BP&R July/August 2014

British Plastics

and Rubber

bp&r july/aug 2014

Intuition meets technology The new MC6 control system Engineering Passion

Harnessing the potential of waste

Interplas: The Preview

A career on the Frontline

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bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk EDITORIAL group Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com

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

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

A teacher for the day

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ith the skills shortage in the visits at two local companies where they industry never far from the were shown first hand exactly how minds of UK plastics innovative plastic products are designed companies, it was no surprise that the and made.

BPF’s latest Business It is a sad reality that Conditions Survey one of the teachers told “If the course revealed that 48 percent me that when questioning of respondents reported his pupils on where inspires the difficulties recruiting children like it has plastic products are technical staff, a number made, all of them said inspired the that has increased China or the Far East. steadily in the past few Now, the teacher told me, teachers then it years. gives me great hope he could give them hard However, one industry and fast evidence that for reversing the initiative that is trying to some of the most encourage a new technical and innovative skills gap in the generation of skilled staff products are being made future.” into the industry at on their doorstep. source is the Polymer If the course inspires Study Tours. Earlier this month I played the children like it has inspired the teacher for the day as I joined a course of teachers then it gives me great hope for teachers from across the country at reversing the skills gap in the future.

Manchester University, where they were If you know a teacher that is taking part in a four-day residential interested in finding out more about the course designed to impart knowledge plastics industry, Interplas 2014 would about the industry that they can take be a great place for them to visit. In this, back and share in the classroom. You our preview issue, we are highlighting a can read my roundup on page 8. selection of exhibitor news, featuring From what I ascertain, this is a those companies that are launching new brilliant initiative with many positive products, debuting machinery, holding benefits. The information given to the live demonstrations and more, turn to teachers ranged from technical lectures page 24. about the up and coming ‘wonder material’, graphene, to ‘hands-on’ testing Enjoy the issue.

Leanne Taylor, Editor of materials in the labs and factory site

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 (8 times/year)

by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (01244) 671074 © 2014 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

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THE BIG STORY

The MC6 control system platform for complex production cells allows two-way operation

Technology with intuition

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ith the MC6 we have developed a control system which meets our customers’ needs for ‘usability’ in every respect,” said Dr. Karlheinz Bourdon, Vice President Technologies in the Injection Moulding Machinery Segment of With a reported 46 percent of UK KraussMaffei. “It plastics companies looking to can be operated recruit in the next 12 months1, clearly and incredibly easily with a markedly high proportion using ‘SplitScreen’ of those being injection and moulders, the need for equipment ‘ProcessDesigner’.” that is user-friendly and easy to KraussMaffei says operate is imperative. Since its the MC6 control launch in 2012, KraussMaffei has system is rolled out its MC6 control straightforward and system for injection moulding intuitively designed machines across all of its to ensure optimum efficiency, with machine series and says it is so features including user-friendly that all operators, split-screen new or existing, can work both functionality for more quickly and efficiently. displaying separate content as well as the simultaneous viewing of process parameters including actualvalue cycles and the injection process.

The integrated ‘ProcessDesigner’ tool clearly presents all current processes in visual terms and enables the user to modify them, depending on requirements, by means of simple drag-anddrop movements or swiping movements for optimum usability.

Eco button for optimum machine setting KraussMaffei says in keeping with its overall energy-efficient design, the MC6 control system has been equipped with an ‘eco button’, meaning a machine setting for optimum production efficiency can therefore be made at the push of a button.

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Featuring the same dual-touch function as a Smartphone The MC6 is equipped with a resistive touch screen – this means the screen is pressure sensitive and therefore can be operated even when wearing gloves. The dual-touch function allows the MC6 to be operated using two fingertips, much in the same way as a smartphone. All the mentioned features are not only available on the machine display, but also on the accompanying robot handheld pendant.

Integrated operating concept The new operating concept for industrial robots (IR) involves the integration of KraussMaffei automation solutions in the machine control system. An additional operating area for the robot is no longer required, says the company, as the control buttons are contained within the machine control system. This is designed to make the machine operators’ work easier and reduce operating errors whilst increasing productivity. Just as the robot can be operated from the machine control system using the MC6 control system, the machine can also be controlled using the robot handheld pendant.

Intuitive, simple programming KraussMaffei says the ‘WizardX’ and ‘VisuX’ programming and operating wizards integrated in the MC6 “greatly simplify” the operation of automated production cells.

With the WizardX graphical programming wizard, the linear robots used in the injection moulding area can reportedly be programmed quickly and without error. The programming wizard enables error-free programme code to be generated even by operators with no knowledge of programming.

KraussMaffei says in VisuX it has developed a user interface that provides the operator with all the necessary information on the industrial robot (e.g. programme selection, counter, times, current axis position). All information is grouped and clearly presented on seven pages. The operator is therefore able to diagnose the current manufacturing process at any time and make any necessary adjustments.

The simplifications to the programming and operation of the robots reduce personnel training requirements, says the company, therefore programming errors are avoided, saving time and money. further information: www.kraussmaffei.com

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Data from BPF Business Conditions Survey, June 2014

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on the cover

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Intuition meets technology The new MC6 control system Engineering Passion

bp&r BRITISH PLASTICS &RUBBER

contents

july/august 2014

on the cover Technology with Intuition Since its launch in 2012, KraussMaffei has rolled out its MC6 control system for injection moulding machines across all of its machine series and says it is so user-friendly that all operators, new or existing, can work both quickly and efficiently.

See page 4

22-23 FEATURE

REGULARS INDUSTRY NEWS

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Bioplastics

Materials

35

Polymers that save the planet – are bioplastics the answer?

machinery

46

SOFTWARE

47

BUYERS’ GUIDE

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28-31 FEATURE Interplas: The Preview

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A selection of exiting exhibitor news to whet your appetite for the show

EDITOR’S LETTER A teacher for the day

12 FEATURE A Career on the Front Line Outgoing BPF Director-General, Peter Davis, reflects on a career in plastics

14-16 FEATURE Reclamation and Recycling Jonathan Short looks at harnessing the potential of the UK’s plastic resource

38-41 FEATURE Mould Making and Tooling “World’s first” seven-component mould gets its teeth into production

42-44 FEATURE Medical Global medical polymer market to reach USD 17.05 billion by 2020

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18-20 ]FEATURE Blow Moulding Product innovation influences blow moulded bottle demand

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Industry News

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news

The latest figures have indicated that positivity within the industry is still high, but has remained at a stable level since the beginning of the year

Teachers get a site tour at bpi films in Bromborough

Polymer Study Tours: taking plastics to the pupils After the end of a long term, teachers across the country rolled up their sleeves for an extra-curricular course in plastics.

The Polymer Study Tours, which are organised under the aegis of the Worshipful Company of Horners and supported by the IOM3 and BPF, saw three courses take place in early July at the Universities of Manchester, London Metropolitan and Edinburgh Napier.

The tours, which are designed for science and technology teachers, aim to help solve the skills shortage at source, by giving both practical knowledge and insight into the modern plastics industry for integration into classrooms.

During the Manchester course this year, the teachers benefitted from site visits, including one to BPI Films in Bromborough, as well as participating in polymer workshops which saw them trying processing and testing first hand in the University’s materials labs.

“A textbook can only tell you so much,” one teacher told BP&R during the four-day course. “It’s fascinating to be able to put what you teach into context by seeing it in a real-world situation.”

Over the previous 25 years, more than 3000 teachers have taken advantage of attending the course, which, thanks to the sponsorship of companies and industry bodies, is free to all participants.

“I have taken lots of photographs to take back to the classroom and show my pupils. These sorts of resources are invaluable when you are explaining to children how plastic products are produced – and that they are produced in the UK,” commented another teacher.

For information about the courses in 2015 visit the website below. further information: www.polymer-teachingresources.com

Industry confidence plateaus at current peak, latest BPF figures show Confidence within the plastics industry remains high but stable, according to the latest figures from the British Plastics Federation.

In its latest survey of Business Conditions in the UK plastics sector, conducted in June 2014, the figures were at a similarly high level to those reported in January, with little significant change in the subsequent six months.

“The overall message is that the level of business confidence remains high but has reached a plateau, at least momentarily,” commented Philip Law, the BPF’s Director General.

Some 72 percent of respondents forecasted an increase in UK sales turnover, compared with 73 percent in the January survey. Similarly, 46 percent of respondents expected their profitability to increase in the next 12 months, down slightly from 49 percent in the previous survey.

Exporters also reported a stable situation, with 56 percent expecting sales to remain the same over the next twelve months, although this was up from 50 percent in January 2014.

The survey illustrated an increasing trend in investment intentions. Some 42 percent of respondents are planning ‘significant investments’, up from 36 percent in the January 2014 survey and 31 percent in January 2013.

The growing disparity between the plastics industry’s aspirations to recruit more staff and its actual ability to find appropriately qualified manpower was further revealed. Forty-six percent were expecting to increase staff levels over the next year, the highest level seen in four years. Yet, 48 percent were experiencing difficulties in recruitment, up from 36 percent in January. Technical Managers were cited as being particularly hard to find. further information: www.bpf.co.uk

“Shocking” sales skills gaps risk UK plastics businesses missing opportunities In the BPF’s latest Business Conditions survey it was revealed that 72 percent of respondents are forecasting an increase in UK sales turnover in the next 12 months (above). However, recent research has indicated plastics companies may miss out on opportunities due to “glaring gaps” in the UK’s pool of sales personnel.

The latest research carried out by Sales Initiative Magazine (SI), the UK’s only periodical for sales managers and directors, reveals a “shocking” lack of core sales skill sets amongst industry management. Nearly three-quarters of respondents admitted they had little

awareness of their direct competitors and a further 64 percent admitted they were unable to assess customer needs adequately.

