BP&R January 2013

British Plastics

and Rubber

bp&r

THE MONTHLY MAGAZINE FOR BRITAIN’S POLYMER PROCESSORS

January 2013

New legislation Rotomoulding materials – challenges creates compliance challenges and opportunities

Characterising high-modulus composites

comment

bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk

EDITORIAL Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com

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

ART Production & Design Manager: Samantha Hamlyn T: +44(0)1244 680222 E: sam@rapidnews.com

Launching into an exciting New Year Happy New Year and welcome to the first may be based. The directories will still issue of BP&R for 2013. It’s been a year hold the same information and literature since we successfully launched our newas the old directories, but now with more look print and digital magazines, which detail in terms of feedback, reviews and we have received great feedback to. Now ‘starred’ ratings, based on experiences it’s time for our website to get the same with specific suppliers. For more treatment. We have information, turn to been busily working 40.

“It’s been a year page behind the scenes to The coming year is set ensure that our new to be a great one. Not since we online look is are the plastics and successfully only consistent with the rubber industries at the printed magazine in Launched our helm of some of the design and format. most sophisticated new-look print innovations and Without blowing our own trumpets (well, advancements across a and digital maybe a little), it’s number of important magazines” pretty all-singing, all sectors, 2013 will see dancing, and, we the return of trade show believe, the perfect platform to bring you giant, K Show, the 80th anniversary of the latest news, views and features from the British Plastics Federation and the across the industry. The switchover will 80th anniversary of the discovery of happen later this month, so keep your Polyethylene. BP&R will not only be eyes peeled for the new-look site. covering these events, but also new Also new for 2013 is plastrep.com, a features, updates on established as well global plastics directory that will replace as growing markets and also informative the individual, web-based directories and advisory articles. across all of Rapid News Communication May I take this opportunity to thank Group’s plastic titles, including BP&R, you for reading and wish you a profitable EPPM, MEP and MPN. We’ve made this and successful New Year. change so that we have a cleaner, more efficient and up-to-date service designed Enjoy the issue. for quick and simple sourcing of a local Leanne Taylor — Editor product or supplier - wherever the user

Production: adrian price T: +44(0)1244 680222 E: adrian@rapidnews.com

SUBSCRIPTIONS Subscriptions Manager: Tracey Nicholls T: +44(0)1244 680222 E: tracey@rapidnews.com

PUBLISHER Mark Blezard T: +44(0)1244 680222 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, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44(0)1244 680222 F: +44(01244 671074 © 2013 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

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THE BIG STORY Service is the name of the game for Summit Pioneers of the 24/7-service ethic in its field of materials and product handling equipment for the plastics industry, Tamworth-based Summit Systems states that this offering is stronger and more efficient many years on from its inception.

The company’s new advertising campaign, which will be featured in BP&R during the coming year, will emphasise the message that the quality of Summit’s service to its customers is of paramount importance to owner and Managing Director, Mike Jordan. “Our genuinely regionally based team of technical engineers are there for our customers when they are needed. They do not have to wait for office hours to receive a call from them if an issue occurs.”

Mr Jordan emphasised the importance of service - from the very first contact a potential customer has with the company, through to the completion of an installation - where the customer should feel that Summit has done its very best to deliver, and that the company’s experienced sales team has explored all available options. “We recognise that not all operations are the same,” he stated. “We will do everything we can to ensure that a customer ends up with a smile on their face – whatever it takes.”

Recently, Summit has increased the technical strength of its team with the addition of more Project Engineers, who have all previously worked in production. The aim is to be able to deliver everything a customer needs to keep both efficient and competitive.

Supplying big name customers in the fields of automotive supply, packaging, manufacturing, construction and recycling, Summit says it is experienced in the demands of highpressure operations. In many cases the company’s teams of Engineers have been able to install new machinery or systems with very little disruption to production.

Summit is the only UK supplier to have its own metal fabrication facility for the production of bespoke solutions and pipework.

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t ises in equipmen Summit special y tr s indus for the plastic

The company’s service does not stop at installation. To further ensure that customers gain the maximum value from an investment, Summit offers a range of Service Contracts, which ensure processors machinery continues to work at its optimum level. Machinery works hard and although it may continue to do so for a very long time, it is likely to be much more efficient if it is regularly serviced.

Summit states service visits from its Engineers can be arranged at times to suit customers.

Summit Systems’ portfolio includes conveying and handling equipment for both raw materials and finished products, a comprehensive range of drying technologies, which include what it says is the most technically advanced, energy saving dryers in the world, as well as diverse types of dosing and blending machines.

Continually seeking the latest innovations in plastics processing, Summit Systems says it selects only the best equipment from quality suppliers and is additionally using its wealth of expertise to push the boundaries by designing its own solutions. Uniquely, Summit also operates a specialised, separate division offering recycling solutions through which they say can assist processors in making their operation more profitable. Many processors do not realise the full potential of the scrap that they are either throwing away or selling on, unprocessed, for a minimal price. Summit says its recycling specialists can show how, with a small investment, scrap can be converted for re-use in the production process or refined to make a more valuable product for re-sale.

In fact Summit’s own recycling line, Boomerang Plastics, is doing just that. Winners of a category in the Packaging Industry Awards last year, Boomerang is recycling plastic packaging and selling the resultant high quality material to moulders in the UK. For further details of material for sale contact Boomerang via Summit Systems.

Further Information: www.summitsystems.co.uk

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on the cover

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bp&r BRITISH PLASTICS &RUBBER

contents January 2013

on the cover Service is the name of the game for Summit Pioneers of the 24/7-service ethic in its field of materials and product handling equipment for the plastics industry, Tamworthbased Summit Systems states that this offering is stronger and more efficient many years on from its inception.

See page 4

3 EDITOR’S LETTER Launching into an exciting New Year

9-13 FEATURE

22-25 REGULARS FEATURE INJECTION MOULDING Recycled Materials Innovative black colourants open up new markets for recycling packaging waste

26-29 FEATURE Health and Safety

30

ENGINEERING MATERIALS

34

INDUSTRY NEWS

40

FROM THE FRONT LINE

42

CURRENCY CORNER

43

SOFTWARE

43

BUYERS’ GUIDE

44

Tougher international legislation on chemicals creates new compliance challenges for health and safety management

32-33 FEATURE Rubber

Composites Characterising high-modulus composites

14-17 FEATURE

Study reveals new materials era in ‘green tyres’ for cars

36-37 FEATURE Automotives

Rotomoulding Rotomoulding materials – challenges and opportunities

Renault-Nissan sponsors UK plastic experts to speak at automotive conference

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19-21 ]FEATURE Film and Sheet Irish PVC manufacturer expands capacity with counter-rotating extruder

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Composites power into Olympic history The powerboat driven up the River Thames by David Beckham to bring the Olympic flame to the London 2012 opening ceremony was made from UKbased chemical company Scott Bader’s range of Crystic composites.

The Bladerunner BR RIB35 fibreglass powerboat’s laminate construction, designed and manufactured by Surreybased ICE Marine Ltd, uses a combination of chopped strand matting, biaxial and unidirectional glass and carbon fibre fabrics, as well as PVC foam cores and sandwich laminate sections used extensively in the structural design of both the hull and deck.

Leftover cashew nuts take to the slopes in biocomposite snowboard Innovative biocomposite materials are heading for the slopes, after engineers at the AMRC Composite Centre produced a prototype snowboard from flax, cashew nut husks and recycled plastic. The team are investigating the potential use of these biocomposites for electric vehicles and other applications.

The ARMC states that as the trend for lightweighting in the aerospace and automotive sectors continues and the use of composite materials increases, it believes replacing some or all of these raw materials with sustainable alternatives can significantly improve the environmental performance of composites manufacturing.

The AMRC Composite Centre, based in Rotherham, started working with biocomposites as part of E-light, a collaborative European project to investigate new lightweight materials for electric vehicles. The team investigated the use of fibres from flax and bamboo, as well as an epoxy resin derived from cashew nut husks which would normally go to waste, and produced two fairing panels for the AMRC’s exhibition lorry as showpieces.

Some of the young researchers at the AMRC Composite Centre then started looking at the potential for these materials in an area of special personal interest:

Composites

news

The Bladerunner BR RIB35 powerboat being driven up the Thames by David Beckham

Jeremy Watts, Managing Director ICE Marine and also the Bladerunner driver during the torch handover part of the opening ceremony event, commented: “We have been very impressed with the quality and performance reliability of Scott Bader products, which are also easy to use on the shop floor as they have excellent batch-to-batch consistency, so we know what we are getting every time.”

To achieve the highest long-term mechanical performance of the laminate sandwich structures in key stress areas, ICE Marine states PVC foam cores are first

primed using a light coating of catalysed Crystic 489PA resin and then bonded in with Crystic Crestomer 1196PA, a low density gap filling structural adhesive specially designed for core bonding.

ICE Marine uses vacuum bagging to ensure void-free adhesion and to maximise the penetration of the gap filling structural adhesive around the PVC core material.

snowboarding. The team launched an internal project, which became known as SUSC: Snowboard Using Sustainable Composites.

“Snowboards need to be stiff, strong and light, so are typically made from glass fibre or carbon fibre composite with a wooden core,” said Development Engineer, Craig Atkins. “We decided to take a look at replacing these with more sustainable materials. Flax is a relatively cheap bio-material, with good mechanical properties, and a very good candidate for use in snowboards.”

The team produced two boards from flax fibres embedded in a resin containing 30 percent of cashew shell epoxy. The core was made from recycled PET foam, derived from old plastic bottles and other waste.

One board is currently being put through its paces by one of the AMRC team, Alistair Murray, during a sabbatical in the Canadian mountains. The other is

on show at the centre, having drawn interest from businesses at the Composites Engineering Show at NEC in November 2012 as well as from the extreme sports community.

“There’s a number of areas we need to investigate before these biocomposites can go into commercial production,” commented Dr Tim Swait, AMRC Research Engineer. “We will research how we can increase the concentration of fibres to give material properties that are at least a match for synthetic composites, and how we design the lay-up for a biocomposite component to optimise its performance.

We’re also investigating other techniques to improve the energy efficiency of composites manufacturing, such as microwave curing, and whether these can be applied to biomaterials.”

Craig Atkins, Development Engineer at the AMRC Composite Centre, holding the finished board

further information: www.scottbader.com

Further Information: www.amrc.co.uk

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Composites

news

An architect’s image of the new building

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National Composite Centre awarded further funding for development Chancellor George Osbourne has announced an investment of £28 million to enhance the capabilities and capacity of the National Composites Centre (NCC).

The NCC, located near Bristol, opened in November 2011 to meet the needs of industry that is increasingly making use of composite materials that are light, strong and corrosion resistant. The Centre, which is owned by the University of Bristol, has world-class expertise and industrial-scale facilities that are being used to develop the technologies, which will result in more fuel efficient land, sea and air vehicles as well as, for example, the next generation of wind and marine renewable energy devices.

The NCC, which is a part of the High Value Manufacturing Catapult, will invest the money to construct additional facilities

adjacent to the existing building. As well as providing increased capacity and a dedicated high speed composite manufacturing technology facility, part of the new building will be utilised to ensure a sustainable future for the composites manufacturing skills in the UK workforce by bringing together leading businesses, colleges and Universities at a world-class training facility.

The announcement has reinforced the NCC’s continued success in providing a hub for the UK composites industry, and brings the total Government funding contribution to the centre to over £40m.

NCC Chief Executive, Peter Chivers, said: “I am thrilled by the announcement which reflects Government’s on-going commitment to high value manufacturing and its growth in the UK. Composites is key to the future of many UK sectors and their endeavours to reduce CO2 emissions. The extended NCC, which will provide for further innovation in multisectoral manufacturing and technology development, skills and education, and

offer greater support for SME’s and the supply chain, will be fundamental in allowing the UK to remain competitive in this rapidly growing global market.

Working with the newly formed UK Composites Leadership Forum, we now have a world-class platform for catalysing growth.”

Professor Guy Orpen, Pro ViceChancellor of Research at the University of Bristol, commented: “This is a clear signal that the renaissance in research-driven high value engineering is a key pillar in the UK’s economy. This is great news for the interface between leading research and industry for Bristol and the UK. The new building is planned for completion by the second quarter of 2014. *Treasury website ref: http://www.hmtreasury.gov.uk/as2012_south_west.htm Further Information: www.nccuk.com

New technology for mass production of composites using the injection moulding process Scientists at the Fraunhofer Institute for Chemical Technology (ICT) in Pfinztal, Germany, together with injection moulding machine manufacturer, Engel, have devised a technology that allows the series production of continuous fibre-reinforced thermoplastic composites with an injection moulding process for the first time. To date, it has only been possible to use the injection moulding process for fibre-reinforced composites made of short or long fibres.

“Continuous fibre-reinforced composite structures with a thermoplastic matrix are becoming increasingly popular, and will be used increasingly in the automotive industry,” states Dr.-Ing. Lars Fredrik Berg, Scientist and Project Manager at the ICT. “With the injection moulding process, components that have high fibre contents by volume and therefore outstanding mechanical characteristics can be produced efficiently in high volume series.”

Based on the results of their own research, the scientists of the ICT developed, together with Engel, a prototype machine for injection moulding. The reactive components are prepared and mixed, and the material is injected into the moulding die of an Engel e-victory 120.

In-situ polymerisation also takes place within it, after textile reinforcement structures have been introduced.

