rochdale, OL11 4HJ T: 01706 655402 F: 01706 657735 E: info@tws-mail.co.uk W: www.extruder-screws.co.uk

secondhand and reconditioned DM Machinery Ltd Second-hand Injection Moulding Machine Stockists 40 Thomas Lane, Wakefield West Yorkshire, WF1 5RR T: 01924 290206 E: Katy@dmmachinery.co.uk W: www.dmmachinery.co.uk

silk screen and pad Mascoprint Developments Ltd

hopper dryers

Stags End Cottage Barn, Gaddesden Row, Hemel Hempstead, Hertfordshire HP2 6HN T: 01582 791190 F: 01582 791199 E: info@mascoprint.co.uk W: www.mascoprint.co.uk

PRODUCT HANDLING materials handling and storage

mould curtains & chutes Seltek Solutions

mixing, feeding, drying Colortronic (UK) Ltd

gravimetric/volumetric blending Colortronic (UK) Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@colortronic.co.uk W: www.colortronic.co.uk

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PLASTICOLOR B A Thorne (Machinery) Ltd 19A Imex Business Centre, Oxleasow Road, East Moons Moat, Redditch, Worcestershire B98 0RE T: 01527 584714 F: 01527 584784 E: bat@bathorne.co.uk W: www.bathorne .co.uk

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

metal detection & separation equipment Colortronic (UK) Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@colortronic.co.uk W: www.colortronic.co.uk

Unit 25 Stockwood Business Park, Stockwood, Nr Redditch, Worcestershire B96 6SX T: 01386 793274 F: 01386 792154 E: sales@selteksolutions.co.uk W: www.selteksolutions.co.uk Mould curtains and mould chutes to prevent spillage of parts and to ensure mouldings land where they should without damage. Available in a wide range of standard sizes, special sizes on request. Also tie-bar covers and drum covers.

quick mould change systems EAS PO Box 716, St Albans AL4 9ZX Tel: 01727 855758 Fax: 01727 842823 E-mail: angus_mac.eas@bt connect.com Web site: www.EASchange systems.com

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

Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com Rawmec (EEC) Ltd Rawmec Industrial Park, Plumpton Road, Hoddesdon, Herts EN11 0EE T: 01992 471796 F: 01992 471797 E: rawmec@btconnect.com W: www.rawmec.com TransXL International Ltd Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

static control Arrowquint Ltd Building 5, Hendrickson Site, Sywell Aerodrome, Wellingborough Road, Sywell, Northampton, NN6 0BN T: 08450 655455 F: 08450 655456 E: sales@arrowquint.co.uk W: www.arrowquint.co.uk Static control solutions, equipment sales and rental, repairs and on-site servicing.

UK/Eire agent for Eltex – market leaders in static control systems.

testing equipment

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

hardness - IRHD and shore MAPRA Technik Co — BAREISS Unit D13 The Seedbed Centre, Langston Road, Loughton, Essex IG10 3TQ T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

inspection & measurement MAPRA Technik Co – MARCEL AUBERT – DOSS – KAFER Unit D13 The Seedbed Centre, Langston Road, Loughton, Essex IG10 3TQ T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

spark testers Buckleys (UVRAL) Limited Buckleys House, Unit G, Concept Court, Shearway Road, Shearway Business Park, Folkestone, Kent, CT19 4RG, ENGLAND. T: +44 01303 278888 F: +44 01303 274331 E: sales@buckleys.co.uk W: www.buckleys.co.uk

thermoforming equipment