The survey and its results have prompted the launch of a new manager assessment tool that can be used to accurately evaluate potential sales candidates in just 45 minutes, vital for those plastics businesses looking to increase staffing levels. It will also allow sales management to target sales training where it is most needed amongst existing staff.

The survey is available exclusively at www.si-store.com

Industry News

news New research centre will “help manufacturers improve efficiency” A specialist research centre dedicated to finding ways to help businesses improve manufacturing has been set up as a collaborative partnership between Teesside University, the Institute for Manufacturing at

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Representatives from the centre, from left: Mangesh Gharfalkar, Dr Graham Hillier, Dr Richard Court and Callum Campbell.

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Cambridge University and the Centre for Process Innovation (CPI).

The Centre for Resource Efficient Manufacturing Systems (REMS), is based at Teesside University and its aim is to research and investigate manufacturing processes and supply chains to help companies improve production processes by reducing emissions, saving time, reducing cost and minimising the resources they use.

A number of UK-based companies have reportedly already expressed an interest in working with the centre to understand their supply chains and investigate ways in which they can improve their whole manufacturing system to increase efficiency and reduce resource consumption.

The Centre’s director, Dr Graham Hillier, the Director of Strategy and Futures at CPI, commented: “There is a finite amount of raw materials in the world and, at some point in the future, some of the most important could start to run out. The challenge is to use the resources we have as efficiently as possible. The REMS Centre will work with companies to help them to understand how to make better products with lower environmental impact while still making enough money to succeed economically - in short to become more resource efficient.” further information: www.uk-cpi.com

INEOS to buyout BASF for full ownership of Styrolution INEOS has announced it will acquire BASF’s 50 percent share in Styrolution, buying out the company in a deal worth €1.1 billion.

Styrolution will continue to operate as an independent company until the completion of the deal, which is still subject to approval by the appropriate authorities and shareholders, but is expected in the fourth quarter of 2014.

“Styrolution has fulfilled its promise as a globally competitive business that competes effectively with large-scale producers from Asia and the Middle East. We are pleased to bring Styrolution fully into the INEOS family,” commented Jim Ratcliffe, Chairman, INEOS Capital.

“After the purchase, Styrolution will be run separately as a standalone company within INEOS, and continue to operate as it does today.” The business will be a subsidiary of INEOS Industries Holdings Limited.

Styrolution was founded in October 2011 as a 50-50 joint venture between BASF and INEOS, and is a leading global styrenics supplier. further information: www.ineos.com

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from the front line

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a career on the front line Peter Davis OBE, Director-General of the BPF, retired from the role at the end of June. Here he reflects on his career, the changes in the plastics industry and the challenges it faces.

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Peter Davis (right) and Philip Law, new Director General of the BPF (left) at Chinaplas in 2014

n my twenties I was fortunate enough to be employed by Metal Box and benefited hugely from the training they gave in all aspects of packaging. I worked on lined cartons in the Paper and Plastics Division, but the real action and excitement was in plastics. My next post was a marketing role in 3M Medical Products, where plastic-based products for dressing, stethoscopes and dentistry predominated. I then became a product manager at Dylon Ltd, makers of household dyestuffs for clothes and footwear, and got heavily involved in commissioning new packaging, mostly plastic, for new product ranges.

My career then went into politics, as a Special Adviser to a Cabinet Minister, and then a spell as a Director of the Royal Institute of British Architects.

I came back to the packaging and plastics world when appointed Chief Executive of Incpen, the Industry Council for Packaging and the Environment in 1992. Incpen covered all packaging materials and it was a crucial time when we had to actively help Peter Davis is optimistic about the future of the UK’s plastics industry shape how the UK would comply with the EU Packaging Directive.

In 1997 I accepted the BPF role, which for me was a great move because it widened my scope from their shale gas revolution. beyond packaging and the BPF had an excellent Looking ahead I am very optimistic reputation as ‘one voice’ for plastics. about the future for the UK Plastics When I joined the BPF, PVC was under strong industry. The latest ONS (Office for attack from environmental pressure groups that said it National Statistics) Statistics data was a “sunset” material. We tackled this with the Vinyl singles out the manufacture of 2020 and VinylPlus voluntary agreements to take out plastics as the largest single surge in certain heavy metals and greatly increase 1st Quarter manufacturing. I am quite sure that recycling. We have improved PVC’s image so Interplas on 30th September – 2nd October this “Looking ahead I much that it was practically a “material of choice” year will benefit from this and I do hope our am very during the 2012 London Olympics. companies send their apprentices to the show. As The plastics industry benefitted enormously in optimistic about business improves, skills shortages become the early 1990’s from substantial inward worse and we need to convince young people that the future for investment by US and Japanese companies. The at all levels in our industry they can have a the UK Plastics rewarding career. industry had to improve its quality and delivery and in every sense have a more global We are seeing re-shoring, manufacturing in industry,” – Davis perspective.

China particularly, being brought back to the UK. More recently, the plastics industry has had to We have many UK strengths for plastics cope with the EU’s REACH legislation (Registration, Evaluation, manufacturing. A ready supply of oil, gas and chemicals needed Authorisation and restriction of CHemicals.) Polymers are not for plastics production, world-class universities specialising in targeted, but many of the additives we use are adding a huge polymers and a world-class design sector designing everything tranche of extra regulation and cost for our additives companies. from cars to housewares.

The latest recession was very difficult for our companies, with On energy security we do have concerns that there is little 2009-10 probably the worst years. We roughly estimate at least urgency in replacing old power stations that are being closed, or 9,000 jobs were lost, but certainly our companies did try to retain increasing UK gas storage. We import over 50 percent of our gas. their most experienced staff.

The winter of 2015-16 could lead to plastic firms being asked to When at last, after many years of lobbying, the BPF finally got shut down production when energy supply does not equal a Climate Change Agreement with the Government in October demand. But UK reserves of shale gas, estimated to meet needs 2009, this gave our companies some relief with the discount on for 100 years, must be explored and extracted to give us local the onerous Climate Change Levy in exchange for achieving energy supplies but also hydrocarbons to provide raw materials energy reduction targets. We have a large scheme with 325 for the plastics and chemicals industry. members’ sites in it.

As I retire from the BPF to seek new opportunities, I am full of In my sixteen years at the BPF I have seen the rise of India and confidence that the UK Plastics Industry and the new BPF team China as major markets for plastics and equipment and, only in have a golden future ahead. recent years, a huge interest in plastics recycling. Now we see the rise of the United States as a major plastics producer, benefiting Peter Davis OBE FRSA

reclamation & recycling

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news M&S and Sainsbury’s launch trial to “significantly increase” black tray recycling A consortium of organisations from the UK’s packaging, retail and recycling industries, led by Marks & Spencer and Sainsbury’s, are to launch an in-market trial programme aimed at significantly increasing the number of black CPET trays that are recycled, it has been announced.

Approximately 1.3 billion black CPET trays are used in ready meal packaging in the UK every year. Whilst they are recyclable, the trays have proven difficult for the UK recycling industry to process as the black colour of the tray is not detectable with Near Infra Red (NIR) optical sorting equipment at plastic sorting facilities.

The project team consists of: WRAP, M&S, Sainsbury’s, Faerch Plast, the Kent Resource Partnership, Biffa Waste Management, Recoup (RECycling Of Used Plastics Limited), and Nextek Limited.

Resource efficiency expert, WRAP, has worked with industry experts (coordinated

by Nextek) to identify a new type of black CPET tray, using alternative colourant, which sorting trials have shown to be able to be detected and separated for recycling.

“This represents a world first on several levels in the recovery of black plastic CPET trays from the post-consumer stream,” said Edward Kosior, Managing Director of Nextek Limited.

“The trial represents the logical extension of over four years of technical investigations, sponsored by WRAP, to fine tune the development of these special colourants so that they function without any negative impacts on the manufacturing and recovery of these widely used plastic trays. The technology has the potential to be shared with other packaging and durable applications such as appliances, office equipment and automotive components and could mark the beginning of a new capacity to capture black plastic products at high speeds in the modern MRFs used throughout Europe.”

The project team says it will now seek to prove the effectiveness of these new trays through an in-market trial, commencing mid July, by demonstrating the ability to manufacture, distribute and recover them through household recycling collections at plastics sorting facilities.

The trays will then be reprocessed using

en trays have be Black CPET r fo lt u diffic have proven to cling industry the UK recy s ar ye e som process for

proven decontamination technologies for assessment of the ability to manufacture them back into food grade black CPET trays, aimed at achieving a closed loop system. disposal cost reduction and A public report will be available once commercial viability. the trial is completed and a full review has been carried out. This will examine sorting further information: efficiency, carbon footprint reduction, www.recoup.org

The in-market trial Faerch Plast has manufactured approximately 2 million detectable CPET trays, which will be used by M&S and Sainsbury’s across their ready meals range. These meals will be sold in the UK over a four-week period, with a high density in the South East of England, where the recovery of the trays is planned to take place.

Biffa will take a lead in using NIR detection technology reprogrammed to sort the detectable black CPET trays.

Guidance for reprocessors wanting to make this change on their systems is available on the WRAP website.

Nextek will assist with the automatic sorting and supervise the recycling and decontamination of the material back to Faerch Plast for assessment of the ability to manufacture them back into black CPET trays.

UK makes “significant contribution” to success of PVC recycling PVC recycling continues to grow across Europe, with the UK contributing more than 20 percent — or 88,648 tonnes — to the total recycled through Recovinyl, the PVC industry’s recycling scheme, in 2013.

A total of 435,083 tonnes of waste PVC was recycled through Recovinyl last year across its 16 European member countries. To date, the Recovinyl recycling network comprises 141 companies.