“The ICT and Engel have developed a robust, compact and fully automated technological system to series readiness that is flexible and quick at the same time. It is exactly this technology that the automotive industry has been lacking for continuous fibre-reinforced thermoplastic composite structures. The process, which to date had been distributed across several machines, can now be carried out on a single one,” said Peter Egger, Head of the Technology Centre for Lightweight Composites at Engel.

The e-victory has already passed its first crucial test: Engel produced, as an example, a brake pedal insert made of fibre glass-reinforced polyamide for the automotive supplier ZF Friedrichshafen.

In contrast to the injection moulding processes for fibre composite materials to date, where only short fibres could be processed, continuous fibre-reinforced composite structures can reportedly be fed into the evictory and be impregnated with a very low viscosity plastics matrix.

“We have developed a process in which the in-situ polymerisation of thermoplastic matrix materials works.

We allow monomers, which are highly reactive molecules, to polymerise directly in the machine. The monomers have a shorter molecule chain than polymers, and therefore a lower viscosity. When being processed, the viscosity of the reactive plastics matrix is similar to that of water. This means that the fibre structures can be wetted down in an ideal manner, without displacing the structures in the form,” explained Berg.

Further Information: www.fraunhofer.de www.engelglobal.com

Composites

news

Using the Engel e-victory 120, thermoplastic composite structures can be mass-produced using the injection moulding process.

Image courtesy of Engel

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Composites

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Alan Smith and staff gather to celebrate the Honour

Chairman of UK plastic company named in New Year’s Honours List Founder and Chairman of Pipex px, Alan Smith, has been awarded an MBE in the 2013 New Year Honours List for “Service to the Manufacturing Industry.”

Pipex px specialises in manufacturing construction products from thermoplastics and advanced composites and spearheading innovation in fast track, corrosion resistant, minimal maintenance solutions.

Recent projects completed by the company include the first ever FRP (Fibre Reinforced Polymer) footbridge installed at a Grade II listed railway station in Dawlish; GRE (Glass Reinforced Epoxy) Pipe Systems and FRP Phenolic gratings for the flight deck walkways on the Queen Elizabeth first of class aircraft carrier (the largest warship ever built in the UK) and thermoplastic PP-H (polypropylene) passive rainwater harvesting systems which are currently being installed in various UK schools.

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NetComposites and Composites UK part ways after successful partnership As of January 1st 2013, Composites UK will set up its own independent offices, ending the successful partnership it has enjoyed with NetComposites.

NetComposites has been contracted to administer Composites UK since

Having started the business from scratch in 1975 with a small bank loan, Alan began the company by exporting thermoplastic pipe systems to pharmaceutical and petrochemical projects in the Middle East. ‘Pipe exports’ was abbreviated to give the company name Pipex Limited. At that stage there was no manufacturing facility and Alan sub-contracted the fabrication work required.

Thirty eight years on, the company (now Pipex px) has manufacturing facilities in Plymouth and Glasgow, five engineering divisions, employs 130 people, runs an apprenticeship scheme, donates 5 percent of surplus profits to national and local charities, and is multi award winning in all areas of the business.

Alan Smith commented: “I am humbled and very touched to receive this award, I feel this MBE is for Pipex px and all my colleagues who have worked so hard with me to make the company what it is today.”

Further Information: www.pipexpx.com

autumn 2008, in which time the network has expanded from 80 to 150 members.

Following this period of growth, Composites UK is now in a position to employ staff and run its own operations.

Whilst NetComposites will no longer have any involvement in the day-to-day running of Composites UK it is hoped that the long established relationship between the two organisations will continue. NetComposites and Composites UK will continue to liaise through this transition period.

PolyOne is looking to expand its range of special ity materials offerings. Image Co urtesy of PolyOne Corporation

PolyOne enters composites market with acquisition of Glasforms PolyOne has acquired advanced composites materials producer, Glasforms, as the company looks to expand its range of speciality materials offerings.

Purchased for $34 million (approx £21m), PolyOne states it expects the acquisition to be accretive to earnings in 2013. Glasforms has grown at a 36 percent CAGR since 2010 and in fiscal year 2012 reportedly achieved revenues in excess of $50 million (approx £31.3m).

“Our acquisition of Glasforms marks yet another important milestone in PolyOne’s transformation, as we further broaden our specialty solutions portfolio to include these new and adjacent technologies and applications,” said Stephen D. Newlin, Chairman, President and CEO, PolyOne Corporation.

Glasforms manufactures advanced composites products for use in applications across the electrical and telecom, energy, transportation, healthcare and security and defence markets. End applications include applications for endoscopy wands, wind turbine blade stiffening components, flooring, doors and decking amongst others.

Further Information: www.polyone.com

NetComposites has reassured customers that business will continue as normal, including a full programme of conferences, events and training for 2013, which includes the ACIC and ECOCOMP conferences as well as network activities, events, training, newsletters and other consultancy.

Further Information: www.netcomposites.com

As the use of lightweight materials becomes increasingly prominent in the automotive industry, The Analysing and Testing Unit of Netzsch explains how its Dynamic-Mechanical Analysis equipment can be used to analyse and evaluate composite materials for use in high-performance parts.

For many decades, steel was the primary material used in the automotive industry. In more recent years, a shift toward electric motors for safety and comfort has increased the popularity of lighter metals such as aluminium and magnesium, to counterbalance the resulting increases in vehicle weight.

Today’s research trends focus not only on purely electric vehicles, but also on hybrid cars, which have heavy batteries for their electric motor as well as a traditional engine with lower fuel consumption.

Technological advancements such as these make it necessary to continuously seek lighter and lighter materials, but without sacrificing the required stiffness over a broad temperature range.

The key to reducing vehicular weight has been found in the use of fibrereinforced polymers. These high-modulus composites have already proven their performance in the aircraft and aerospace industries. However, cycle times for the production of car parts are much faster and the thermosetting resin must therefore cure in only a few minutes, not a few hours.

Dynamic-Mechanical Analysis (DMA) - Method and Instrumentation The focus of the DMA method is on the visco-elastic properties of polymers. The stiffness and damping behaviour are determined under an oscillating force as a function of temperature, time and frequency. The robust design of the Dynamic-Mechanical Analyzer DMA 242 D provides highly accurate Young’s modulus values for all composites across the temperature range from -170°C to 600°C.

The measurement result in the graph shows the storage modulus E’ (green curve), loss modulus E’’ (red curve) and loss factor tanδ (blue curve) for a carbon-fibre reinforced epoxy resin as a function of temperature. The lamellar sample was measured in bending mode at a frequency of 10 Hz and a heating rate of 3 K/min. Prior to reaching 120°C, the material is even stiffer than titanium: 140000 MPa. At 158°C (extrapolated onset temperature of E’), the modulus drops due to the glass transition of the epoxy matrix. The corresponding peaks for E’’ and tanδ are at 180°C and 188°C respectively.

DMA 242 D - Advanced Features for Composites and More The new DMA 242 D offers advantages in the research and development, quality control and failure analysis of composites. The modified single cantilever bending sample holder with free push-rod (fig. 4) guarantees quantitatively high storage modulus values (E’) at low damping values (E’’, tanδ). Here, the sample is tightly fixed at one end and a free push-rod oscillates at the other end with a superimposed static force. For data acquisition, Fourier transformation carries out highly sensitive and accurate deformation amplitudes and the exact phase shift.

This digital filtering improves the signalto-noise ratio to one order of magnitude without any phase lag as compared to the conventional analogue technique.

The 5-dimensional system stiffness calibration routine for sample holder type, dynamic force, deformation amplitude, frequency and temperature takes into consideration all influencing factors from the DMA setup. Even the phase shift of the DMA electronics is taken into account by means of “rotation tuning”. This provides low tanδ values for extremely stiff materials such as composites, metals and ceramics.

Further Information: www.netzsch.com

Composites Feature

Characterising High-Modulus Composites reinforced plastics Use of carbon-fibre in automotive industry

DMA measurement result on a high-modulus carbon-fibre reinforced epoxy resin

The DMA 242 D

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Rotomoulding

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news BPF Rotational Moulders Group rounds off 2012 with double the members The BPF Rotational Moulders Group is celebrating hitting a record high in membership, with the group growing by over 50 percent in 2012.

Attracting a broad section of moulders, material suppliers, machinery manufacturers, ancillary equipment suppliers and service providers; 493K, ACO Technologies, Francis Ward, Leafield Enviromemtal, Orchid, Rotomotive, Rototek (a trading name of Trent Mouldings Ltd), Tecni-Form and Steel Tool Solutions all joined last year.

The Rotational Moulders Group has been incredibly active in promoting the industry and hosted its annual ‘Design and Innovation in Rotational Moulding

New report documents versatility in rotational moulding industry In a recent report documenting the rotational moulding industry in Europe, Applied Market Information Ltd (AMI) highlighted the versatility of the rotational moulding process and its ability to be a cost-effective alternative to blow moulding.

A three-percent drop in the number of rotational moulders listed in ‘AMI’s Guide to the Rotational Moulding Industry in Europe, 7th Edition’ highlights the effects of the global economic crisis on the European plastics industry. The remaining 336 listed production sites across Europe are estimated to have been responsible for the consumption of 211,000 tonnes of polymer in 2011, down from the prerecession highs of 250,000 tonnes in 2006. Although the industry has a long way to go to regain those lost volumes, the market is expected to show some growth for 2012.

AMI reports the weakness in the rotomoulding sector was largely a consequence of the continued economic uncertainty in Europe, which resulted in the reduction of infrastructure projects and impacted on the demand for rotationally moulded water and fuel tanks, which make up the largest end use application for this process. Other sectors however performed better and the

Seminar’ at PDM last May. The Group is now in the process of working on an educational tool to secure greater understanding of the rotational moulding process and its contribution to engineering and design amongst university students.

The BPF Rotational Moulding Group was represented in full force at the Affiliation of Rotational Moulding Organisations (ARMO) Conference in Lyon in October 2012. The Group showed its unity and strength at the conference with over 20 UK companies in attendance.

Karen Drinkwater, BPF Rotational Moulders Group Chair, commented: “Our key targets are future graduates, employees and customers,” stating the group is “strategically vital in providing a communications platform to reach out to them.”

Further Information: www.bpf.co.uk

economic downturn resulted in some applications, which may have traditionally used blow moulding, switching to rotational moulding because of the smaller volumes of articles required and the economic advantages of using rotational moulding for small runs. The materials handling market has been relatively unaffected by the recession and the market for intermediate bulk containers (IBCs) is still growing. This

Karen Drinkwater, BPF Rotational Moulders Group Chair

market is maintained by the requirement for most containers to be replaced a minimum of every three years. The offshore industry and fishing remains a solid and growing market, especially in the Nordic Countries where over 50 percent of rotational moulders supply the marine and fishing markets.

Further Information: www.amiplastics.com

Distribution of polymer demand for rotational moulding in Europe 2012

Akulon fuel lock enables ICO Polymers’ rotomoulding monolayer tank solution

news New PA6 solution for rotomoulding of monolayer tanks launched Akulon Fuel Lock, a polyamide 6 technology developed by DSM, forms the basis of a new solution for rotomoulding monolayer tanks developed by ICO Polymers, a producer of rotational moulding polymers.

The monolayer PA6 solution, named ‘Icorene 7620 Fuel Lock’, which was launched during the Conference of the Alliance of Roto Moulding Organisations (ARMO), held in Lyon, France, last October, was developed for small engine tanks for off-road vehicles.

The new monolayer PA6 solution is reportedly based on the successful Akulon Fuel Lock, originally designed for injection and blow-moulded fuel tanks that are used for engines in hand-held and groundsupported lawn and garden equipment, as well as recreational, professional landscaping and marine applications.

Tim Vorage, Application Development Manager of DSM, stated: “Our newly developed cost-effective Akulon Fuel Lock for the rotomoulding (RTM) market is the outcome of an intense cooperation with the research department of ICO Polymers.

Rotomoulded bin speaks volumes in litter reduction Wiltshire-based Leafield Environmental has launched a new, rotationally moulded polyethylene bin that it claims can reduce the volume of used drinking cups by a factor of ten.

The Envirobin Economy M-T Cup Bin has six apertures through which plastic or paper cups are deposited and a central

The material not only shows a permeation factor of below 20 percent of the EPA limit, but it also exhibits high toughness at low temperatures.”

DSM states Icorene 7620 Fuel Lock eliminates the need for after-treatment procedures such as the environmentally challenging fluorination process.

Moreover, it states this monolayer solution obviates the need for complex multi-layer concepts, delivering improved equipment efficiency and productivity – and therefore lower energy consumption during processing. In use, the monolayer solution is said to ensure a durable barrier performance over the required liability period of five years, and this does not diminish over time.

Heinrich Lingnau of ICO Polymers said: “PA6 will surely establish a position in the RTM market because of its combination of high strength, modulus and relative high

aperture through which excess liquid and residual dregs are poured into a removable 7.5 litre reservoir.

Leafield states the tubular moulded design maximises cup collection capacity by encouraging the cups to nest inside each other up to the full height of the tube. In this way some 500 cups can be collected in a single bin.

Further Information: www.leafieldrecycle.com

The Envirobin Economy M-T Cup Bin

melt temperature. Working with DSM, we were able to develop this significant innovation that helps to meet the dual challenges of climate and energy.”

Ralf Ponicki of DSM added: “The rotomoulding solution is very much appreciated by customers that already use our injection and/or blowmoulding solution, since they can now use a solution for permeation reduction from one source with proven technology that gives peace of mind regarding liability.”

Besides EPA compliant tanks, Icorene 7620 Fuel Lock can reportedly be used in any applications that require low fuel permeation, low temperature impact performance and UV stability.