Recovinyl is the operational arm of VinylPlus, the ten-year Voluntary Commitment of the European PVC industry, which is tackling the sustainability challenges for PVC and delivery of current recycling targets to 2020.

Waste PVC-U profiles comprised 50,421 tonnes of the UK’s recycling effort in 2013, with pipes, rigid and flexible PVC films and cables making up the rest.

“These latest figures show that PVC recycling is maintaining its upward trend, with demand continuing to grow for good quality recycled material that can be reused in a variety of new products, from

mes PVC fra g Waste lin c y c e r r ready fo

windows to flooring and advertising banners,” commented Project Manager, Jane Gardner of Axion Consulting, Recovinyl’s UK agents.

“Once again, the UK has made a significant contribution to the success of PVC recycling, thanks to ongoing commitment from the sector and sustained investment in recycling infrastructure across the country,” continued Gardner.

Having already established significant

volumes of PVC recycling with Vinyl 2010, Recovinyl’s strategy now is to consolidate and increase the steady supply of PVC waste being recycled in Europe by creating demand — a ‘pull-market’ for recycled PVC material — from the converting industry.

Potential new recycling opportunities for PVC include non-infectious medical PVC waste from hospitals, such as IV Fluid and oxygen bags. This type of waste is the focus of a new VinylPlus-funded research project undertaken jointly by Axion Consulting and the BPF Vinyls Group.

Gardner added: “We are now looking to collect and recycle PVC from new sources, such as non-pharmacologically active waste from hospitals. Trials would be based on a successful Australian study and we would be interested to hear from organisations looking to explore these recycling options, such as medical and care organisations.” further information: www.recovinyl.com

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Harnessing the potential of our plastic resource of PRN/PERN system Short believes reform nt to encourage investme is a key requirement the ng uri ens and in domestic markets tor -degree recycling sec development of a 360

reclamation & recycling

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Comment:

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e are still losing out to the Far East when it comes to recycling. Every year, hundreds of thousands of tonnes of plastic material is baled and shipped across the oceans, taking with it a much-desired item in the recycling world, the humble plastic bottle.

As the highest value material in the post-consumer plastics family, it is bottles that provide British re-processors an essential revenue stream used to invest in new infrastructure, capable of processing other types of postconsumer plastic resource. Plastic bottles represent the foundation for a modern, selfsufficient recycling industry

By Jonathan Short, that is at the heart of a Founder and Deputy circular economy.

Chairman of ECO Plastics In March 2012 the Department for Environment, Food and Rural Affairs (DEFRA) made the necessary move of introducing mandatory packaging recycling targets – despite being called recycling targets they are in fact collection targets; there is a huge difference. As a result the UK expects to collect 57 percent of its packaging resource by 2017.

Although the announcement was welcomed by the industry, targets alone will not deliver the necessary changes for a thriving recycling sector.

These targets must be accompanied by other regulatory amendments to ensure that we not only collect more, but actually recycle more. And to do so we need to focus on building the UK’s domestic recycling sector so that it’s capable of recycling all this collected material. The most important change needs to be an update of Government’s recycling incentives policy, which continues to favour exports over domestic recycling.

Currently, UK plastic reprocessors can only claim a Packaging Recovery Note (PRN) credit based upon the input to the washing process, or in extreme cases melted down.

Losses of up to 30 percent of the original feedstock through the removal of dirt, moisture and other contamination can be expected during sorting and before the washing stage.

Whereas exporters can claim the export version of a PRN, the PERN, on 100 percent of the tonnage by simply baling unprocessed material, usually containing contamination like waste paper, dirt, glass, liquid and organic residue.

Although the Government has already taken some action to level the playing field by specifying that contaminated bales will not qualify for PERNs, without strict enforcement and clear set contamination thresholds, the system will continue to inadvertently incentivise export ahead of UK manufacturing, which risks undermining the growth of our home-grown reprocessing industry.

About the Author Jonathan Short is the founder and Deputy Chairman of ECO Plastics, based in Lincolnshire, UK. Jonathan has over 25 years of industry experience in the recycling sector and has driven the

As a member of the BPF’s recycling group, BPFRG, we fully support the recommendation for obligated companies to be required to demonstrate compliance through first purchasing a percentage of PRNs (our split target proposal), the balance being made up of PERNs. This would have the benefit of providing much needed revenue to the UK recovery and collection infrastructure, which was the original goal behind the inception of the PRN system.

I also believe that the revenue from PRNs and PERNs should be used either for further investment in reprocessing infrastructure or for consumer education programmes about exactly what can be recycled. Again, with strict audit checks confirming that funds have been utilised correctly.

Reform of the PRN/PERN system is now one of the key requirements to encourage investment in domestic markets and ensuring the development of a 360 degree recycling sector. Encouragingly, it does not require complex legislation, additional funds or widespread stakeholder engagement programmes to implement. But it does require action.

Therefore, we strongly call for the Government to reverse its recent decision to pullback from introducing market reforms and instead focus on ensuring the policy recognises that packaging, which has traditionally been viewed as waste, is actually a valuable resource for the UK economy instead. further information: www.ecoplasticsltd.com

company to be at the forefront of mixed plastics processing within the UK with a principal focus on the sorting and treatment of mixed plastic bottles for industrial applications and, most recently, for direct food contact.

han Jonat t r Sho

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blow moulding

All electric inject and blow for a low energy world

news Product innovation influences blow moulded plastic bottle demand A recent report from industry group, AMI Consulting, looking at recent end-use applications trends and competing packaging formats that shape demand for plastic blow moulded bottles in Europe, suggests that moulders need to align with winning brand-owners and fillers in order to prosper.

Balancing the conflicting needs of individual customers within mass production operations will continue to challenge converters over the next five years, finds the report. The increasingly complex product mix of private label vs. premium brands and standard products vs. proprietary, combined with filler demand for flexibility are forcing strategic change within blow moulders universe.

The report states currently the European market for blow moulded plastic bottles is nearly 4.5 million tonnes magnitude, with beverages accounting for two-thirds of the market demand in units.

The growth trends differ depending on both the drinks category and the geography, but the overriding trend within

the beverages market in Europe is toward ‘healthier options’. The demand for blow moulded beverage bottles in Europe is fuelled by continued substitution of glass bottles, cartons and cans. Moreover, consumers tend to make more impulse purchases whist ‘on-the-go’, which drives additional demand.

Liquid food is benefiting from a growing penetration of plastic bottles at the expense of cartons in white milk both in fresh and UHT sectors. This is thanks to increasing sales of dairy-based drinks as well as new technical advancements in barrier bottle technology for UHT milk bottles.

Household chemicals are a maturing application and shelf differentiation is a key driver for packaging innovation.

Design innovation focuses on consumer convenience and accurate dosing.

Competing plastic formats such as pouches, other flexible solutions, as well as thermoformed and injection moulded containers are expanding market share, directly eating into the demand for bottles.

Moreover, more concentrated product formulations as well as ‘value’ sized bottles adversely influence the frequency of purchases. Given the high plastic penetration already achieved in that segment, the growth in bottle demand is expected to stagnate.

Drivers in toiletries and cosmetics packaging are similar, but this market is still generating organic growth across Europe. Mini-bottles have witnessed accelerated growth in demand following airline hand-luggage restrictions. That format is also used for liquid makeup products, which are experiencing a packaging shift from glass to plastic. further information: www.amiplastics.com

Household chemicals are a maturing application and shelf differentiation is a key driver for packaging innovation.

Biesterfeld Petroplas says it is seeing a great potential for the transparent bio-copolyester

Biomaterial has bottles of potential, says distributor Abingdon-based distributor, Biesterfeld Petroplas, says it is seeing a great potential for the world’s first transparent bio-copolyester from SK Chemicals.

The material, Ecozen, reportedly has the ability to be used in virtually all blowmoulding processes, including equipment designed for PET. Biesterfeld Petroplas says in addition to the obvious marketing appeal of a biosourced material, Ecozen is available in a wide range of grades, including some with a temperature resistance of up to 100oC for food-contact applications, thus enabling the production of hot-fill containers on standard PET machines.

BPA-free Ecozen is also seen by many as a natural substitute for polycarbonate in injection moulded food-contact applications, when the bans on materials containing BPA will be prevented from use in some EU countries later this year.

FUrther information: www.biesterfeld-plastic.com

electricity SStatic tatic elec tricity ccontrol ontrol ttechnology echnology ffor or use in industrial both industr ial and cleanroom cleanroom areas areas

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Call Call +44(0)1993 706700 or visit w www.meech.com ww.meech.com

Tel. 01327 263082

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www.3pa.uk.com

Nampak’s Infini milk bottle

New technologies for faster, safer and more efficient blow moulded bottles Packaging machinery manufacturer, Velocity Equipment Solutions, has announced the completion of two new technologies for extrusion blow moulding of HDPE containers in collaboration with the UK’s leading producer of plastic milk bottles, Nampak Plastics.

The first is the only all electric, quickchange, reciprocating blow-moulding machine in the world, says Velocity. This machine uses electro-mechanical actuators to replace the hydraulic cylinders, pumps and actuators common to other reciprocating blow moulding platforms.

“The failure points common to reciprocating blow moulding machines such as ball splines and thrust assemblies have been eliminated. All motions on this machine are precision-guided, as opposed to the rails and shoes common on other machines, leading to longer life of components,” explained Dave Evans, Velocity’s UK representative.

This first machine was specifically designed for Nampak to be changed from

an Infini four-pint, 35g bottle on 10 heads to a two-pint, 22g bottle on 12 heads within an eight-hour shift.

The benefits of the machine include the ability to do complete changeovers – including cavitation and moulds – within eight hours, as well as lower energy and maintenance costs, faster motions of clamp and extruder and improved mould trimming, particularly on lightweight containers.