Further Information: www.dsm.com

Rotomoulding Feature

Rotomoulding Materials challenges and opportunities Dr Nick Henwood of Rotomotive Limited writes for BP&R on the growth of The rotomoulding Process and how new materials solutions are sought after to sustain this growth in the future.

Fig. 1: A typical rotomoulding application is for flexible road furniture, like bollards

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For many years, rotomoulding has been a process that has enjoyed strong growth; even in developed markets, like Europe and North America, growth was for several decades two to three times the general economic GDP for these areas.

More recently, developing markets, such as Latin America, the Far East and Africa/Middle East have also developed strongly, mainly on the back of infrastructure growth.

Although the world financial crisis took its toll on all manufacturing sectors, rotomoulding appears to have substantially bounced back and growth rates are still good, even if not yet at their former high levels. Many rotomoulding market application niches tend to be regional in nature, due to the large size of many hollow rotomoulded products; potential cost savings from offshore manufacture tend to be negated by high unit shipment costs.

In developed markets, these positive indicators are still prevalent today, but there is growing concern that future growth in the roto process is being threatened by the lack of suitable plastic raw materials, with which to build new applications and product/market segments.

Rotomoulding is unusual as a plastics process in its almost total dependency on one type of raw material – polyethylene (PE). It has been estimated that over 97 percent of all plastics rotomoulded worldwide are some form of PE or a close variant. There are good reasons why this is the case and, while there were plenty of new applications being created for rotomoulded PE products, the lack of alternative materials has not been a major concern. However, there is a hardening consensus that, for sustained growth in the roto sector, new materials solutions will need to be developed to encourage new customer industries to consider the process.

As a rotomoulding material, linear medium density PE (the main type used in the process) has many advantages. It is relatively easy to mould, with a wide ‘window’ to accommodate process variations. PE offers a good balance of properties for large, durable items like tanks; grades can be found that provide acceptable stiffness with excellent toughness, even at sub-zero temperatures. Finally, grades are available at a relatively low price, from a variety of suppliers.

Fig. 2: A typical use for XLPE is fuel tanks for speciality vehicles such as boats, tractors and trucks

It will thus be appreciated that PE is a “hard act to follow” and potential material substitutes all have significant disadvantages for widespread adoption.

Some of the main potential alternatives are discussed below: PE variants PE’s with a very low density (0.900 g/cm3 and below) have been developed for applications requiring extreme flexibility. Other flexible copolymers of PE, like EVA and EBA have also been used. A typical rotomoulding application is for flexible road furniture, like bollards (see Fig. 1). Crosslinkable PE (XLPE) grades have also been available for a number of years; these materials offer improved performance compared to standard PE, especially in terms of long-term resistance to stress cracking and lack of dripping in products that are required to be fire tested. A typical use for XLPE is fuel tanks for speciality vehicles such as boats, tractors and trucks (see Fig. 2).

Polypropylene (PP) PP would seem to be an obvious choice as an alternative material. Homopolymer PP offers well over twice the stiffness of PE and in some plastics processes (especially injection moulding) PP has, in many cases, replaced PE as the material of choice.

Injection moulding PP grades sell at a similar price to that of PE. Homopolymer PP’s tend to be brittle, but copolymer PP grades offer improved impact properties, albeit at some reduction in modulus.

Unfortunately, for rotomoulding, the PP grades so far developed offer major disadvantages. Unlike PE, it is extremely difficult to produce the powders that the rotomoulding process needs from PP; usually some form of cryogenic grinding process will need to be employed, which is much more costly than the ambient grinding process employed to make PE powder. This is particularly true for impact modified PP grades and homopolymer PP is generally too brittle for large durable rotomoulded products. Finally, PP is substantially more susceptible to degradation by heat and UV attack; this is especially problematic with rotomoulding, which is an extremely heat-aggressive production process. As a result of all these issues, rotomoulders who use PP tend to suffer from high materials purchase costs as well as high moulding scrap rates, which often makes the use of the material uneconomic.

Polyamide (PA) Neither PE, XLPE nor PP can offer much barrier to permeation by fuel and, for these applications, some variant of PA is typically incorporated into the moulded part. In view of the relatively high cost of PA’s, they are sometimes used as a fuel resistant layer in a multi-shot structure

with PE. For other applications, where materials cost will allow it, the whole part may be rotomoulded from PA. Unlike PE and PP, PA’s are paintable, which can be a major advantage for some applications.

Temperature resistance is also significantly superior. The easiest forms to rotomould are PA11 and PA12, which are, unfortunately, also the highest cost materials. Cryogenic grinding is necessary and powder drying is also required because the materials are moisturesensitive. PA6 is considerably cheaper to purchase that PA11/PA12, but its significantly increased sensitivity to moisture means that additional moulding and post-moulding procedures need to be employed to ensure that acceptable rotomoulded parts can be produced. Once again, this reflects adversely on scrap rates and overall part cost. As a result, sales of PA’s for rotomoulding are very small compared to sales of mainstream PE grades and applications have been limited to speciality niches where the high cost can be justified. Examples are motorcycle fuel tanks and hot hydraulic oil reservoirs.

Polycarbonate (PC) PC has very high stiffness, high temperature resistance, excellent impact strength, transparency and inherent flame retardant properties. Although it is possible to produce a part, it is generally

seen as very difficult rotomould on a commercial scale without unacceptably high scrap rates. Rotomoulded PC has been used in the past mainly for applications such as lighting globes.

Other polymer options A number of other materials (eg PVC, ABS, acetal, cyclic PBT, polyurethane) have been tried in the rotomoulding process, but they all present considerable difficulties. Most often, potential alternative materials suffer from either unsuitable melt rheology under the very low shear conditions prevalent in the roto process and/or sensitivity to the aggressive heat conditions that prevail.

Despite these apparently gloomy prospects, the potential value is considerable for opening up new application areas for this versatile and designer-friendly process. There are a few specialist organisations working to tackle the many barriers to entry for rotomouldable polymers. Rotomotive Limited, a UK-based consultancy and research organisation, is one company who is working closely with several universities to solve the challenges presented in this area.

Further Information: www.rotomotive.net

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Irish PVC sheet manufacturer expands capacity with counterrotating extruder Plastic sheet manufacturer, Brett Martin, has significantly expanded its production capacity for PVC sheet production since the beginning of 2012 by using battenfeld-cincinnati’s most powerful counter-rotating twin-screw extruder with an output of up to 2,000 kg/hr.

Brett Martin, based in Newtownabbey, Northern Ireland, makes high-quality speciality plastic products for the building construction, manufacturing, printing, roofing and display industries. In the area of sheet production from PVC, PMMA or PC, Brett Martin Ltd has produced a range of customised products ranging from light domes for the Wembley Stadium to typhoon-resistant McDonald’s signs.

Brett Martin operates several extruders from battenfeld-cincinnati in its

BPI invests into manufacturing but wary of recycling targets At a formal ceremony attended by the Minister of State for Business and Enterprise, the Rt Hon Michael Fallon MP, British Polythene Industries (BPI) commissioned its latest co-extrusion line at its films facility in Sevenoaks, Kent.

At cost of two million pounds, BPI states this latest investment further increases its capacity as the European market leader in the production of specialist polythene films for the food packing sector.

Surrounded by more than 50 guests, including suppliers and BPI staff, the Minister unveiled a commemorative plaque and spoke of the need for the industry to invest in new, high technology production equipment.

In reply, BPI Films Managing Director, Andrew Green, thanked the Minister for his support of the Sevenoaks factory during the last 15 years but warned that unintended consequences emanating increases to recycling targets will impact across all food packaging sectors.

Green said: “We have absolutely no issue with stretching recycling targets.

Indeed as the largest recycler of polythene

production plant, as well as the most recent addition.

“We were particularly impressed by the outstanding flexibility of this extruder, which enables us to produce PVC sheet with a wide range of thicknesses from three to 25 mm,” said Technical Director at Brett Martin Ltd, David Robinson. battenfeld-cincinnati states in addition to its wide processing window, the largest counter-rotating extruder in the company’s portfolio offers the benefits of high output, robust design and easy operation. With its closed-loop, self-regulating Intracool screw tempering system and its efficient apc (air power cooling) barrel cooling system, the extruder is said to ensure constant melt temperatures and therefore high standards in product quality.

Above: Largest counter-rotating twin screw extruder from battenfeld-cincinnati’s range of machinery

Film & Sheet

news Below: Corrugated and flat sheet from Brett Martin for a great variety of applications.

Image copyright of Brett Martin.

Further Information: www.battenfeld-cincinnati.com www.brettmartin.com

Pictured (L to R): Andrew Green, Managing Director at BPI Films, and Rt Hon Michael Fallon MP, Minister of State for Business and Enterprise

film waste in Europe, we actively support stretching recycling targets. Our concern with the (new) targets as now set by DEFRA is that they are unachievable.

Having increased the amount of plastic waste we recycle as a nation by 500,000 tonnes in the last 13 years, these new targets require our industry to increase the volumes of plastic waste we collect and recycle by 600,000 tonnes within the next five years.

“To achieve the Government targets the UK will need to become the biggest

recycler of plastic bottles, pots, tubs, trays and plastic film in the EU. The one area where the UK is currently top is that we have the highest proportion of our plastic waste, currently 70 percent, exported for recycling overseas. This is neither environmentally nor commercially sustainable. Having such a high proportion of our recycling activity dependent on overseas, and generally Far East recyclers, is a significant risk factor in meeting our targets and has been responsible for the export of UK jobs in recycling for a number of years.”

In a warning to all ‘players’ in the food sector including retailers, packers and producers, Green continued: “The consequences of failing to hit these unrealistic targets in 2017 is that we will see huge and disproportionate costs to businesses handling plastic packaging over the next few years as we fall short. It will also create a huge incentive for fraudulent activity generating evidence of plastic reprocessing. Ultimately, it could undermine all the positive work our industry has achieved over the last 15 years by once again appearing to the general public as if plastic packaging is a problem, rather than part of the solution.”

Further Information: www.bpifilms.co.uk

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Film & Sheet

news Multi-million pound investment for film and packaging producer Roberts Mart & Co Ltd, an independent UK manufacturer of flexible packaging, has just invested a further £2.5m in new plant machinery to boost production capacity at its two facilities in Leeds.

The company states the investment signals growth for 2013, with the potential for 25 new jobs to cope with increased product requirements following the purchase of a state-of-the-art printing press and laminator for its Aire Valley factory, as well as an extruder for its sister business, Romar Packaging.

The printing press will be used to supply specialised, high performance films to a variety of industry sectors, including food, beverages, pet food, supermarket own brand, bottled waters and textiles. The

Clariant unveils new technology for agricultural films Clariant has launched stabilisation solutions to improve the durability of greenhouse films in a move it hopes will fulfill market needs for durable crop protection and improved productivity.

Clariant states the service life of greenhouse films is severely impacted by combined aggressive effects from intensive solar radiation exposure and increasing use of agrochemicals, such as sulfur and halogenated chemicals. Light stabilisers based on amino-ether HALS outperform standard HALS in terms of agrochemical resistance which enables superior UV protection and extends the lifetime of the greenhouse film.

Clariant states it is now offering film producers customised amino-ether light

Clariant has launched new technology for agricultural films

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company states the installation of the new three-layer co-extrusion line will boost the production of coextruded low density blown polythene film by 1600 tonnes per year.

The latest increase in capital expenditure takes Roberts Mart’s overall investment to just over £15.5m. Sales Director, Ben Roberts, said: “This significant new outlay we are making on capital equipment underlines our confidence in developing our existing and new markets.”

Roberts produces high performance films for a number of sectors including food packaging

Further Information: www.roberts-mart.co.uk

stabilisation solutions based on its ‘Hostavin NOW’ technology to achieve outstanding UV protection. The tailormade solutions are said to be available in a easy to handle granular form. Clariant says its solutions offer improved and safer processability compared to current available light stabilisers.

Ernesto Dongiovanni, Head of Marketing Polymer Additives, commented:

“This step-change advance in HALS technology reflects Clariant’s on-going commitment to support the agricultural industry in its efforts to increase productivity and find sustainable solutions to the growing global food demand.”

Further Information: www.clariant.com

news New UV-cutoff film achieves world’s highest level of protection from ultraviolet light Teijin DuPont Films has developed a high-performance polyester film that it says achieves the world’s highest level of protection from ultraviolet (UV) light.

The film is expected to be launched commercially in 2013 and sales of 2.5 billion yen (31.5 million USD) are envisioned by fiscal 2020. Teijin states protective films for electronics materials are expected to be the primary application.

The new film reportedly incorporates Teijin DuPont Films’ unique technologies for UV absorption agent, and blocks UV radiation up to 390nm, or nearly 100 percent of all harmful ultraviolet light.

Visible light, however, is said to be transmitted at a rate equivalent to or greater than that of conventional films. Until now, the rate of visible light transmission has decreased as UV cutoff performance is increased in conventional films.

Teijin states UV cutoff properties are

incorporated in the film itself, so there is no need for additional coating as required with conventional films. Since impurities generated during coating are eliminated, the new film’s production is said to generate just one-tenth the amount of impurities compared to conventional film production, thereby helping to reduce overall costs.

UV cutoff films are used for window

glass and films protecting electronics materials. The demand is expected to grow for the protection of highperformance devices such as organic electroluminescent (EL) devices, electronic paper and other next-generation devices, as well as polymer conductive materials in next-generation solar cells and organic semiconductor materials.

Further Information: www.teijin.co.jp/english

Protective films for next-generation devices are thought to be the primary application for the film

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Recycled Materials

news Recycling technology produces high-quality material from difficult to process plastics Plastic recycling systems specialist, Erema, has developed new technology to produce high-quality recycled material from chemically complex waste film that has multiple layers of print.

The recycling system is used to produce high-quality material from production waste

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The TVEplus

PTIC takes recycled materials on board Polymer Training and Innovation Centre (PTIC) is taking the green approach to training, thanks to a new partnership with Blue Sky Plastics Recycling. This partnership will see Blue Sky supporting PTIC by supplying premium quality recycled compounds derived from UK post-consumer scrap sources.

The centre, based in Telford, is now using a range of recycled polymers from Blue Sky including PP, PS and ABS on its range of technical training courses using its own in-house moulding machinery.

Blue Sky will also take back any scrap produced by PTIC from polymers supplied, ensuring a zero landfill solution.

PTIC state this links in with the Government’s Waste Strategy to reduce the amount of waste going to landfill and is a good example of using the waste ‘hierarchy’ pyramid. These issues are all covered in the Chartered Institute of Waste Management (CIWM) Waste Awareness Certificate (WAC) course that PTIC is also approved to deliver.

According to Erema, heavily printed (multiple layer and/or metallised) plastics pose new challenges to recycling systems, regardless of whether it is production waste or post-consumer materials. Binding agents and other additives that are always found in the inks, for example, are a problem as they melt at the processing temperatures of the plastic matrix and break down in parts.

Erema states its TVEplus recycling technology offers efficient filtration, homogenisation and degassing at the highest level and makes it possible to produce high-quality recycled material in a single pass, even from waste film that is covered with multiple layers of print.

Indian-based Uflex Limited, a producer of plastic packaging including BOPP, BOPET, laminated and metallised films, has used the TVEplus recycling system since 2010 to process its production waste and make high-grade injectionmoulded parts from the recycled material.

Erema states TVEplus recycling technology is not only suitable for production waste but also for postconsumer material. Additionally, the company states the ecoSAVE design of the system promotes greater efficiency with less energy consumption.

Chris Riddle, Managing Director of Blue Sky, said: “We are delighted to support PTIC by supplying our premium quality recycled compounds, introducing tomorrow’s injection moulders to the advantages of using recycled materials has to be good news for everyone involved.”

Steve Harratt, Polymer Sector Account Manager for PTIC, added: “The results using our state of the art machinery, indepth PTIC training and these recycled polymers never fail to amaze the students; it really is a win-win situation for everyone.”

Students at the PTIC will train using recycled materials

Further Information: www.erema.at

Further Information: www.blueskyplastics.co.uk www.wolvcoll.ac.uk/polymer

The SWAPP facility in Manchester

Further investment in North West recycling facility Plastics recycler, Axion Polymers, invested a further £1 million in 2012 to optimise materials recovery from end-oflife vehicles at its purpose-built plant at Trafford Park, Manchester – one of the most advanced of its type in Europe.

Axion’s in-house engineering team designed, built and now operates the highly-specialised, multi-million pound Shredder Waste Advanced Processing Plant (SWAPP) jointly with S Norton & Co, a UK ferrous and non-ferrous metal recycler.

Opened in January 2011, Axion states the plant is already capable of delivering over 95 percent recycling and recovery of materials from end-of-life vehicles (ELVs), ahead of the 2015 EU ELV recycling and recovery target.

Director, Roger Morton, said: “This latest cash injection is part of on-going efficiency optimisation at the facility, which has an annual 200,000 tonnes capacity. It enables Axion to separate the non-metallic fractions from the equivalent of about 800,000 cars a year.

“Although the operation is still developing, we are already delivering the 95 percent recycling and recovery target through a combination of plastics recycling, producing materials for the construction industry and fuel to substitute coal,” explained Roger. Plastic concentrate is taken to Axion Polymers’ Salford plant for further processing into a range of plastic products, such as the Axpoly PP51 extruded pellets that go to a wide range of customers, including some in the automotive sector, thereby ‘closing the recycling loop’.

Axion states that the polypropylene recovered from automotive post-consumer

waste presents a great opportunity for manufacturers to tap into a stream of truly sustainable materials. Creating new manufactured products using materials resources that are ‘mined’ from closedloop recycling routes provides a complete ‘cradle-to-grave’ approach for vehicle producers that is both sustainable in the long term and also lower cost.

As well as automotive applications, Axpoly PP51 has potential uses in the utility, construction and wider manufacturing industries.

Further Information: www.axionpolymers.com

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Black APET trays being thermoformed during trials at Linpac Packaging

Innovative black colourants open up new markets for recycling packaging waste

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Materials technology that enables the mechanical recycling of black plastic packaging currently destined for landfill or energy recovery has been developed through a project commissioned by WRAP. Innovations resulting from the project, undertaken by Nextek Ltd, have the potential to create new business for plastics colourant and material suppliers, packing manufacturers and recycling companies while delivering benefits over existing waste management options. Tony Gaukroger, Managing Director of Colour Tone Masterbatch, summarises the developments and implications of the project.

New black colourants allow Near Infrared (NIR) spectroscopy to sort black plastic packaging waste, such as pots, tubs and trays, by polymer type so they can be recycled into high quality materials.

The colourants work in APET, CPET, PP, HDPE, PS, and PVC materials.

Colourants now available for packaging and other sectors, including EEE and automotive, allow the automatic detection and recovery of materials so that they can be used in new applications as substitutes for virgin plastics.

Additionally they offer improvements in recycling revenues as well as savings in carbon emissions and landfill volumes.

The project report ‘Development of NIR Detectable Black Plastic Packaging’* says there are approximately one million tonnes of rigid mixed plastic packaging in the UK waste stream and black plastic packaging could represent between 3-6 percent of this volume. Conservative industry estimates indicate that this could

be around 26,000 - 30,000 tonnes per annum of black plastic packaging.

Estimates from other industry sources suggest that the figure could be as high as 60,000 tonnes per annum.

Sorting the problem Carbon black is widely used as a colourant in food contact packaging because it provides a contrasting background and allows the colours of food to stand out. Additionally it is low cost and has good dispersion and masking properties which allows off-cuts of other colours to be mixed together and manufactured into black items. However, carbon black absorbs NIR and does not return a signal, effectively blocking identification of the polymer type by the automatic NIR sorting systems widely used by material recovery facilities.

This project explored four possible approaches to enable automated sorting of black plastic packaging: alternative

spectroscopic techniques, physical sorting methods, addition of detectable markers and the development of alternative colourants.

The report concluded that only the alternative colourant technique allows sorting of black packaging with existing NIR based mixed plastics sorting facilities.

Identification of colourants The key principles utilised in identifying suitable black colourants were based on either of two characteristics; One: High levels of absorption of visible light and little absorption in the NIR spectrum, or two: Pigments which absorb in the visible spectrum but reflect in the NIR spectrum.

Pigments from both categories were identified from a number of suppliers and evaluated. The range was reduced to a small number in order to evaluate the key principles. The results are shown in Table 1.

The following colourants were found to enable polymers to be readily detectable

by NIR: PP/PE - Black 95491 (pigment) – Colour Tone Masterbatch Ltd PP/PE - Black 95492 (pigment) – Colour Tone Masterbatch Ltd PP/PE - Black 95493 (pigment) – Colour Tone Masterbatch Ltd PP/PS – Lumogen AK (pigment) – BASF PP/PS – Sicopal K0095 (pigment) – BASF APET - Dye Black-5 (liquid colourant) – Colour Matrix Group Inc. Plastic packaging for large volume items, such as food trays, requires pigments and colourants that are low cost and the report identified the following colourants to be potentially economically viable: PP/PE – Black 95493 (solid colourant) from Colour Tone Masterbatch Ltd PP/PS – Sicopal K0095 (solid colourant) from BASF APET - Dye Black-5 (liquid colourant) from Colour Matrix Group Inc. The colourant systems were optimised through experimentation to improve tint strength and the colourants that were finally selected for large scale APET, CPET and PP trials were: Colour Tone IRR Black 95530 for PP and CPET; and Colour Matrix Dye Black 5 for APET and CPET. Manufacturing trials In large scale manufacturing trials at Sharpak, LINPAC Packaging Ltd and Faerch Plast, food contact trays were manufactured with PP, APET and CPET, using either the Colour Tone or the Colour Matrix colourants.

Generally the sheet extrusion was successful and thermoforming operations ran well using standard settings. Initial trials used a two percent addition rate.

During trials with CPET it became clear that the colourants need to be matched to the polymers to eradicate colour bleed and achieve a satisfactory depth of colour.

Since publication of the report, Colour Tone has developed Black 95591, a polymer specific product with good jetness and coverage in PET, APET and cPET. Repeated recycling of PET and PP

materials coloured with both the Colour Matrix Dye Black-5 and the Colour Tone IRR95530 did not impact the quality of colour.

Laboratory trials of filling and sealing tray samples were also successful and NIR detectable colourants were found to make no significant difference to the heat required achieving seals.

Industrial scale sorting trials In large scale sorting trials at Jayplas Plastics, virtually all the PP and PET trays (>99 percent) were correctly identified by the NIR detectors and were successfully sorted.

TITECH, S+S, RTT Unicorn and Pollen, all manufacturers of NIR sorting machines, were also sent samples of trays made with detectable black colourants and found that they were able to sort them by polymer type and colour. The only adjustment necessary was tweaking of the operating software to ensure that a black tray was not misinterpreted as a clear tray against the background of a black conveyor belt.

Costs and benefits WRAP carried out a cost assessment to provide a preliminary evaluation of financial viability of the alternative black pigments compared with carbon black pigments. Its estimates were based on pricing information provided by the colourant manufacturers in April 2011.

Indicative costs at various addition rates for the novel pigments were calculated and compared to conventional carbon black masterbatch for a lightweight PP tray and a heavier CPET ‘ready meal’ type tray. See Table 2.

Detectable black colourants are more expensive than conventional carbon black pigments, with an indicative price range similar to other specialised organic pigments of the order of £9 to £16 per kg.

The indicative increases in cost of using these alternative pigments in place of carbon black is in the region of £1.80 to £3.50 per 1000 PET trays, at a one percent addition rate. For thinner PP trays this would be in the region of £0.75 to £1.50 per 1000 trays at a one percent addition rate - around 0.075 pence to 0.35 pence per tray at a one percent addition rate and implies an incremental cost per tonne of trays manufactured in the region of £70-£140.

Cost differential is of course influenced by the final addition rate.

Implementation of either detectable black colourants or novel sorting technologies at facilities that enable the recovery of black plastic packaging is expected to have significant net environmental benefits over the current situation where black plastics are primarily ending up in landfill. Previous analysis by WRAP has found that approximately 0.6 tonnes of CO2 can be saved for every tonne of mixed plastics mechanically recycled.

Recycled Materials Feature

Table 1: Summary of trials with alternative detectable black colourants and carbon black tested using NIR spectroscopic techniques. The recognition rate shows which pigments allow black articles to be sorted into polymer streams. Carbon black coloured items could not be sorted.

www.colourtone-masterbatch.co.uk www.wrap.org.uk *The WRAP report ‘Development of NIR Detectable Black Plastic Packaging’ was written by Robert Dvorak, Edward Kosior and Lesley Moody of Nextek Limited.

Table 2: Summary of cost evaluation data

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Health & Safety

Albis UK has been recognised for its Health and Safety management

news Albis UK wins British Safety Council’s Sword of Honour Award Knutsford-based compounder, Albis, was awarded the British Safety Council’s ‘Sword of Honour’ at the end of 2012 in recognition of its exemplary performance in the area of health and safety management.

Alex Botha, Chief Executive of the British Safety Council, announcing the winners said: "On behalf of the British Safety Council I warmly congratulate the winning organisations and their employees. This year 79 organisations won the Sword of Honour”.

The 2012 awards marked the 33rd year of the British Safety Council’s Sword of Honour. The winners had established that their specific site achieved the maximum rating in the British Safety Council’s five star health and safety

management system audit. The companies also demonstrated to an independent adjudication panel a culture of best practice for health and safety throughout the business – from the boardroom to the shopfloor.

"What unites them is their shared belief that proportionate and competent risk management brings both financial

and social benefits to their organisations.

Managing health, safety and environmental risks effectively does not need to be onerous; it is quite the opposite,” added Botha.

Health and safety the top priority for recycling business Lincolnshire-based recycler, Eco Plastics, has been awarded health and safety management standard, OHSAS 18001. The company states the certification represents another milestone in its ongoing drive to ensure all levels of its manufacturing activity demonstrate best practice.

The certificate was presented to the business after a seven-day assessment of Eco Plastics’ health and safety management systems at its Hemswell facility.

The audit process for OHSAS 18001 involves on-site assessment, and a thorough investigation of all production systems and processes by Lloyd’s Register Quality Assurance, one of the leading UKAS-accredited providers of management system certification and training.

This achievement follows ECO Plastics’ environmental accreditation in the form of ISO 14001, a voluntary standard aimed at helping businesses integrate environmentally friendly processes into their operations, in 2011.

Receiving the certificate, ECO Plastics’ Health, Safety, Environmental and Fire Manager, David Jarvis, said: “As a forward-

thinking and responsible company, securing the OHSAS 18001 was a crucial step in demonstrating Eco Plastics’ dedication to its staff. This systematic approach to safety forms part of the positive management culture we are working towards.”