“Being an all-electric machine there is no risk of hydraulic oil leaks and it’s safer

and quieter to operate,” Evans continued.

The second machine installed is a quick-change, high-speed rotary impact trimmer. This machine has also been designed to be capable of changing from one container to another within an eighthour shift and is capable of speeds up to 160 bottles per minute. It also eliminates the common problems associated with other rotary trimmers such as scrap handling and a very narrow operating window.

“All of the drive mechanics are located above the spindles leaving the underside completely open for the scrap-handling funnel. Also, although the trim tooling travels in a rotary motion, the actual trimming is a conventional impact trim.

Therefore, the machine is capable of achieving very high speeds while still enjoying a wide operating window,” added Evans.

The installation completes a three-year R&D effort that was carried out in close cooperation with Nampak Plastics Europe Limited. further information: www.velocityes.com

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Blow moulded bottle makes sporting

move

Wales-based manufacturer, Gwalia Packaging, has launched a drinks container that is worn on the wrist. Desig ned for sports use, the 330ml bottle is extrusion blow moulded in high-density polyethylene and, according to Gwalia, “will not wear out”. further information: www.dragonp lastics.com

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blow moulding

Tel. 01327 263082

news New ‘Optiblo’ range puts the colour into blow moulding Silvergate Plastics has launched ‘Optiblo’, a range of colour masterbatch designed to significantly reduce cycle times and improve the surface finish of blow-moulded parts.

The company says this advanced technology brings extensive benefits to polymer processors working within blow moulding. It works to eradicate many common processing problems by eliminating die build up, enhancing pigment dispersion, and improving both wall thickness uniformity and dimensional stability. What is most attractive to many processors, says Silvergate, is that Optiblo can increase output and lower energy requirements, saving substantial operating costs.

Optiblo works by reducing friction against metal surfaces, which enables melt to smoothly flow at a faster rate. By improving pigment dispersion and eliminating die build up, this new colour masterbatch offers many benefits to manufacturers producing bottles, drums, oil containers etc. It also reduces warp on large parts, and reduces energy consumption by allowing the processor to operate at lower temperatures.

Optiblo is said to not only facilitate the manufacture of a better product in less time, it does so by reducing energy and processing costs. This new range also enables faster colour

ND

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www.3pa.uk.com Silvergate has launched a new range of colour masterbatches specifically designed for blow moulding

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Blow moulded bottles and containers at Silvergate’s colour matching suite in Wrexham, North Wales

changes, which is another benefit for processors to relish.

The launch of this product comes at a time when Silvergate is seeing an increasing demand from processors wanting raw materials that enhance operating efficiencies. This trend is rising not only in the UK but also across the Continent.

“Our customers want quality products quickly, that hasn’t changed. What has changed is a need to improve their own operating practices by introducing high performing raw materials to their manufacturing processes,” explained Giuseppe Chiacchio, Silvergate’s Export Sales Manager.

“As a supply chain partner keen to support our customers’ goals, we have responded to their needs by introducing Optiblo to our vast range of products. We have listened and understood the challenges many processors face when moulding at high temperatures. Many of the inherent problems include flow lines, poor surface finish and die build up. Optiblo is a colour masterbatch that helps to prevent these factors from occurring.

“What is really exciting is the fact that Optiblo enables the polymer to flow far faster and much smoother, even at low temperatures. This reduces energy demands, eliminates die lines in 15 minutes and increases output. We believe Optiblo will become the preferred choice in colour masterbatch for many blow moulding producers.”

The new Optiblo range is available in any colour for worldwide distribution from Silvergate’s manufacturing facilities and headquarters in Wrexham, North Wales. further information: www.silvergate.co.uk

Injection Moulding Rotational Moulding Extrusion Blow Moulding Thermoforming Vacuum Forming Film Extrusion Recycling Materials Design

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NEC, BIRMINGHAM, UK

www.interplasuk.com

bioplastics

news Whey to go: UK company coverts waste dairy product for bioplastics production Industrial biochemicals company, cellulac, says it is the first to produce lactic acid for bioplastics from deproteinised whey in continuous production runs.

The company has recently concluded a 10-day production run after which it delivered optically pure D(-) lactic acid suitable for conversion to bioplastics.

“We are the first company to achieve continuous production of optically pure lactic acid from deproteinised lactose whey at industrial scale. This is a major breakthrough that we will exploit in our Dundalk plant, Ireland,” Gerard Brandon, CEO of cellulac, commented. “Our resulting lactic acid can be used for

cellulac has produced technology that is able convert a dairy by-product and produce lactic acid for use in the production of bioplastics

industrial strength and heat resistant bioplastics.”

Whey is considered a high volume wastewater obtained as a by-product of the cheese production process following the separation of fat and casein from milk.

As it has a high chemical oxygen demand, it is considered a major pollution problem for the dairy industry.

cellulac says its cutting-edge technology is able to take this by-product and convert it into lactic acid which can be used in the production of bioplastics as well as other industrial chemicals. further information: www.cellulac.co.uk

A research project led by Biome Bioplastics has demonstrated the feasibility of extracting organic chemicals from lignin for the manufacture of bioplastics.

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Wood you believe it – bioplastics made from trees A research project led by Biome Bioplastics has demonstrated the feasibility of extracting organic chemicals from lignin for the manufacture of bioplastics.

The results stem from a grant from the UK’s innovation agency, the Technology Strategy Board, awarded to a consortium led by Biome Bioplastics in early 2013 to investigate lignin as a new source of organic chemicals for bioplastics manufacture, which could significantly reduce costs and increase performance of these materials.

Lignin is a complex hydrocarbon that helps to provide structural support in plants and trees. As a waste product of the pulp and paper industry, lignin is a potentially abundant and low-cost feedstock for the high performance chemicals that could provide the foundation for the next generation of bioplastics.

The research was undertaken in conjunction with the University of Warwick’s Centre for Biotechnology and Biorefining, led by Professor Tim Bugg, whose team has been working to develop methods to control the breakdown of lignin using bacteria and extract these chemicals in significant quantities.

The project has successfully demonstrated that bacteria can be

effective in the selective degradation of lignin, and that the breakdown pathway can be controlled and improved using synthetic biology. Crucially, several organic chemicals have been produced at laboratory scale in promising yields that have potential use in bioplastic manufacture.

Initial scale-up trials on several of these target chemicals have demonstrated the potential for them to be produced at industrial scale, suggesting the commercial feasibility of using ligninderived chemicals as an alternative for their petrochemical counterparts. Biome Bioplastics has also transformed these chemicals into a material that shows promising properties for use as an advanced bioplastic.

The next phase of the project will examine how the yields of these organic chemicals can be increased using

different bacteria and explore options for further scale-up of this technology. The first commercial target is to use the ligninderived chemicals to replace the oilderived equivalents currently used to convey strength and flexibility in some of Biome Bioplastics’ products, further reducing cost and enhancing sustainability.

Paul Mines, CEO of Biome Bioplastics, commented: “We are extremely pleased with the initial results of the feasibility study, which show strong promise for integration into our product lines. Looking ahead, we anticipate that the availability of a high performance polymer, manufactured economically from renewable sources, would considerably increase the bioplastic market.” further information: www.biomebioplastics.com

Polymers that save the planet – are bioplastics the answer?

R

APRA and innovation are great partners and our continued commitment to bring new technologies This month, Steve within the Shaw, Executive accessible reach of our Director at RAPRA, varied client discusses how new base is always types of plastics going to get made from us excited. alternatives to Following fossil fuel are more recent posing a new set of enquiries questions for the received, it is industry. hard not to recognise the popularity of bioplastics. Still, we are aware that as with most development programmes, there is always going to be great debate for each new technological advance.

Bioplastics are continually proving their capabilities for commercial purposes in various industry sectors. We see examples in packaging, agriculture, consumer electronics and automotive to name a few.

There is also great potential for the development and use of biodegradable plastics, especially in the medical and healthcare industries, where specially deigned medical implants that dissolve in the body can prevent the need for secondary operations.

In all, bioplastics seem to prove a very promising alternative to the petroleum-

Bioplastics have found use in packaging applications

based plastics and hold a promise of the long-term benefits of reducing both global warming pollution and human dependence on fossil fuels.

However, there are still many ongoing arguments, not least in the recycling industry, as to their impact, as well as wider confusion surrounding degradable and oxo-biodegradable alternatives.

Capitalising on bioplastics also brings with it discussions surrounding food security and the use of arable land. With all the food shortages in many regions of the world, would it be selfish to allow

bioplastics to interfere with the food supply chain? The arguments are complex.

If you are currently working on any aspect of polymer research and need our assistance, RAPRA is happy to hear about your current or future projects, so don’t hesitate to ask for assistance, technical support or advice whenever you need it.

We are here to help. further information: www.rapra.org

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VISITOR INFORMATION: 4PLAS - STAND J10 www.4plas.com

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STAND C4

Interplas: The Preview

W

ith Interplas only a matter of weeks away, preparations are well underway to making this year’s outing the best yet. As headline media partner to the event, BP&R is giving readers a sneak preview as to what’s in store at Interplas from a selection of the exhibitors.

From product debuts and demonstrations, to the processing of plastics and

popping of corks, exhibitors have clearly identified Interplas 2014 as the essential UK plastics industry event.

These previews are just the tip of the iceberg – to see the best of the rest head to www.britishplastics.co.uk Still need to register?