Jonathan Short, Managing Director of Eco Plastics, commented: “This accreditation reflects how far Eco Plastics has developed as a business. As one of the UK’s leading recyclers, we are committed to employing safe and sustainable practices across our everyday business. We are extremely proud of our health and safety record, with our key performance indicators tracking closer to the trend lines associated with manufacturing businesses.”

Further Information: www.albis.com www.britsafe.org

Further Information: www.ecoplasticsltd.com

EcoPlastics' Hemswell facility

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News from HSE BPF Health and Safety seminar announced for 2013 The BPF has announced it will hold a health and safety seminar at the BPF offices in London in April 2013 aimed at all those in the plastics industry who want to improve their knowledge and understanding of health and safety.

The BPF has been involved with the SIMPL (Safety In Manufacturing Plastics) initiative, supported by the Health and Safety Executive (HSE), since October 2010.

The initiative, which will run over three years from 2011 to 2014, brings together

The BPF is holding a Health and Safety seminar in 2013

all parts of the industry including trade organisations and unions in a bid to stimulate progress on accident and illhealth reduction by helping to embed a health and safety culture within businesses.

The BPF states over 60 of its company members have signed the SIMPL pledge, committing to the SIMPL initiative’s objectives to comply with existing laws in practical ways that are right for their business, whilst improving health and safety standards for the workforce.

For more information on SIMPL, or to find out more about the upcoming BPF event, visit: www.bpf.co.uk/SIMPL

Slips and Trips Through analysis of injury data, the Safety in Manufacturing Plastics Group (SIMPL) have identified that slips and trips remains a big issue for all sectors of the plastics and composites industries.

To help manage this issue and to try and reduce the number of accidents that happen each year the British Plastics Federation have shared their slips and trips information sheet with industry to help target the causes of these injuries in the workplace.

For more information visit HSE's SIMPL page on managing slips and trips in the workplace.

Do Your Bit - Training Materials HSE, in association with a third party training provider, delivered two types of subsidised training as part of the 'Safe and sound at work – do your bit' initiative in 201011.

The HSE ‘Safe and sound at work – do your bit’ training materials are now available to download and are primarily aimed at training professionals and any employers who have the necessary resources/knowledge and training expertise to deliver the training ‘in-house’.

For updates to HSE’s Worker Involvement webpages, sign up to the e-bulletin on the Worker Involvement homepage.

Information courtesy of HSE. For more details visit www.hse.gov.uk/plastics

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Health & Safety Feature

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TOUGHER INTERNATIONAL LEGISLATION ON CHEMICALS CREATES NEW COMPLIANCE CHALLENGES FOR HEALTH AND SAFETY MANAGEMENT This month Manufacturers’ Organisation, the EEF, urged UK companies to understand the significance of REACH regulations that require a change in the way certain hazardous substances are controlled, used or sold.

Malcolm Carroll, Director, Reach Delivery writes for BP&R on how businesses can ensure they comply.

When REACH - the EU System on Registration, Evaluation, Authorisation and Restrictions of Chemicals (REACH) came into force in 2007, it placed responsibility on the safe shipping and distribution of dangerous or hazardous goods in a highly regulated environment firmly onto the shoulders of the industry, making all parties in the supply chain from manufacturers, distributors through to downstream users directly responsible.

Much of the focus to date has, of course, been on the wider process of registration, but one of the main areas currently attracting more attention is in addressing the parts of the legislation regarding the shipping of composite products and in particular, the requirements for documentation in the supply chain.

As is often the case with new legislation, there have been reports of significant increases in administration and monitoring as companies try to ensure that their customers are supplied with Safety Data Sheets, exposure scenarios and other critical safety information, often with the requirement to actually deliver and update at regular intervals, rather than simply sending these documents. In addition the requirement to ensure that all internal personnel, that may come into contact with hazardous materials, are also provided with the most current (M)SDS, exposure scenarios etc. has increased

REACH came into force in 2007, ensuring the safe shipping and distribution of dangerous or hazardous goods

record keeping and increased already time consuming tasks.

Currently, the industry is focusing its attention on gearing up for the REACH landmark of 31 May 2013, when companies that manufacture or import in the EU phase-in (those already preregistered) substances in quantities above 100 tonnes a year will need to register and meet the full compliance legislation for their products. This stage of REACH will impact a greater number of companies and far more SMEs, many of whom will be finding the process of compliance complex, time consuming and challenging.

Looking beyond the REACH legislation in the EU, we have also seen a wave of new REACH-like health and safety regulations being established outside the EU including China, Korea, Turkey, Switzerland etc. as well as updated domestic health and safety legislation for example in the USA. To comply with these regulations chemical companies and downstream users worldwide must now consider not only how they maintain compliance but also how they can demonstrate their compliance, and most importantly, prove it should any legal action arise.

To do this they will need to have easily retrievable records and preferably audit trails of the MSDSs and exposure scenarios that have been sent and

received by customers and their own staff.

They will also need to demonstrate that new or updated documents have replaced previous versions both internally and externally, plus maintain past versions and in many cases, records that demonstrate compliance, for over 30 years. The additional workload in administration can be quite significant and needs to be anticipated or automated by systems to address this workload implemented by many smaller SMEs now.

To add further complexity to the situation, we are seeing a great deal of overlap in legislation mainly because the new international legislation has to coexist most commonly with domestic health and safety directives. Whereas the requirement to register hazardous materials is clear in its own right, other elements have parallels in existing regulations. The supply and delivery of Safety Data Sheets for example will be addressed often in more than one relevant piece of legal requirement.

In the UK, COSHH (Control of Substances Hazardous to Health) sits alongside REACH with both calling for risk assessments and utilising the information in Safety Data Sheets.

The issue of how (Material) Safety Data Sheets should be supplied and delivered to customers is being addressed in more than one piece of legislation and the requirements can vary globally, although

Material Safety Data Sheets are required for hazardous materials

many of the newer rules are, as expected, far more stringent.

One thing that is clear, however, is that global legislation is moving in the same direction as REACH and the onus is firmly on suppliers to ensure their customers are supplied with (M)SDS, exposure scenarios and other critical safety information, often with a requirement to actually deliver, rather than simply sending these documents. There is also a need to ensure that all personnel within an organisation that may come into contact with hazardous materials are also provided with the most current (M)SDS and exposure scenarios and are using chemicals safely, consistently and correctly.

The need for systems to aid and automate this whole process is very clear.

One such system is the new REACH Delivery 2013 Edition, which is designed to enable companies to comply with all relevant international and domestic

legislation easily and cost effectively. The system is a plug and play networked service that you use from your own computer, it supports the sending receiving, internal distribution and automated update of (M)SDS and associated documents for large and small companies alike.

It meets the various legislative requirements by guaranteeing delivery and monitoring and auditing the actual receipt by customers and staff, as well as ensuring that the latest version of the document is always available.

The saving, in time and cost of administering (M) SDS and other important documents under the new legislation, is considerable.

Complying with REACH 2013 and other health and safety legislation is a challenge many organisations are now facing but with the right system in place – companies can have peace of mind that they are compliant in terms of the delivery of critical safety information to their customers and staff.

Further Information: www.reachdelivery.com

Chemical companies and downstream users worldwide must now consider how they maintain and demonstrate their compliance to REACH

Injection Moulding

Engineering Passion

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news KraussMaffei and Netstal to merge UK operations The KraussMaffei Group has announced that in a bid to form a stronger market presence in the UK and Ireland, Netstal’s UK division will be moved from Stone, Staffordshire, to KraussMaffei’s UK base in Warrington, Cheshire, with effect from January 1, 2013.

Under the organisational umbrella of KraussMaffei (UK) Ltd an independent market presence of the Netstal, KraussMaffei and KraussMaffei Berstorff brands will be maintained.

“By amalgamating the operational business units of KraussMaffei and Netstal under one organisational roof we will be strengthening our market presence. We’re bundling the expertise and skills of our employees; strengthening our brand portfolio and improving our range of products and services. This will

RPC acquires injection moulder Manuplastics for £7m RPC Group has announced the acquisition of specialist injection moulding plastic packaging manufacturer Manuplastics Limited. The company will become part of the RPC Bramlage-Wiko cluster.

First incorporated as Prestware Limited in 1933, the current Manuplastics Limited was established following a management buyout from Cope Allman Plastics Limited in 1976. The company operates from a purpose-built factory, opened in 2007, in Wimbledon, London.

Manuplastics specialises in the manufacture of plastics packs for the personal care and food markets, its principal products including a range of cream jars in sizes from 15 to 500ml for leading brands such as Body Shop, Boots and Alberto Culver, jelly pots for the Hartley’s brand of desserts, and Sweetex containers for Reckitt Benckiser.

RPC states the business provides the ideal complement to RPC Bramlage-Wiko, creating a high quality UK manufacturing and sales base. In particular Manuplastics will now be able to offer RPC’s complete range of personal care products to both existing and new customers. It will

KraussMaffei's UK Headquarters in Warrington

have clear benefits for our customers,” said Mike Bate, Managing Director of KraussMaffei (UK).

KraussMaffei stated that with the new structure the independent market presence of the Netstal, KraussMaffei and KraussMaffei Berstorff brands would be maintained.

“Thanks to the organisational merger, we can use coordinated management to offer our customers the right product which they need for their specific requirements and to increase our sales and service power to the market,” said Bate.

Nigel Baker, Managing Director of Netstal Limited, decided to step down from his position and to leave the company. He has worked for Netstal in various functions since 1988. “The company would like to thank him for all his work and wish him all the best for the future,” said Bate.

Richard Mumford, Director of Sales at KraussMaffei UK, will head up the

reportedly also work alongside RPC’s UK injection moulding cluster to maximise opportunities in the food sector. Equally important, RPC states the availability of technical expertise and exchange of knowledge within the clusters will contribute to the development of new products for both sectors.

RPC is acquiring Manuplastics for a cash-free, debt-free consideration of £7m.

In its last financial year the company reported sales of £7.8 million.

“This is an important acquisition which supports our strategy of continuing to consolidate and grow our core market positions,” commented RPC Group Chief Executive Ron Marsh.

Further Information: www.rpc-group.com

Manuplastics will become part of the RPC Bramlage-Wiko cluster

respective Sales team for both Netstal and KraussMaffei Injection Moulding Machinery brands.

“I am convinced this step will be accepted and welcomed by our customers. There will be no reduction in the sales, service and spare parts personnel that have been available to the Netstal customer base. The former office of Netstal in Stone, Staffordshire will be closed and the spare parts warehouse will be moved to Warrington within next two months. On the contrary, there is now a much larger organisation available to support the needs of our Netstal brand,” added Bate.

Further Information: www.kraussmaffei.co.uk

www.kraussmaffei.com Stäubli’s CombiTac programme has been introduced in response to the increasing requirement for multiple connections on modern machinery and equipment.

A modular connection system for all circuits Modern machinery and equipment often requires connections not just for electric power, hydraulics, cooling fluids and pneumatics but frequently also data transfer, fibre optics, sensors and thermocouples. Stäubli states its CombiTac range of modular connectors allows all of these connections to be made in one simple operation, saving time and improving circuit integrity.

Stäubli’s CombiTac programme has been introduced in response to the increasing requirement for multiple connections on modern machinery and equipment. The company states it combines the versatility of selecting the most suitable fluid, air, data and electrical couplings from their wide range and fitting these onto a single, easy to use, space saving connector plate. There are over six million possible configurations.

Stäubli states benefits result from speeding up the connection procedure and also eliminating any chance of wrong

or cross connection, since the connection plates can only be connected in one position. High performance guiding and locking systems are said to ensure safe and secure connections. Dry break connectors bring the added advantage of preventing any loss of fluid on connection or disconnection and also preventing any ingress of containments into the circuits.

The CombiTac range is IP65 rated (IP68 is available on request) and is said to provide a complete and specially tailored solution for each application. The modules can accommodate seven types of quick release fluid or air couplings from 3 to 8mm diameter and numerous electrical contacts, including 4-pole and 2-pole modules from 1 to 8mm diameter with up to 26 contacts per module and a capability up to 600V and 125A. Data

Boost from Mars Eco is 'out of this world' Following the introduction of the entrylevel Haitian Mars Eco series of injection moulding machines late in 2011, Premier Moulding Machinery (PMM) completed a very productive year in 2012 with record sales.

Last year saw the installation of the company’s largest machine to date, a 1000t servo hydraulic Haitian Mars MA10000.8400 universal machine into a tier one automotive customer, along with a number of other machines into similar automotive customers.

PMM states the Haitian Mars Eco series has proven to be a popular choice with existing and new customers alike; one such longstanding customer is Swindon-based moulder, Elbmar Ltd, who installed its third Haitian machine, a Mars MA3200.1700 Eco, earlier this year.

Elbmar Managing Director, Kevin Rich, explained: "Prior to purchasing the Mars MA3200eco, we had bought two Haitian machines, a HTF320W and a HTF300X; both machines have proven to be very efficient and have had impeccable reliability. However, we needed to increase our capacity and with ever increasing energy costs we decided to buy the MA3200eco this time. The energy savings have exceeded our expectations and once again the machine has been impeccable.”

"Haitian has been growing in reputation within the UK, since the introduction by PMM eight years ago," commented Paul Hulin, PMM’s Managing Director. "However, the Mars Eco series has boosted our sales greatly,” he continued.

transmission by CAT 5 and 6, Ethernet IEEE 802.3, Profibus, Interbus and CANbus; up to 2 contact carriers of eight poles per module.

Each CombiTac module has been designed to be housed either in a mobile housing for manual connections or as a rackable solution for automatic connection. Stäubli states its programme can accommodate every configuration.