Interplas is FREE to attend for all visitors, so avoid queues on the day and head to www.interplasuk.com

Fast facts TUES 30 SEPTEMBER 2014 09.30am – 5.00pm

NEC, BIRMINGHAM, B40 1NT www.thenec.co.uk

WEDS 01 OCTOBER 2014 09.30am – 5.00pm

Nearest airport: Birmingham International

THURS 02 OCTOBER 2014 09.30am – 4.00pm

Nearest train station: Birmingham International Accomodation: www.interplasuk.com

Technical materials questions will be addressed on stand J10

ANCILLARIES A “plethora of products” set for debut and display at Interplas The UK’s first ancillaries specialist to provide both standalone and integrated solutions will be exhibiting at Interplas 2014 with an array of products for materials handling and process cooling requirements.

Staffed by engineers - not salesmen - AB Systems’ says its stand is the place to go for technical, to-the-point advice about materials handling and process cooling solutions designed to increase efficiency, improve productivity, and cut costs in plastics processing plants.

AB Systems says a “plethora of products” from its comprehensive range, produced by world-leading manufacturers such as NovaFrigo, SB Plastics, Lorandi, and OMP, will be on show, covering everything from chillers and air blast coolers, to conveyors, dosers and big bag unloading, to name just a few.

Taking innovation to the next level, AB Systems’ new, wireless iPad-driven control panels and LAN connection chillers will also be on display, allowing visitors to experience the technologies first-hand. Other products to make their debut include the new NovaFrigo NTC range of water and oil temperature control units, as well as AB Systems’ range of cost-effective ‘all system’ pneumatic conveying products.

VISITOR INFORMATION: AB Systems - Stand F12 www.ab-ltd.co.uk

AB Systems is offering technical advice about its ancillary systems at Interplas

interplas: the preview

MATERIALS Materials supplier has something 4 everyone with product launches 4PLAS is debuting at Interplas 2014 with the launch of its new 4TECH product range of high performance speciality thermoplastic technical moulding compounds, combining a wide range of performance engineering polymers, with a comprehensive range of speciality fillers, fibres and additives.

The 4TECH grades include ultra-stiff, super-tough, highheat, thermally conductive, electrically conductive (from anti-static through to high conductivity) highly flame retardant UL listed grades including halogen free and low smoke/low toxicity, lubricated, laser markable, food/medical, high density and antibacterial.

Available in standard grades and custom compounds to suit all requirements, the 4TECH product range compliments the existing wide range of standard engineering materials from 4PLAS including PA, PBT, PET, PC, ABS, PC/ABS, POM and filled polypropylenes.

The 4PLAS technical and sales team will be on stand J10 to show examples and describe applications for the 4TECH range, and to discuss any requirements or opportunities for the entire 4PLAS product range.

In addition, Interplas 2014 sees the launch of the all new 4PLAS technical brochure and website, which now boasts an all-new, custom designed interactive material selector, allowing visitors to the site to be able to select materials or grades by application, attribute or properties or any combination of the three.

MATERIALS ALBIS UK and Addmaster to Give Away Free Antimicrobial Bags for Life at Interplas UK-based technical polymer compounder and distributor, ALBIS UK, will be giving away free antimicrobial bags for life to visitors to its stand at Interplas.

The bags are protected with ‘Biomaster’ antimicrobial technology, developed by ALBIS’ UK-based technology partner, Addmaster, following extensive work with the UK’s Food Standards Agency (FSA).

The bags are designed to promote ALBIS’ own brand of pre-approved compounds with built-in antimicrobial protection, namely ‘ALCOM Hygienic Material (HM) Biomaster Protected’, available in a wide range of base polymers.

Made exclusively by UK manufacturer, Solent Group, the bags have been treated with Biomaster technology, which is proven to inhibit the growth of bacteria that might otherwise transfer from the bag into groceries.

When bacteria comes into contact with the surface of an

st their Visitors can te the at ls ria te ma AMETEK booth

from Lloyd Instruments, Chatillon and Davenport ordered at Interplas.

VISITOR INFORMATION: Ametek - Stand H14 www.ametektci.com

ALCOM HM polymer compound, it is unable to replicate, and therefore dies. The active agent that achieves this protection, a silver ion additive, is built into the material during the manufacturing process and as a result the protection lasts for the lifetime of the product. “ALCOM Hygienic Material polymer compounds with Biomaster antimicrobial technology are ideal for product design engineers looking for preapproved antimicrobial plastic surfaces,� explained ALBIS Product Manager, Sam Anson. “Working with a compound allows efficacy tests to be performed on the compound’s formulation, providing peace of mind that no matter how the plastic part is formed, the antimicrobial protection will be built in and pre-approved.�

VISITOR INFORMATION: ALBIS UK - Stand G60 www.albis.com

VISITOR INFORMATION: Atlas Material Testing – Stand - H14 www.atlas-mts.com

interplas: the preview

TESTING EQUIPMENT Accurate testing come rain or shine Atlas Material Testing, a provider of weathering technology and services, is exhibiting at Interplas 2014 to demonstrate the effects of light, temperature and moisture on plastic products.

Atlas will present an array of testing instruments that support those involved in the plastics and rubber industries in addressing how these influences may affect their product’s warranty and performance claims.

Visitors to the stand will see the company’s Suntest XLS+, an advanced benchtop xenon instrument with state-of-the-art UV-control, which Atlas says is perfect for reliable R&D screening tests and for labs with limited available space or lower capacity testing needs.

Also on display, the Xenotest 440 is said to set a new standard in economical, midsized, air-cooled xenon devices.

The Xenotest 440 will be on display at Interplas

TESTING EQUIPMENT Visitors invited to get ‘hands on’ with materials testing AMETEK Test and Calibration Instruments (TCI), exhibiting the latest technology for measuring the physical properties of plastics at Interplas, is inviting visitors to get ‘hands on’ at its stand.

The company says visitors can perform tests on its LS1 and CS225 material testers, allowing users to see exactly how a material tester from Lloyd Instruments gives “high precision and reliable� results.

AMETEK TCI will also be displaying the latest video extensometer for high accuracy and high elongation measurement, as well as the company’s PETPlus IV testing machine. The PETPlus offers high accuracy, solvent-free measurement of intrinsic viscosity.

AMETEK TCI is offering a 10 percent discount on all products

Designed for fast and economical testing, the Xenotest 440 combines new XenoLogic lamp operating technology with an efficient design that includes ultrasonic humidifiers to reduce water consumption.

Kongskilde your conveying specialist

Kongskilde offers complete systems for conveying and handling large volumes of plastics materials generated from today’s production lines.

7KHVH V\VWHPV HQVXUH D KLJK HIĂ€FLHQF\ VLJQLĂ€FDQW savings and an improved working environment.

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

STAND F28

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Bacterial growth is inhibited on plastic surfaces made from ALCOM Hygienic Material (HM) polymer compounds.

interplas: the preview

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Instron’s stand will take on a theatrical air at Interplas

VISITOR INFORMATION Instron - Stand G12 www.instron.co.uk

MACHINERY ARBURG to showcase energy efficient 320 tonne machine at Interplas ARBURG is returning to Interplas 2014 with a stand filled with moulding solutions for optimum energy efficiency.

The focal point of its stand will be an ARBURG Allrounder 720S 3200 2100 320-tonne injection moulding machine with a fully integrated ARBURG Multilift Select robot system.

The 2100 injection unit will be equipped with a 70mm high wear resistant plasticising unit.

The show machine is from the ‘S’ range of hydraulic machines, which span the complete ARBURG range from 12.5 to 500 tonnes clamp forces.

The machine features a generous 720 mm distance between tie bars and is equipped with the latest Selogica Direct software, and also features an ARBURG Servo Hydraulics (A.S.H.) system. The A.S.H system regulates the speed of the motor driving the machine’s hydraulic pump.

MATERIALS Lights, camera, action!

Polymers put on a performance at Interplas Hall four of Birmingham’s NEC arena will take on a Hollywood feel during Interplas 2014, with a live demonstration highlighting how polymers play a part in some of TV and films’ biggest blockbusters.

On Wednesday, October 1st, polymer distributor, Biesterfeld Petroplas, will host partner company, PS Composites, to show visitors how prosthetics are created using various silicone elastomers from Dow Corning’s ‘Xiameter’ range. This will take place between the hours of 11am-2pm on stand E70.

Visitors heading to the Biesterfeld stand will be able to learn more about the company’s full range of polymers, from standard commodity polyolefin products from Borealis and CP Chem, to more specialist engineering materials, such as K-Resin SBC from CP Chem and Santoprene TPV’s from ExxonMobil.

The Biesterfeld UK sales team will be present over the three days of the show, alongside European Product Managers from Hamburg.

Representatives from Borealis, Indorama, LG Chem and CP Chem will also be present. This additional support will provide the Biesterfeld stand with the

TESTING EQUIPMENT Now showing at Interplas: ‘What’s the Cost to your Reputation?’ starring Instron Manufacturer of testing equipment for the plastics market, Instron, has designed a trade show experience that will take visitors on a journey through the challenges (and occasional horrors) of plastics materials testing.

On its stand, visitors will be issued a ticket for a cinematic experience in what it describes as a “truly theatrical setting.”

Instron will be depicting real-life customer stories, some of which, it says, could easily occur in visitor’s labs and end up being very costly to both business and reputation.

The company says, however, that it “guarantees there’s a happy ending to the horror story for everyone.”

y will displa ARBURG ns o ti lu so moulding las at Interp

“The key advantage of this system is that the servo motor adapts quickly and precisely to pressure and flow requirements in the hydraulic system during the machine’s cycle. This ensures that the machine optimises energy usage and is as energy efficient as possible throughout the cycle,” explained Colin Tirel, Managing Director of ARBURG UK. The ARBURG product range incorporates machines from 25 tonne to 500 tonnes with machines in hydraulic, hybrid and electric technologies.

“I am delighted that ARBURG is returning to the Interplas show after some years,” said Tirel. “As a leading supplier of moulding technology it is important for us to demonstrate innovative and relevant technology to our market, and the UK and Irish markets have been key for us for many years.”

VISITOR INFORMATION ARBURG - Stand H4 www.arburg.com

The Centre for Polymer Micro and Nano Technology (Polymer MNT)

SERVICES AND CONSULTANCY Polymer micro and nano expertise comes to Interplas The Centre for Polymer Micro and Nano Technology (Polymer MNT) is a new facility within the world-class IRC Polymer Engineering laboratories at the University of Bradford.

Experts from the centre will be at Interplas to discuss how the recent advances in micro and nano-technology have resulted in a huge range of applications in the telecommunications, medical, and automotive sectors.

The centre provides access to the equipment and expertise required for companies of all sizes to develop a successful micromoulding, including the nano-scale surface feature moulding process, as well as inspection capabilities to ensure high quality.

VISITOR INFORMATION: Polymer MNT - Stand G73 www.polymermnt.brad.ac.uk technical expertise to answer all customer enquiries, says the company.

“Interplas is a great platform for the UK arm of Europe’s largest polymer distributor to showcase our world leading suppliers to the UK market,” commented Guy Payne, Managing Director, Biesterfeld Petroplas. “These include the likes of Borealis, CP Chem, LG Chem, ExxonMobil and DuPont.”

VISITOR INFORMATION: BIESTERFELD Petroplas Stand E70 www.biesterfeldpetroplas.com

The NEC will host a live demonstration of how silicone elastomers are used for TV prosthetics

STAND F4

interplas: the preview

MATERIALS Metal replacement grades and solutions for demanding technologies on display K.D. Feddersen will be promoting several new materials and developments including Akrotek PK (Polyketone) and Akrotek PEEK compounds at Interplas 2014.

The company, which specialises in the distribution and market development of engineering thermoplastic polymers for the UK and Ireland, has a new stand for the show this year, on which it will promote materials from its key partners, including as Akro Plastics, Kolon Plastics, Dimelika Plast and Teijin.

K.D. Feddersen is inviting visitors to discuss materials for metal replacement, as well as process-optimised solutions for demanding gas injection and water injection technologies.

VISITOR INFORMATION: K.D Feddersen UK Limited Stand A47 www.kdfeddersen.co.uk

MACHINERY BILLION to demonstrate new application technology for counterfeit protection BILLION will demonstrate a new technological process at Interplas aimed to provide products with a unique and hidden identification mark for plastic moulded components to protect them against counterfeiting.

The technology has been jointly developed between PEP (Pole European du Plasturgie) based in France, MIMOTEC, based Switzerland and BILLION. The process uses nanotechnology integrated into an injection moulded component to provide a discreet, but easy to read ID, which is embedded in the product.

The cell features a BILLION H80/50 SELECT all-electric injection moulding machine for the high level of precision required to consistently replicate the micro surfaces, aided by air evacuation of the cavity prior to

injection and SISE heating / cooling process control to optimise melt flow and product shrinkage.

The mould and process has been developed and manufactured by PEP in conjunction with MIMOTEC who have provided the technology for the nano structured insert, produced by a photo- lithography UV-LIGA manufacturing process.

The embedded ID can be easily and economically revealed by simply using a laser, which opens up the application field immensely. The read simplicity will be demonstrated directly after moulding by a SEPRO sixaxis cell, which will demould the component and pass it through a laser each cycle.

Pete Kirkham, Managing Director of BILLION UK, said the process has a “wide range of application possibilities”, including those in the packaging, optical, medical, biomedical, cosmetic, logistics, automotive

MATERIALS Interplas debut marks second successful year for UK distributor Gazechim Plastics UK is using its first appearance at Interplas to celebrate its second successful year of distribution to the UK market.

The entire Sales and Customer Service teams will be present during the show in order to discuss Gazechim’s expanding

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The cell with the new technology will be on display at Interplas and aeronautic sectors. “The technology has huge scope for product differentiation, authentication and traceability,” he added.

VISITOR INFORMATION: BILLION - Stand C4 www.billion.fr

materials portfolio with visitors to its stand.

To celebrate, the company says it will be serving some “tantalising refreshments and canapés” typical of the Group’s French heritage.

VISITOR INFORMATION: Gazechim - Stand E68 www.gazechim.co.uk The Gazechim UK team will be on hand to discuss its materials portfolio

MACHINERY Four working BOYs to take to the floor at Interplas Northants-based BOY Limited will be showing four BOY injection moulding machines in full operation at Interplas 2014.

A Boy 35E will be “centre stage” at the show, thanks to its compact design as well as having one of the smallest footprint-to-clamp-force-ratios in its size range. The machine will be complimented by the latest BOY60E running a hot runner tool and automation.

The smallest machine on show will be the BOY XS, demonstrating miniature moulding capabilities. A special edition BOY22A will be shown detailing its added new features, which are said to allow complete integration with other main suppliers’ machines of similar size.

BOY Limited will reveal what it says is an “unbelievable show price” for these machines at the start of Interplas.

Both the BOY 35E and BOY 60E machines that will be on

show are fitted with the company’s energy saving servo control system coupled to the hydraulic pump. Using the latest Alpha 2 control system, BOY says it can demonstrate both the 50 percent energy savings of this system and the increased optimisation control that the new energy parameter pages allow.

BOY will also demonstrate the energy savings it says can be achieved by the introduction of the “revolutionary” plasticising concept of the ‘ECONPLAST’ unit, which can reduce heating energy consumption and energy losses during dosing by a reported 50 percent.

mould clamping, including manual, hydraulic and magnetic solutions, as well as mould load and unload solutions for faster, more efficient operation.

Finally, for efficient parts handling and processing Stäubli will demonstrate its automatic gripper changer for robot arms using a Stäubli TX40 multi-axis robot.

VISITOR INFORMATION Staubli Connectors Division - Stand E12 www.staubli.com

BOY 35 E with EconPlast unit, Alpha 2 control and energy-efficient servo-drive

MOULD CLAMPING, CONNECTING AND TRANSFER Calling all plastic moulders looking to maximise productivity Stäubli Connectors Division is presenting its full range of products for the plastics sector at Interplas, and has revealed it will launch its latest connector series (HTI and HTM) for the safe control of temperature circuits up to 300°C. In addition, the company will show a complete range of mould loading, clamping, connecting and transfer solutions designed for the plastics moulder to maximise efficiency and productivity.

“High utilisation and efficient operation of moulding machines is essential in today’s competitive environment; a good opportunity to improve

performance and productivity is solutions for applications such by selecting ancillary equipment as temperature control, core that minimises downtime on pulling and valve gate control. mould changeover, loading, Stäubli will also feature clamping and connection as well examples of its range of multias automating parts handling coupling systems ranging from and processing,” explained modular off the shelf solutions Spencer Wills, Plastic Industry for water or hydraulic Manager at Stäubli UK. connections to bespoke The products being launched products where all connections at the show are two new to the mould can be achieved in connector ranges, HTI mono a single action. connectors and HTM multi In addition to the new couplings, both specifically connectors and couplings, designed for the control of high Stäubli will demonstrate its temperature circuits. Both of systems and technologies for these new products will be demonstrated on the stand.

For moulders looking to speed up mould changes, Stäubli’s new Stäubli will have on connectors will display products be launched at ranging from full flow Interplas quick release couplings to spill-free, flat-face, clean-break

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VISITOR INFORMATION: BOY Limited - Stand B30 www.boy.ltd.uk

interplas: the preview

MACHINERY Manufacturer marks milestone with plastics, packaging and popping corks Sumitomo (SHI) Demag is marking its 40th anniversary at Interplas 2014 along with two other big milestones. In a UK debut, two fully operational, 100 tonne injection moulding cells will be exhibited on the company’s 105m² stand, one focusing on precision plastic moulding, the other on packaging.

A fully-electric IntElect 100 machine (clamping force 1,000 kN) will enable visitors to experience first-hand the benefits of Sumitomo’s activeFlowBalance technology.

Suited to high-repeatability, mass-produced precision automotive and medical applications, the team will use a

MACHINERY Extrusion control system technology takes a bigger stand at Interplas With increased stand space for Interplas 2014, PLAST-CONTROL says it is taking the opportunity to display a larger representation of its current developments in extrusion control system technology.

Being exhibited at this year’s show will be the latest version of the company’s PRO-CON profile control blown film air ring system with the Air CC true non-contact capacitive on-line profile measurement system. Keeping with the theme, PLAST-CONTROL will also demonstrate the PROLAB off-line laboratory profile measurement system for flexible film.

Also featured is the current version of the company’s Gravimetric Extrusion Control and Continuous Gravimetric

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PLASTCONTROL will display a large representat ion of its extrusion control system technology

This is the first time a public European audience will see the IntElect Smart equipped with the optional “fast clamp” for high speed applications

Dosing systems, incorporating easy clean design features and ultra-high resolution stepper drive control for additive feed rates from 0.2kg/hr to 500 Kg/hr. Alongside this, PLASTCONTROL will also demonstrate the Nano Batch Blender system with compact fully integrated extrusion control and high accuracy metering system.

Both the Dosing and Nano Batch system are equipped with PLAST-CONTROL PCH high efficiency hopper loaders and vacuum control systems.

The company’s complete suite of ACS control software, running in full simulation mode, will be available for visitors to evaluate, demonstrating the ease of use and level of control which can be achieved on both new and retrofit continuous extrusion machine applications.

VISITOR INFORMATION: Plast-Control UK Ltd Stand E51 www.plastcontrol.co.uk

32-fold rawl plug mould to demonstrate the impact of activeFlowBalance and how it combats uneven and fluctuating filling of multi-cavity moulds.