Six standard housings can be selected as well as numerous bespoke designs, as appropriate for the type and number of connections included and each specific application.

Applications are wide ranging, wherever a combination of fluid and electrical connections is required, Staubli states the flexible and adaptable CombiTac system can provide a fast, reliable and safe solution.

Further information: ]www.staubli.com/en/connectors/

“I believe that we have found the best cost / performance balance for this entry level series, as our customers gain exceptional power savings and reliability for a price that rivals typical used machinery costs.

“For example, we have installed two Haitian MA3800.2250 Eco machines, at a cost of only £75,995.00 each, including installation, filled with oil and two years warranty. Additionally, our customers gain the confidence of our service and spares support in the UK, and from our principle, Haitian Europe, based in Germany,” Mr Hulin concluded.

Not wishing to stand still, Haitian will be adding further innovations to the Mars series from the start of 2013, including the latest software package to the Keba 2580 controller, which provides a freely programmable machine sequencer as standard.

Further Information: www.pmmuk.net

Rubber

news The IRC will take place in Paris for 2013

International Rubber Conference 2013: the international event for the Rubber industry France will be hosting the next International Rubber Conference from the 20-22 March 2013 at the Palais des Congrès, Porte Maillot, Paris.

The international rubber and polymer industry event, organised by French plastics and rubber association, the AFICEP, with the support of the International Rubber Conference Organisation (IRCO), will bring together all types of companies operating in these industries across the world, including raw material suppliers; distributors; processors; product blend manufacturers; equipment and machinery manufacturers; control and measurement systems; design offices; research and training centres; clusters and government agencies.

Leading manufacturers have reportedly already confirmed their

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Study reveals new materials era in ‘green tyres’ for cars Leading figures in the tyre industry see a clear trend toward low-rolling-resistance tyres, not only in Europe but globally as well, according to a study commissioned

by Lanxess.

According to the findings, which are based on the opinions of decision-makers from the marketing and development departments of 32 tyre manufacturers from around the world, this will mean improved high-performance solution styrene-butadiene rubber grades (SSBR) as well as Nd-PBR (Neodymium based Performance Butadiene Rubber) will be sought after, meaning the industry will be looking to work closely with highly specialised synthetic rubber manufacturers.

Lanxess states that industry experts have long been saying that the introduction of tyre labeling across Europe in 2012 would completely change the tyre sector. “It seems paradoxical but cheap tyres made only of conventional types of rubber have simply become too expensive for cost and environmentally conscious consumers,” said Joachim Grub, Head of the Lanxess Performance Butadiene Rubbers business unit. According to the company, rising fuel prices are the driver behind the demand for ‘green’ tyres, along

presence, with exhibitors having the opportunity to show-off their expertise and unveil their innovations.

The programme of speakers for the conferences at the event include representatives from Hutchinson, Michelin, Pirelli, and other prestigious industry names who will inaugurate the 2013 IRC during plenary conferences with strong content on the global rubber industry inviting serious reflection.

Christian Casse, Director of R&D at Hutchinson, will speak about ‘Elastomers: a century and a half of history and advanced materials’. Pierre Robert, Director of Research Programmes for Michelin, will present ‘The science of rubber and sustainable mobility’ and Didier Fegly, President of the Elastopole competitiveness cluster and CEO of Sacred, will talk about ‘Innovation and competitiveness’.

The LRCCP, French Rubber and Plastics Research and Testing Laboratory,

is also strongly involved in the 2013 IRC. This reference laboratory in the rubber industry, specialising in rubber and polymer research, control, and evaluation, will present its latest developments in R&D. It will focus on studies of considerable importance to the industry on rubber/metal adhesion, the environment, surface treatment of polymers, and numerical simulation.

Presentations delivered by speakers from across the world will lead debates across a variety of themes, including: chemical aspects and formula ingredients; manufacturing processes and optimising procedures; eco-design and end of life recovers; safety, health and the environment; innovation in rubber product design and uses, as well as prospects and perspectives for the rubber industry.

with their long service life and better safety properties.

‘Green Tyres’, according to Lanxess, can reach their peak performance with formulations containing both Nd-PBR and SSBR. Nd-PBR is used in the treads and sidewalls of a tyre as it helps reduce the rolling resistance and increase the fuel efficiency. Nd-PBR is said to be highly resistant to abrasion and plays a significant role in making tyres safer and, above all, more durable. SSBR is mainly used in the tread compound, where it helps to reduce rolling resistance and improve grip on wet roads.

The study suggests 85 percent of all tyre companies questioned expect the new EU labeling regulation to positively impact their daily business. The authors of

the study believe that in five years time, twice as much SSBR will be used in car tyres as conventional emulsion-styrenebutadiene rubber (ESBR), although 85 percent of the experts surveyed see the supply situation as being fairly critical.

The global tyre industry experts were said to be extremely interested in how the SSBR grades currently available will continue to develop in terms of processability. Lanxess states supply of ever better green tyres will be largely dependent on the provision of increasingly refined SSBR grades, therefore the sector is in favour of working closely with raw material manufacturers.

Further Information: www.irc2013.com

Further Information: www.lanxess.com

High quality, ‘green tyres’ offer numerous advantages to car drivers and the environment. Photo: Lanxess AG

p’s UK Tyres made at Dunlo the y ppl su facility will line air se ine Ch

Dunlop wins China Eastern Airlines tyres deal Dunlop Aircraft Tyres’ joint venture facility in Jinjiang, China, has clinched a three-year deal to support China Eastern Airlines’ fleet of ten Embraer 145LI regional jets with new and retreaded tyres.

The deal will see the Shanghai-based airline receive new tyres made at Dunlop Aircraft Tyres’ factory in Birmingham, UK, that will be distributed from and retreaded at the manufacturer’s joint venture company, Dunlop Taikoo (Jinjiang) Aircraft Tyres.

“Our tyre distribution and retread facility in China is going from strength-tostrength and we have now secured business with a number of major airlines in the region,” said Dunlop Aircraft Tyres’ Chief Executive Officer, Mike Askew.

“This is our first deal with a significant Chinese airline and it further strengthens our position in the regional aircraft market, where we have a fantastic history of supporting the most popular jet and turboprop airliners.”

Airlines from countries including

Biesterfeld expands further into rubber market Chemical and polymer distributor, Biesterfeld AG, has purchased Küttner GmbH of Germany and its Russian subsidiary, OOO Küttner, in a move it hopes will position it to expand its business for thermoplastic elastomers, rubber and rubber chemicals.

This acquisition builds on the purchase of French rubber distributor, SMPC, in 2010, by Biesterfeld Plastic, the largest subdivision of the Biesterfeld

Group, which initiated the company’s diversification into a new independent business unit for rubber and additives.

“Building on a long history of success in the polymer resin business, in recent years Biesterfeld Plastic GmbH has built a specialised rubber distribution structure across western Europe. Our new addition enables us to move further into the highly strategic markets of Central and Eastern Europe," commented Carsten Harms, Managing Director of Biesterfeld Plastic GmbH. Liam Beamish, who joined Oxfordshirebased Biesterfeld Petroplas, a subsidiary of Biesterfeld Plastic, six months ago, has

British company launches effective tyre cutting machine Massive dumps of scrap tyres could become a thing of the past, thanks to a high-speed flat-packing system that will make recycling much easier and reduce the space needed to store and transport them, according to Symphony Recycling Technologies.

The new SymTyre-S300 semiautomatic tyre cutter, which is said to be small enough to be used by local garages, reportedly reduces a tyre completely in 60 seconds, making it impossible to use again except for recycling, or as a feedstock for waste-to-energy or waste-to value recovery.

Symphony Recycling, based in Herts, UK, states instead of having to remove waste tyres en masse, with all the cost and logistic inefficiencies of transporting whole tyres, garages can now flat-pack them on

site, and the valuable components of rubber and steel can be recycled later.

Once tyres have been cut into sections they occupy up to 70 percent less space for storage and transportation purposes.

The company states recovering the material from tyres in a commercially viable way has long proved a difficult – and until now – almost impossible task, which has contributed to the difficulty of disposing of scrap tyres.

For the first time the technology used in this system allows tyres to be cut into three parts in one process: the two sidewalls and a tread. It then makes a transverse cut of the tread, turning it into a strip of rubber.

When the tyre has been dismantled, the components can be loaded into a specially designed cage or ‘stillage’ leading to considerable space and energy savings in storage and transport.

Symphony believes that the SymTyreS300 will allow more control over the way scrap tyres are disposed of, saying it

Australia, China, India, Indonesia, Japan, Korea, Philippines and Taiwan are among those being served by Dunlop Taikoo (Jinjiang) Aircraft Tyres.

Further information: www.dunlopaircrafttyres.com

Biesterfeld Plastic is continuing to expand its rubber business

been appointed to spearhead the rubber business in the UK and Ireland.

Further Information: www.biesterfeld.com

should reduce illegal tyre dumping, and opportunities for organised crime in the scrap-tyre trade.

Symphony Recycling Technologies is planning to offer a collection service for the flat-packed tyres from garages and tyre depots. The machines will be available on a sale or rental basis.

Further information: www.symphonyrecycling.net Mountains of scrap tyres could become a thing of the past with the new technology

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Engineering Materials

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news

Smell of success in the air for University spin-out A Coventry University spin-out company specialising in particle technology has joined forces with another Midlands-based SME to create a scented plastic floor tile.

Exilica, which is based on the University’s Tech Park, has developed and patented a unique technology that allows long-lasting fragrances to be manufactured into a variety of plastics and other polymer-based materials.

The company recently collaborated with Birmingham-based Barkley Plastics and fragrance firm Seven Scent to create the tile, and has recently launched a trial run of the product in toilets on Coventry University’s campus.

Using Exilica’s micro-particle technology, floor tiles manufactured by Barkley Plastics have been loaded with both a fragrance and an anti-bacterial agent.

The particles developed by Exilica are tiny spheres which act like microscopic sponges, capable of absorbing twice their

Exilica founder Daniel Lynch shows off the tiles equipped with his company's technology

own weight in a variety of other substances – including scents – and then discharging them via a slow release chemical mechanism for several years.

Exilica states what is unique about the technology is the particles’ ability to blend seamlessly into any polymer-based material without affecting that material’s properties, potentially opening the door to revolutionary applications in industries such as healthcare, cosmetics and manufacturing.

Exilica’s technology has reportedly attracted interest from as far afield as East Asia, with highlights including an invite from the Japanese government for the company to exhibit at one of the world’s foremost nanotechnology trade fairs in Tokyo.

Daniel Lynch, founder and technical director of Exilica and former reader in applied chemistry at Coventry University, said: “It’s certainly a tough climate out there for small businesses and start-ups, but if you have an ambitious idea and possess patience and determination in equal measure, there’s a great deal you can do to boost your prospects. We’re always open to opportunities for collaboration, particularly with other local

enterprises. Our work with Barkley Plastics on this latest initiative has been of enormous benefit to both companies, and will hopefully help to position the Midlands as a leader in novel applications as we move into 2013.”

Mark Harwood, Managing Director of Barkley Plastics, said: “Collaboration of this kind between companies adds strength and new opportunities to existing or new products. We initially manufactured the tile tool to cover our factory floor in our own tiles with the Barkley logo, but soon visitors started enquiring about purchasing them so we rebranded it Plasfloor. One of these enquiries came from Exilica with the idea of a scented tile, so we started trials in our own toilets and the result was impressive.”

A number of other small-scale trials have taken place for Exilica’s technology with a variety of companies involved in odour masking and positive fragrancing, including those exploring the use of scents in textile fibres, paints, wallpapers and automotive interiors.

Further Information: www.exilica.co.uk www.barkleyplastics.co.uk

Trelleborg enhances manufacturing capability in the UK Advanced polymer technology group, Trelleborg, has announced it is to further enhance its manufacturing capabilities with the expansion of its factory in the UK. The multi-million pound, 3,750 metresquare development of the company’s state-of-the-art manufacturing facility will see Trelleborg consolidate its two Skelmersdale-based facilities onto one site.

Alongside the expansion, Trelleborg states it will also upgrade its existing equipment to include new advanced polyurethane dispensing equipment and an upgrade of its current syntactic and static bending stiffener plant. New dynamic bending stiffener manufacturing equipment will also be built at the Skelmersdale site.

Operations Director at Trelleborg Offshore UK, Ray Cann, said: “The

UK start-up launches new bioresin system for the composites, coatings and adhesives market Dragonkraft Europe, an eco-conscious start up with the backing of Akcros Chemicals, has launched a new bio-resin system for the composites, coatings and adhesives market. It promises manufacturers an environmentally friendly alternative to traditional oil-based resins.

Eccles-based Dragonkraft states its new epoxy resin system boasts 100 percent renewable carbon content whilst its hardener/booster package contains 20 percent renewable matter. In addition, Dragonkraft promotes a 97 percent renewable UV cure system, which sets within 15-30 minutes in natural daylight.

The company states these products help manufacturers to address tightening environmental regulations but also reduce the consumption of finite petrochemical resources.

The Dragonkraft formulation can reportedly be used for many applications and the curing speed can be adjusted to suit user requirements. Drangonkraft states the system is a strong contender to traditional resins as it produces a high strength flexible cured resin with a non-

Trelleborg produces products for the offshore oil and gas industry.

investment into our site in the UK demonstrates our long-standing commitment to servicing the growing offshore oil and gas industry.