Sumitomo says experts will reveal noticeable quality improvements and show how activeFlowBalance addresses challenges like jetting, sink marks, short shots, flash, voids and warping without lengthening the cycle time. “In just one cycle time, there’s a visible difference,” commented Managing Director, Nigel Flowers. “This is a rare opportunity for manufacturers to get a glimpse of what goes on inside the mould cavity and the ease in which activeFlowBalance can be deployed into existing injection moulding equipment.”

In its packaging-focussed feature, Sumitomo says bottle cap manufacturers will be excited to learn how its newest clamp unit innovation has

shaved 0.2 seconds of production cycle time (from 2.6 to 2.4 seconds). However, the company has teasingly said Interplas visitors have to wait until the opening day to discover how the company’s engineers have mastered the heat and lubrication battle without compromising on reliability and affecting machine wear and tear.

Finally, visitors are being prepared for the popping of corks on 30th September, as the opening day of Interplas also marks 40 years to the day when Sumitomo (SHI) Demag launched. Nigel and the team are inviting everyone to share in their success and join them on their stand to toast the company’s future.

ANCILLARIES Seven new products make their show debut at Interplas Motan Colortronic is to demonstrate several new products for the first time at Interplas 2014.

The first, the new Luxor A dryer, has unique dewpoint regulation where a consistent dewpoint within +/- 1°C can be maintained, said to save energy without damage to materials.

Also to be displayed from the Luxor range of dryers is the CA compressed air dryer with a double-insulated glass hopper.

From the company’s range of dosing and blending equipment there will be upgraded gravimetric masterbatch units for optimum control and materials savings, which will sit alongside a new range of hopper loaders for granule applications.

Temperature control equipment will make an appearance in the form of a new Regloplas Vario thermal regulator with heat recovery for vast energy savings, as well as new Reglochill units with remote gateway for remote monitoring of the process.

Finally, for plastics recyclers, there will be new Herbold Meckesheim granulator and shredder models displayed, as well as metal detection and separation units for application on machine, in-line and gravity feed of plastic granules and detection down to 0.4 mm (Fe-ball) where required.

VISITOR INFORMATION: Sumitomo (SHI) Demag Stand D30 uk.sumitomo-shi demag.eu

VISITOR INFORMATION: Motan Colortronic Limited - Stand F4 www.motancolortronic.co.uk

Motan Colortronic will show several new innovations including dryers from the Luxor range

ANCILLARIES New ‘in demand’ dryer to debut at Interplas…but hurry – it’s fast Summit Systems will exhibit a new material dryer from Maguire at Interplas that it says can achieve faster and more efficient drying.

The new VBD Dryer is the result of Maguire having worked on its existing vacuum dryer principle and making it “a lot more efficient.”

Summit says recent production — scale demonstrations have reportedly shown that the dryer can achieve the required quality of dried material in 35 minutes from cold startup.

ANCILLARIES Space-saving silos to take spotlight at Interplas Genesis Process Solutions will be exhibiting a flexible silo on its stand at Interplas this year to demonstrate the space-saving storage alternative it can provide to the plastics industry.

The silos, which are available in sizes up to 50 tonnes, provide advantages over storage systems such as octabins and FIBC’s according to the company, as they are designed not only for internal

Quantum, the new gravimetric blender on from Piovan, will be s pla ter In at display

“Using these dryers it is possible to dry from sample batches to production of up to 450kg of polymer in a third of the time as traditional desiccant dryers and uses less than half the energy,” explained Mike Jordan, Managing Director at Summit Systems. “Fast drying means no material degradation and revolutionises production planning.”

The reported demand for this new dryer across the world means Summit Systems will only show one model at Interplas, whilst Maguire “ramps up” production.

Alongside the new dryer, Summit will be introducing two new ranges of technically — advanced granulators designed for processors looking to address the in-house reclamation of scrap.

VISITOR INFORMATION Summit Systems Stand E30 www.summitsystems.co.uk

use, therefore eliminating the need for planning permission, but can also be manufactured specifically to fit into the space available.

Genesis will exhibit the silo along with Brabender feeders, as well as some new products.

“Talk at the moment seems to be about reducing waste, losses and manpower so the advantage of having smaller silos (daybins) instead of multiple FIBCs, octabins and 25kg sacks is a huge benefit of the silos,” Phil Cameron, Sales Director at Genesis Process Solutions, said.

He added: “We had a really successful time at the last Interplas, at a time when the talk

SERVICES AND CONSULTANCY UK company offers alternative to traditional trade finance For plastics companies at Interplas looking for finance or funding options to grow their business, TradeRiver Finance is a non-bank, online funding solution which finances trade, both cross- border and in the UK. The firm will have representatives at Interplas to discuss how it can enable companies to have access to working capital at any point in the supply chain to help support and develop their business.

It works by providing the buyer with a pre-approved, revolving facility that can be used to finance trade with multiple suppliers and it gives the buyer 120 days to settle the balance. All payments are paperless and sent via a secure was more about recession than business. With a stronger economy we are hoping for an even better show this year.”

A fellow exhibitor that is aware of the benefits of the silos is Suffolk-based Broadway Colours, who recently took delivery of two 6.5 tonne flexible silos from Genesis.

The company, which supplies the plastics industry with polymer specific masterbatch and rotational moulding powders, uses the silos for storing LLDPE compounded pellet prior to it being ground to a very fine and specific powder.

interplas: the preview

monitor energy consumption.

The ‘Energy Consumption Monitor’ measures the effective energy use, both of individual machines and specific manufacturing cells or cooling systems, in real-time, providing reports and graphs that show the actual energy consumption.

In addition, Piovan says new developments in mould temperature control and innovations in refrigeration will also be presented at the UK’s largest plastics industry exhibition.

VISITOR INFORMATION: Piovan - Stand E20 www.piovan.com

online platform.

TradeRiver says it has attracted a fast-growing community of “forward-thinking” businesses looking for an alternative to traditional trade finance that offers “flexibility, responsiveness and agility” that isn’t available from traditional bank-based finance.

By offering this service, it says it provides a viable alternative or additional source of unsecured working capital for UK companies looking to plug funding gaps in their supply chain.

VISITOR INFORMATION: TradeRiver Finance Stand J52 www.traderiverfinance.com

TradeRiver will be on hand to offer advice to plastics companies at Interplas

ANCILLARIES Ancillary equipment: a preview of what’s new Piovan’s exhibition stand at Interplas 2014 will be displaying a “full array” of product innovations and new technologies for a wide range of processes.

Firstly, the company will introduce visitors to its new filterless vacuum receivers, called PureFlo, which it says are designed for all those applications where cleanliness and maintenance are key factors for the consistency of the process.

A new range of gravimetric blenders, Quantum, which are said to help improve the quality performance of production lines and “redefine technical standards and market applications” will be on show, said to deliver outstanding features of flexibility, precision, safety and efficiency.

Lybra dosing units, in the latest configuration, are designed to dose masterbatch, additives and recycled material and are suitable for all types of applications, says the company.

As for supervising the system, Piovan has introduced a new feature in its ‘Winfactory’ supervision system designed to

Nick Barber, Operations Director at Broadway Colours, commented: “When we started to produce rotational moulding powders in 2012 we knew that flexible silos would meet our demanding production schedule without the problems associated with traditional silos. We are so impressed with them that we will soon be looking to add a further four larger silos from Genesis when we move to our new custom built site in the summer.’’

VISITOR INFORMATION: Genesis Process Solutions - Stand E28 www.genesisps.co.uk

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interplas: the preview

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The eCanbio machine series MACHINERY First UK public showing of evolved machine series at Interplas At this year’s Interplas, Negri Bossi will have the first UK public showing of the latest variant of its ‘Canbio’ series machines, which is prefixed with the letter ‘e’ for evolution, so as to reflect the extent to which they have been developed, says the company.

New additions to the machine include the new ‘Smart

Flex’ clamping groups, which are said to be more generous with regard to distance between top tie bars; the new eV300 tonne offering for example, having 720 mm between bars, compared to

CLAMPING SYSTEMS Magnetic clamping set to be ‘hot attraction’ at Interplas 2014 Roemheld will be exhibiting its innovative M-TECS magnetic clamping systems designed to offer flexibility and fast changeovers for the rubber, thermoplastics and plastic processing industries.

Visitors to the Roemheld stand can see the M-TECS 210 magnetic clamping system, which can operate at temperatures of up 210oC, and

the M-TECS 130 system, which can operate at up to 100oC. Roemheld says M-TECS is extremely safe as it is based on a permanent magnet solution and requires no external power to remain clamped. The unique long pole technology also ensures maximum safety, power and reliability.

Benefits of M-TECS magnetic clamping are said to include reduced downtime, low set-up costs, increased productivity, fewer rejects and less mould wear. The systems are designed to suit all types of machines, whether horizontal or vertical

AUTOMATION Integrated automation solutions will do “the robot” at Interplas Showcasing some of its robotics automation processes for turnkey solutions and integration in the plastics industry, FANUC will demonstrate live equipment for visitors at Interplas 2014.

The company is set to display its S150iA injection moulding machine running a 16cavity medical toothed rod mould supplied by KEBO. The polymer used in this demonstration is POM and the cycle time is seven seconds. The installation, featuring Motan polymer handling equipment, will also be fitted with an EFI hot runner controller and Moldflow water manifold system; monitoring both flow and temperature of the mould cooling.

The installation will

showcase components being removed from the mould by the new FANUC CR10 Cartesian robot, dropped onto a conveyor supplied by Hi-Tech Automation Ltd. The components will then be picked at random and dropped into an inspection chute for quality control, sorted and placed into bags on a carousel by a FANUC LRMate six-axis robot using Visual Line Tracking.

On FANUC’s 3PA stand, an S100iA injection moulding machine will be running a two component mould with a second injection unit and rotary turntable for the moving half of the mould supplied by Plasdan.