“As the industry continues to move towards ever-more demanding subsea applications, it becomes even more essential that we are best placed to meet

their growing demands, not only in terms of capacity, but in terms of developing innovative, cost-effective solutions that provide the upmost quality and performance.”

brittle finish. It is said to have excellent wet out and self-leveling properties, with low shrinkage and high temperature resistance. Its adhesion qualities onto many surfaces including wood, plastics, metals and fibreglass mark it down as a great alternative to epoxy two-pack adhesives, according to Dragonkraft.

When compared to traditional resins it shows equivalent resistance to a number of common chemicals.

Jim Pickett, Commercial Director at

Dragonkraft, commented: “From the beginning, our goal has been to employ bio-derived technologies that can replace existing oil-based resins and surpass performance in areas such as health, safety and environment. Dragonkraft has seen a growing interest for bio-resins and now they are competitive in not only price but performance too.”

Further Information: www.trelleborg.com

Further Information: www.dragonkraft.com

A renewable based Salmon Boats canoe, made using the Dragonkraft resin/hardener system as the adhesive and a Dragonkraft UV coating on the flax fabric for a waterproof flexible finish.

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Engineering Materials

news Plastic could cash in on Sterling deal Paper banknotes could be replaced with plastic substitutes as early as 2015, according to reports.

Polymer bank notes are said to be favoured due to being more hygienic, waterproof and durable. They have been used in Australia since 1988 when they were introduced as an anti-counterfeiting measure.

Paper notes could soon be replaced by plastic

The Bank of England has reportedly put out a £1billion tender from 2015 for the printing of plastic notes. A spokesman for the Bank said: “No definite decisions have been taken yet but the Bank is considering all options.”

Plastic bank notes would be more expensive to produce and existing ATMs would have to be adapted to accept them, however, the notes would be recyclable and more environmentally friendly as fewer would need to be produced.

Further Information: www.bankofengland.co.uk

DSM’s Arnitel Eco delivers ‘human touch’ for consumer electronics

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Thermoplastic copolyester delivers skin-like feeling to consumer electronics A world-leading manufacturer of consumer electronics has chosen a new thermoplastic copolyester from DSM to create an almost skin-like feeling to the soft touch surfaces of electronic devices, like notebooks and tablets.

Applied to the surface using a 2K moulding technique, to enable cost efficient mass production, Arnitel Eco is said to represent the first use in consumer electronics of this material.

DSM states Arnitel Eco is a high performance thermoplastic copolyester

(TPC) with 20 - 50 percent of its content derived from renewable resources. These renewable resources are made from rapeseed oil. Arnitel Eco reportedly delivers a carbon footprint reduction of up to 50 percent when compared to classic

Upcycled polyurethane panels used for the first time in composite façade Students at at Technische Universität Berlin are undergoing a project to test the combination of innovative and recycled materials for new technical and architectural applications.

As part of the research project, 20 students designed and built a "White Pavilion" from timber and demonstrated new ways of using polyurethane in a composite façade, using compressed polyurethane panels made of recycled polyurethane insulation scrap to construct it.

Bayer MaterialScience, puren and ABPolymerchemie are supporting the research and teaching project as part of the EcoCommercial Building Program (ECB), contributing financial assistance to

the TU Berlin project, but also a variety of material solutions.

The "White Pavilion" stands in the centre of the Technology and Innovation Park in Berlin-Wedding. The side is outfitted with vertical, transparent slats constructed of twin-wall polycarbonate sheets made of Makrolon from Bayer MaterialScience.

The students chose Polyurethane (PU), a high-performance but also sustainable building material, for the pavilion.

Compressed panels made of recycled PU insulation scrap, reclaimed in a special upcycling process from ‘purenit’, a new type of construction material, were used to construct the outer skin of the façade. To protect the panels against weathering, they were also treated with a 2 to 3mm PU spray coating manufactured by AB Polymerchemie.

For the students, the pavilion is their own on-campus event location and café.

For TU Berlin, the building gives researchers an opportunity to test and

copolyester solutions, thus supporting the need of brand owners for more sustainable material solutions.

Francis Aussems, Project Manager of Bio-Polyesters for DSM, said: “In consumer electronics, there is a growing awareness of more sustainable material solutions.

DSM is at the forefront with the development of halogen free materials for cables and connectors, the introduction of recycled materials, and, last but not least, the introduction of bio-based polymers like Arnitel Eco and Ecopaxx.”

Further Information: www.dsm.com

evaluate the innovative façade system under practical conditions. Shear and pullout tests conducted by the students themselves at the Institute of Civil Engineering’s testing centre helped to compile initial information on the loadbearing capacity of the PU compressed panels and the purenit/wood screw connections. The results are hoped to ultimately provide some indication of the durability of the new facade design.

Further Information: www.materialscience.bayer.com The “White Pavilion” at TU Berlin is demonstrating new ways of using polyurethane in a composite facade

Automotive

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news

uce new ver will introd Jaguar Land Ro 2013 ut ho ug mes thro model program

Boost for UK auto sector as Jaguar Land Rover announces £370 million investment Jaguar Land Rover has announced it will create up to 800 jobs at its advanced manufacturing facility in Solihull, UK, to support the introduction of new model programmes throughout 2013.

Jaguar Land Rover has recently confirmed a £370 million investment programme for its Solihull site, which

includes the installation of a new aluminium body shop for the all-new Range Rover as well as upgrades to paintapplications technologies, trim assembly and warehousing.

The new announcement comes as the car manufacturer announced its best ever global sales performance, with retail sales up 30 percent following strong market performances from the UK, China and the USA. China is now Jaguar Land Rover’s largest market, although the company states 2012 saw an increase in sales in

every major market, which it says is due to new model introductions and update programmes.

Phil Popham, Jaguar Land Rover’s Director of Group Sales Operations said: “Looking ahead to 2013, we are continuing to invest in our business to support our ambitious plans for growth and we will be introducing eight new or refreshed products throughout the year.”

ARPRO low-squeak makes noise in the automotive market A ‘low-squeak’ grade of ARPRO, the specialist lightweight material from JSP, is making noise in the automotive market as manufacturers respond to customer demand for optimum driver comfort, even in entry-level vehicles.

In order to compete in an increasingly competitive market, vehicle manufacturers are looking in detail at how to improve the driver experience, including how to limit noise vibration and harshness (NVH) issues deriving from ‘squeaky’ interior components, such as sun visors and boot liners.

JSP states the ‘low squeak’ ARPRO formulation has been developed using a non-slip additive that reduces friction and the ‘stick-slip’ effect caused by the transfer of kinetic energy between adjacent vehicle

components. This in turn is said to dramatically reduce interior noise.

Paul Compton, JSP President and Chief Executive Officer – Europe, MiddleEast and Africa, said: “There are certain components in a vehicle that are likely to make noise as the car moves and causes vibrations. ‘Clam shell’ style sun visors for example tend to be made of a lightweight material and metal arm and, when opened and closed, can make an irritating noise.

“Now that powertrain and road noise in the modern car are lower, vehicle interiors have become the focus for NVH reduction. Also, as quality standards improve and filter through the market, even drivers of entry-level vehicles expect these types of issues to be addressed, and manufacturers need to respond to this demand.

“Using ARPRO as the core material in these types of interior components provides a simple solution. Without compromising on performance in other

areas, ARPRO low-squeak reduces ‘stickslip’ and therefore noise. Additional benefits of ARPRO include energy absorption, component consolidation, easier assembly, lighter weight and enhanced recyclability, making it an incredibly versatile solution.”

Further Information: www.jaguarlandrover.com

Further Information: www.arpro.com

The ‘low-squeak’ grade of ARPRO is said to reduce interior noise

Right: General Motors Company’s 2012 Chevrolet Camaro ZL1 Sports Car Far right: Chevrolet Camaro ZL1 sports car’s air extractor with integrated water deflector

Sabic resin used in winning carbon fibre composite car part A carbon composite air extractor used on the hood of the 2012 Chevrolet Camaro ZL1 sports car was named the winner in the Performance and Customisation (Aftermarket) category of the Society of Plastics Engineers’ (SPE) 42nd-annual Automotive Innovation Awards Competition.

This carbon fibre prepreg composite part pulls air through the lower grille and out through the hood, cooling the engine, increasing efficiency and reducing lift in the process. The part includes a water deflector moulded from Sabic’s Valox resin, which delivered the high mechanical and thermal performance needed in an under-the-bonnet environment.

“We are pleased to have played a supporting role in helping GM garner this distinguished industry recognition,” said V. Umamaheswaran (UV), Sabic’s Automotive Marketing Director. “Automakers today have higher demands, especially in the ever-evolving under-hood space. The

Renault-Nissan sponsors UK plastics experts to speak at automotive conference Lincolnshire-based technical plastics recycling and compounding company, Luxus, and plastics additive manufacturer, Milliken, have been sponsored by the Renault-Nissan alliance to speak at the next international VDI conference, ‘Plastics in Automotive Engineering’, 1314th March 2013 in Mannheim, Germany.

Sharing the stage at VDI will be Terry Burton, Technical Manager, Luxus; Adam Watson, Business Development Manager, Milliken, and Mark Ellis, Manager, Engineer Materials Design, Renault-Nissan. They will be discussing product trials of Luxus’ next evolution in polymer development – a new, highly sustainable material for auto car interiors known as Hycolene.

Luxus states this new, lightweight Polypropylene compound will enable OEMs to significantly lower the weight of the average car, reduce CO2, deliver improved fuel economy and help meet EU

award winning air extractor, with integrated water deflector, allowed GM to achieve high performance and high temperature resistance, all with the desired styling, which is not possible with a one-piece carbon fibre solution due to design limitations. Sabic’s contribution to this part speaks to its ability to respond with the unique thermoplastic solutions that the industry needs. We look forward to continued collaboration with our customers to help them meet the increasingly complex application challenges that lie ahead.”

Sabic, working with GM and system supplier TransGlobal LLC, helped develop the water deflector by providing material selection assistance, predictive engineering work, as well as tool build design and validation support.

The Camaro ZL1 air extractor is engineered from carbon-fibre composites to achieve the highest stiffness and strength achievable with the lowest mass.

The air extractor makes extensive use emissions targets. Developed to replace standard talc filled grades for car interior components, it is said to offer reduced filler content of just 10 percent down from a typical 25 percent.

Hycolene will reportedly enable much lower weight vehicle components to be manufactured, without compromising on performance and design flexibility. But most importantly, says Luxus, it’s made from up to a high 60 percent recycled content so its offers manufacturers a highly sustainable choice too.

Renault-Nissan’s Mark Ellis explained: “Both Luxus’ technical capabilities and its desire to push the boundaries of Polypropylene applications above and beyond that of virgin material by using a high recyclate is a major achievement and one that Renault-Nissan is keen to support.”

Luxus’ Terry Burton commented: “We are very pleased to have been asked by the Renault-Nissan alliance to showcase

of adhesive bonding to join two components to the one-piece design. Those two components are a polyamide vent screen and the water deflector moulded from Sabic’s Valox resin, a thermoplastic polyester. The adhesive bonding also isolates the carbon composite panel from the rest of the aluminum hood, preventing galvanic corrosion.

Sabic states the Valox resin grade selected for the water deflector delivers up to 216°C in heat resistance, while also offering an excellent balance of chemical resistance, dimensional stability and impact performance.

The Valox resin family is based on polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET) polymers and is available worldwide.

Further Information: www.sabic-ip.com our development work with Milliken at this key event in the automotive calendar.

“For the last ten years our thermoplastic materials have been revolutionising auto interior design worldwide. But it has never before been more important than it is today to develop sustainable materials for car interiors that can deliver a competitive advantage for OEMs in what is a highly sophisticated and rapidly changing market.

“Eco materials can dramatically affect the final product and its impact on the environment, while consumers too are becoming more aware of the eco-friendly handling of materials and are thinking in material cycles. This is why sharing our development of Hycolene at VDI is so important at this time.”

Further Information: www.vdi.wissensforum.de www.luxus.co.uk

Terry Burton of Luxus, who will speak at VDI

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Industry

INDUSTRY news Ward Polymers stocks a wide range of materials

Ward Polymers completes move to new premises Midlands–based materials distributor, Ward Polymers, has recently moved to new, larger premises as well as employing more staff as the company maintains the steady growth it has seen over the last four years.

The new property, which facilitates inhouse stock holding of the company’s

product portfolio, will be the base for free technical advice, product stewardship and material selection services.

Ward Polymers stated: “This continued growth would not have been achievable without the valued support of our customers and suppliers.”

Further Information: www.wardpolymers.co.uk

The new plastrep site will be a useful tool for the plastics industry

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New global directory service launched for plastics industry Rapid News Communications, the publisher of British Plastics and Rubber, European Plastic Product Manufacturer, Medical Plastics News and Middle Eastern Plastics, and the organiser of the Interplas and Mediplas UK events, has launched a new directory platform which will serve the global plastic processing sector.

Plastrep.com is designed to play host to companies at every end of the supply chain, including producers of raw materials, manufacturers of machinery and equipment for every major process, as well as distributors and agents, consultant services and event organisers.

The site is designed for quick and simple sourcing of a local product or supplier - wherever the user may be based. An integrated Google Maps feature gives a clear overview of regional clusters of activity surrounding the various manufacturing processes. The site also offers genuine user interaction, with the opportunity to leave feedback, reviews and ‘starred’ ratings, based on experiences with specific suppliers.

A simple contact form system allows direct communication with the supplier.

The site’s developers believe that it will grow to be one of the most efficient resources for fast, reliable sourcing. To give more detail on their product range, suppliers can even host their own literature on the site.

Pooling the readerships of the aforementioned titles, plastrep.com opens the door to a genuinely global audience for suppliers and their partner offices around the world. Basic listings are free of charge for all suppliers to the plastic processing industry.

Further Information: www.plastrep.com

Above: Bekum blow moulding machinery will now be available through K.D. Feddersen (UK)

Farrow Machinery Sales announces closure Staffordshire-based Farrow Machinery Sales has announced it is closing, ending a 36-year association for its owner, Jeff Farrow, with German blow moulding machinery supplier Bekum GmbH. Mr Farrow, who has been involved with Bekum since working as a service engineer with Hamilton Machinery in 1977, said the reason for the closure was that at 65 years old it was “time to take up a more relaxing way of life.”

Bekum has chosen a successor in the name of Rugeley-based K.D. Feddersen (UK) Ltd, with all blow moulding enquiries now being directed to General Manager, Ian Nott, on ian.nott@kdfeddersen.com or 01889 580212.

In the short term Mr Farrow will still be available for a couple of months to ensure a smooth transition period.

Right: Jeff Farrow is closing Farrow Machinery Sales

“I would like to take this opportunity to say a special thanks to all my customers and thank them for their continued support over the years,” Mr Farrow said.

Other agencies looked after by Farrow Machinery, namely Delta Engineering and Blue Air Systems, will now be handled by Nigel Darvill through H.A. Machinery Sales, contactable on nigeldarvill01@gmail.com or 07803242006.

Further Information: www.kdfeddersen.co.uk www.farrowmachinery.com

events 2013 FEB

27 MAR

19 MAR

20 JUL

5 SEP

25 OCT

16

Ecopack 2013 27-28 February | NEC, Birmingham, UK The UK tradeshow focused on environmentally responsible packaging, showcasing materials, technologies and designs. Includes a high-level conference for senior packaging professionals and decision-makers. www.easyfairs.com

BP&R takes a look ahead at some of the upcoming conferences, trade shows and industry events of 2013.

Financing Growth in the Plastics Industry 19 March | BPF Offices, London, UK A British Plastics Federation event focusing on opportunities to uncover the tax credits, grants and funds that are available to businesses, insights into what to the banking sector has in store in 2013 and the best ways to finance company growth. www.bpf.co.uk International Rubber Conference (IRC) 2013 20-22 March | Palais des Congrès, Paris, France Focusing on the rubber industry, the conference will include presentations on themes including: chemical aspects and formula ingredients, manufacturing, environment, innovation in rubber product design as well as projections and prospects for the industry. www.irc2013.com

K2013 is set to build on the success of previous shows

SPE Eurotec 2013 4-5 July | CitĂŠ Congress Exhibition Centre, Lyon, France Organised by the Society of Plastics Engineers (SPE), Eurotec 2013 is a plastics technical conference with more than 200 original, peerreviewed presentations on such topics as automotive, composites, extrusion, injection moulding, and thermoforming. www.eurotec.ws Mediplas 2013 25-26 September 2013 | NEC, Birmingham, UK Mediplas is a uniquely focused event for the highly specialised area of manufacturing plastic parts for the medical industry.The exhibition floor covers all aspects of the medical plastics supply chain and a dedicated seminar zone is featured on the show floor designed to encourage technology adoption. www.mediplasuk.com K Show 2013 16-23 October | Messe Dusseldorf, Dusseldorf, Germany The largest international trade fair for the plastic processing industry will feature some 3,000 exhibitors from the fields of machinery and equipment for the plastics and rubber industry, raw materials, auxiliaries, and semi-finished products, technical parts and reinforced plastics. www.k-online.de

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UPDATE

FROM THE FRONT LINE Go East, Young Man This month’s update from Philip Law, Public and Industrial Affairs Director at the BPF This year marks the BPF's 80th anniversary. One of the big themes we will be pushing will be the importance of overseas business development. This was classically illustrated by our first big event of the year - our BPF pavilion at the Arabplast fair in Dubai from 7th- 10th January. Our verdict was that it was well worth the effort.

Although official visitor numbers haven't been released, we were advised provisionally by one of the show organisers, Al Fajar Information and Services, that the show attracted approximately 30,000 visitors, up from 18,860 the last show in 2011.

Satish Khanna, Al Fajer's General Manager told us that the numbers reflected the rapid increase of plastic consumption in the Middle East. Per capita consumption of plastics in the Gulf Cooperation Council (GCC) countries is

now as much as 39kgs annually, 33 percent higher than the world average and almost eight times higher than India.

We believe Arabplast is a great place to access not only Middle Eastern customers but also African, Indian, Chinese, Pakistani and Bangladeshi users.

We think there are huge opportunities for our member firms out there, not only through large infrastructure projects such as the World Cup 2022 in Doha, but also in the packaging and recycling markets amongst others. UK exhibitor, CR Clerke, sold the three vacuum forming machines they had on their stand. Overall, machinery to the value of £3 billion was sold during the show.

Striking a similar note, when the recent Institution of Mechanical Engineers’ report, ‘Waste Not, Want Not’, came out this month, most commentators used it to justify the role of packaging and missed the fact that it was pointing up some very significant overseas business opportunities for UK plastics packaging manufacturers.

The report was all about the fundamental need for innovative new

technology in developing countries to help decrease food wastage. It’s pretty obvious to people with experience in these regions that a lot of the current packaging solutions available there leave much to be desired. The report itself highlighted that in ‘ India, for example, 21 million tonnes of wheat annually perishes due to inadequate storage and distribution, equivalent to the entire production of Australia. In neighbouring Pakistan, losses amount to about 16 percent of production’. Readers of the BPF’s ‘UK Plastics Industry Capability Guide’ will pick up how, in terms of design, innovation and sustainability thinking, the UK plastics packaging sector is in pole position internationally and a force in the move towards a low carbon society. It’s in a great position to help.

If you are tempted to join the BPF on its future overseas ventures, space is still available in our Pavilions at Chinaplas and Plastivision. UKT&Investment grants of £1,800 are available for both shows.

Further Information: www.bpfevents.co.uk

RAPRA enters 2013 with a strong service offering

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The past twelve months have seen some of the most significant improvements to the way the Rubber and Plastics Research Association (RAPRA) delivers its original remit of supporting research into and development of innovative uses for polymers.

Since the start of 2012, RAPRA has gone back to its roots by reaffirming its ‘independent and impartial’ status.

RAPRA strongly believes in these core principles and states it demonstrates this by delivering the best possible service through its network of ‘Preferred Service Providers’.

Using the enquiry form on its website, clients ask RAPRA for assistance on a myriad of subjects ranging from sticky sealant, materials failure, training courses and R & D projects. RAPRA states the list of enquiry types and the industries it serves seems endless and proves “constantly intriguing” for the team.

Once the enquiry has been submitted it is worked on using a unique Capability Matrix. The aim is to match the enquiry with the best possible provider within a strict timeframe. RAPRA states it has been

able to deliver an extremely responsive service that has been able to process the vast majority of enquiries well below the 24-hour target.

Once selected, the PSP and client are introduced, but to maintain the highest quality standards, RAPRA says it does not cease its involvement at this point. To ensure the client, whether a member or not, is given the very best service, RAPRA gathers feedback a short time after the enquiry is closed. RAPRA states client feedback on its Enquiry Service indicates an unrivalled satisfaction rating with many

Snapshot of enquiries to RAPRA

taking time to thank the organisation personally.

RAPRA states its services are indispensable for all companies/corporations that have an interest in polymers. The service is the gateway to a whole RAPRA support community that members use to improve their research and development capabilities. Membership is GBP£85/$130US per month.

Further Information: www.rapralimited.org

Uncertainty is the only certainty This month’s view from Smart Currency Looking back on 2012, the theme that springs to mind is uncertainty. The ongoing pressures across Southern Europe, with bailouts in Spain and Cyprus and ongoing concerns about bank capital reserves, as well as the end-of-year dramas associated with the US election and fiscal cliff deadline, caused plenty of confusion, leading to turbulence in international currency markets.

For plastics-related businesses, sourcing materials predominantly from Europe, the Sterling/Euro exchange rate came into sharp focus.

Starting the year within striking range of parity, the Euro had dropped to four-year lows come the end of July, causing a rush of British manufacturers to transfer their pounds and lock in forward contracts to take advantage of the additional buying power.

Unfortunately, the New Year will not bring a return to stability.

Budgetary negotiations, which look set to become increasingly bitter, will be ongoing in the US as we move into February – undoubtedly causing further volatility on the currency markets, maintaining upward pressure on the US dollar.

One of the major uncertainties closer to home will be the German general election. With Chancellor Angela Merkel having been central to previous sovereign bailouts and fiscal reforms, doubts as to whether she will retain power will impact the value of the Euro.

When it comes to sourcing raw materials and selling manufactured goods in 2013, British plastics suppliers are advised to revisit their currency risk mitigation strategy or establish one as soon as possible. After all, potentially thousands of pounds in savings could be made on regular transactions, simply by examining events likely to create currency movements and implementing strategies ahead of time to capture the most favourable rates. further information: www.smartcurrencybusiness.com/bpr

software directory manufacturing management directory 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, Email/Tannoy Alerts, Stand-alone, “Drag and Drop” Scheduler, Standalone, 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.

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, Standalone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages).

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

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

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

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

Affordable systems available for all size of processor.

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.

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

Call Lisa on 01244 680222 for details.

43 bp&r

buyer’s guide printers

mouldmaking

fastenings and fixings

printers of plastic mouldings

services acquisition

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

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

mould release injection moulding

masterbatch

Contract cleaning Injection Moulding Extrusion • • • • • •

Hot Runners Nozzles Moulds Dies Filters Screws Cleaning service for processors Remove all polymers Tel:- +44 121 511 1203 Fax:- +44 121 511 1192 Email:- LesH@claytonholdings.com Web:- www.claytonholdings.com

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

".$$+ ,+0 '+$. +# # .'+0$./ ,') ),"('+% ".$$+ .'+0'+% 1--)'$./ ,+/1)0 +"4 +# . '+'+% $.2'"$/ 4 ,"(&')) '))/ ,)*$/ , # ,3$.!4 .'#%$ $/0 ,.(/&'.$

/')(/".$$+1( ,) ",*

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

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

materials

colour masterbatch

polymer distributors

equipment AEROSOLS

COMPOUNDING

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.

tool making design and manufacture of blow moulds

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

conductive plastics and coatings TBA Electro Conductive Products Ltd Unit 3 Transpennine Trading Estate Gorrells Way, Rochdale, OL11 2PX

T: 01706 647718 F: 01706 646170 E: info@tbaecp.co.uk W: www.tbaecp.co.uk

ancillary

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.branson-plasticsjoin.com 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

pulse staking H.T.E. Engineering Services Ltd 75, Dunboyne Business Park, Dunboyne, Co. Meath, Ireland T: +353 (0) 1 8013261 F: +353 (0) 1 8013262 M: +44 (0) 7435 967632 E: patrick@hte.ie W: www.hte.ie

temperature control

For Temperature Control Rental turn to the experts • FLUID CHILLERS • BOILERS • AIR CONDITIONING • HEATING • DRY COOLERS/ FREE COOLING

0800 026 4717 Rental Systems

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

GATE CUTTERS

hot runner controllers

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

Energy Saving Dryers

chillers/temperature controllers

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

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

heating equipment

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

extrusion systems

injection moulding

ultrasonic plastics assembly systems Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com

InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 816507 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk Telsonic UK Ltd Units 14 & 15 Birch Copse, Technology Road, Poole, Dorset, BH17 7FH T: 01202 697340 F: 01202 693674 E: sales@telsonic.co.uk W: www.telsonic.co.uk Blog: www.telsonicuk.wordpress.com

In Partnership with PC Moulding & Automation

CNC ASSEMBLY MACHINES Cannon Shelley UK agents for Belotti 5 axis CNC machines T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.belotti.com W: www.shelley.biz

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

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

www.pmmuk.net Tel: +44 (0) 1296 658 638 World Class Robotics from Max Robot

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

UK agent for Lyons Electronics.

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

vibration welding

infra red systems

Motan Colortronic Ltd

spin welding

ultrasonic welding

hot runner 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.

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

LABORATORY machines

To advertise in this space contact lisa montgomery 01244 680222

45 bp&r

buyer’s guide mixing, feeding, drying

materials handling and storage gravimetric/volumetric blending Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan colortronic.co.uk W: www.motan-colortronic.co.uk

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

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

metal detection & separation equipment

screws and barrels

secondhand and reconditioned ANGLO PLASTICS LTD Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com

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

nozzles & nozzle tips

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

DTL Machines We Buy / Sell all Makes, Age and Sizes of Injection Moulding Machines & Ancillaries.

Tool room machines and also complete factories / plants.

Factory Clearance Services.

Dismantling / Removal of obsolete plant and machinery.

T: 01925 596170 M: 07838138342 E: douglastrading@gmail.com

hopper dryers

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

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

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

printing machines pad

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

thermoforming equipment

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 Unit 5 Sanders Close, Finedon Road Industrial Estate, Wellingborough, Northamptonshire NN8 4HQ T: 08450 655455 F: 08450 655456 E: sales@arrowquint.co.uk W: www.arrowquint.co.uk Static control solutions, equipment sales and rental, repairs and on-site servicing.

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

www.pmmuk.net Tel: +44 (0) 1296 658 638 World Class Ancillaries from FASI

Cannon Shelley Sales and service for thermoforming equipment T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.shelley.biz

silk screen and pad

testing equipment Mascoprint Developments Ltd 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

screen changers Industrial Plastics Ltd

46 bp&r

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

WATER FITTINGS