The rotary turntable will be controlled by a FANUC servo drive integrated into the main control system of the machine to give full control and position stability of the turntable movement and position.

VISITOR INFORMATION: FANUC - Stand D70 www.fanuc.eu

660mm on the outgoing V330 model.

The other major changes relate to there now being no contact between tie bars and the moving platen, and the moving platen being supported on prismatic guides rather than slide-ways. “These modifications yield multiple benefits, with structural rigidity being optimised and a lubrication free ‘moulding zone’ being produced,” explained Carl Futcher, Managing Director of Negri Bossi UK. “Cycle times can also be improved, for example

the mould closing time being over 20 percent faster at maximum speed.”

The Canbio machines are fully digital and can also be offered in a Smart Energy version, which, according to the company, further enhances both efficiency and accuracy and reduces noise levels, achieving close to, or in some instances, surpassing all-electric technology.

VISITOR INFORMATION: Negri Bossi - Stand D20 www.negribossi.co.uk

and are said to be ideal for retrofitting.

Terry O’Neill, Joint Managing Director of Roemheld, said: “Our M-TECS system sets the standard for magnetic clamping and the relatively low investment costs are quickly recovered thanks to savings made in changeover times. I would encourage anyone thinking of investing in this technology to pay a visit to our stand.”

VISITOR INFORMATION: Roemheld (UK) Limited Stand J4 www.roemheld.co.uk

ANCILLARIES “One stop shop” open for business at Interplas Ancillaries distributor, Hi Class Machinery (HCM), is exhibiting alongside sister company, Boy Limited, to provide a “one stop shop” for plastics processors.

The company will show a range of products from some of Europe’s biggest manufacturers, including hopper loaders, driers, granulators, dosing units and conveyors. In addition, sprue pickers and robotics will also feature in the set-up, which HCM says demonstrates the full

Visitors to the Roemheld stand can see the M-TECS 210 magnetic clamping system

support it is now able to offer customers.

“The synergy between BOY Limited and Hi Class Machinery means that complete integrated machine and ancillaries can be supplied with support under one roof. A true one-stop shop,” explained HCM’s Bob Wilson.

Hi Class Machinery is also planning to re-introduce a large range of injection moulding machines into its portfolio of equipment. Details of the machines available will be unveiled at the show.

VISITOR INFORMATION: Hi Class Machinery Stand B30 www.hiclassmachinery.co.uk

MACHINERY New injection moulding machine series to be launched PMM has revealed it will be launching the all-new ‘Zeres’ series of electric moulding machines from Zhafir at Interplas 2014, demonstrating a Zeres ZE1200.300 that will be running a multi-impression tool with hydraulic core pulling.

The new machines have integrated hydraulics to expand the range of applications, with

Calorimetry (DSC), Dynamic Mechanical Analysis (DMA), Dilatometer (DIL) and. Laser Flash Analysis (LFA).

These techniques, says the company, give an insight into the thermal properties of polymer materials and products, but more importantly, they can be used to determine the composition of plastic and rubber compounds and to gain information regarding the condition or processing history of specific samples relative to reference samples.

Thermal analysis can be used for polymer characterisation and is wellsuited for quality control and

has been the driving force in the development of the new Zeres Series right from the outset,” commented Richard Hird, Sales Director at PMM. “By combining the two systems, servo-electric drive plus

VISITOR INFORMATION: Premier Moulding Machinery (PMM) - Stand E60 www.pmmuk.net quality assurance. Incoming materials inspection as well as materials selection can be carried out safely and easily. Also for the research and development of new materials, thermal analysis is an indispensable tool for investigating a broad range of material properties.

One of the Netzsch machines for polymer analysis and testing

VISITOR INFORMATION: Netzsch Instruments Stand B33 www.netzsch-thermalanalysis.com

E 0 SE ON J1 S U ND A ST

TESTING AND ANALYSING EQUIPMENT State of the art thermal analysis technology comes to Interplas Netzsch Analysing and Testing, part of the Netzsch Group, will exhibit at Interplas with its state of the art technologies for thermal analysis and thermophysical properties testing of polymers.

Netzsch will be on hand to discuss with visitors its main technologies, including Thermogravimetric Analysis (TGA), Differential Scanning

flexibility and in-line with customer demand.

“The highly efficient start-up model for entry into the ‘allelectric world,’ is available with clamping force sizes of from 400 up to 2,300 kN, – this concept

hydraulics, the Zeres now comfortably bridges the gap between all traditional hydraulically oriented processors and the allelectric Venus Series.”

In its essential features, the Zeres is identical in design to the Venus II Series and is said to offer the customer the fullest dynamics and precision, while sustaining more production efficiency because of double-digit percentage energy savings.

interplas: the preview

The new Zeres ZHA moulding machine

Engineering Plastics with a Difference....

4MID® ANCILLARIES Bunting Magnetics Europe to Show Magnetic Separation Equipment at Interplas Bunting Magnetics Europe Ltd says it will use its presence at Interplas 2014 to showcase the latest in magnetic separation technology that has been specifically engineered for the plastics industry.

Taking centre stage at stand H11 will be Bunting’s MachineMounted All-Metal (MMS) Separator, which provides efficient rejection of both ferrous and non-ferrous metal contamination. This high specification unit fits where headroom is limited and bolts directly to the in-feed of

processing equipment, such as extruders, injection and blow moulders. A fast pneumatic rejection mechanism, aided by precise timing, results in accurate cycling and conservation of good material, says Bunting.

Other magnetic separators on show will include Grate Magnets, FF Drawer Magnets, Plate Magnets, and Magnetic Drums for removal of ferrous metal contamination from dry free-flowing material. These units will be accompanied by Inline Magnets, which are suitable for removing ferrous metal from pipelines.

VISITOR INFORMATION: Bunting - Stand H11 www.buntingeurope.com

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Plastic developed by university scientist will “help stop mobile phones overheating” Problems with overheating mobile phones could be reduced significantly thanks to a plastic being developed by Loughborough University scientists.

The material is ultra-high molecularweight polyethylene (UHMWPE), which is used to make a variety of products, from prostheses to body armour.

The plastic, unlike the ones currently used in mobile phone covers, dissipates heat created by the lithium batteries and reduces the likelihood of injury to the owners.

Dr Sara Ronca, the principal investigator for the research, said the new plastic is “vital” because the drive in electronics towards miniaturisation has increased the need for smart materials than can cope with things like heat dissipation. It could be a major boost for manufacturers of all kinds of electronic

New name for EPS in Europe is a breath of fresh air Expanded Polystyrene is now going by a new name in Europe: airpop engineered air.

The decision to rename EPS, which has previously been known as Styropor, Styrofoam, PSE, Piepschuim or Polyfoam to name but a few, has been initiated by Europe’s EPS industry to give the material a name “truly reflective of its characteristics.”

Those involved in the airpop campaign, namely EUMEPS Power Parts, European airpop-converters, their respective National EPS Associations and European EPS

further information: www.loughborough.ac.uk

raw material producers, said the name “immediately brings to mind what the material is made of – it’s air.”

“A lot of air. 98 percent air, to be precise,” the associations said in a statement. “And just a tiny fraction is made of synthetic material, which expands to 50 times its own volume. To protect everything that needs to be protected: our children’s heads, TVs, fresh fish and thousands of other things.”

EPS is now going by a new name in Europe: airpop engineered air

Inventor of Kevlar dies aged 95 Stephanie L. Kwolek, the chemist who invented the super strong and lightweight fibre, Kevlar, has died aged 95.

The American chemist, who worked for DuPont when she synthesised the first liquid crystal polymer 1965, is the company’s only female employee to be awarded its Lavoisier Medal for outstanding technical achievement.

The material’s original use was in vehicle tyres, but throughout the 1980s, DuPont introduced new varieties of Kevlar for such uses as cut-resistant gloves and lightweight body armour.

In a statement, DuPont’s Chief Executive, Ellen Kullman, described Kwolek as “a determined chemist and a true pioneer for women in science.”

engineering materials

The technology could be a major boost for manufacturers of electronic devices

news

devices, says the University, such as computers, electric motors and generators, solar panels, batteries and heat exchangers in power generation.

Dr Ronca has developed a method of synthesising and processing UHMWPE so that it is a good conductor of heat. She is now building on work started by Professor Sanjay Rastogi, with the aim of getting the plastic ready for industry.

Professor Rastogi and Dr Ronca have developed a synthetic/processing strategy that allows achieving less entangled and highly aligned chains able to promote heat transfer by something called lattice vibration.

She said: “We have devised a synthetic strategy that enables us to directly obtain UHMWPE with a reduced number of entanglements. It is easier to process this material in a way that chains are extended and nicely aligned.

“When you get this type of structure the polymer is not conductive electrically but it can conduct thermal energy by lattice movement. We have demonstrated that this material can be easily processed, without the need for any solvent, to give tapes and filaments with high chain alignment. The question is, can we get a material that has different thermal conductivities according to the polymer’s molecular characteristics and can we tailor thermal conductivity by tailoring the material properties?

“The results from the project will enable us to realise a lightweight, cheap, easy to process and to recycle material where the thermal conductivity can be tuned in a range of useful values by suitable modifications of the synthetic processing steps.”

further information: www.dupont.com

Kwolek was the chemist behind DuPont’s Kevlar fibre, used in body armour

The group, along with IK, Europe’s biggest trade association within the plastics packaging industry, launched the new title at Interpack 2014. airpop represents an industry of approximately 200 mainly small and medium sized converters for moulded parts in Europe, processing about 300,000 tonnes of raw material into airpop moulded parts. Main customers are producers of household applications, electronic technologies companies, the HVAC and the food industry. further informatioN: www.airpop.com

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RubberCon 2014: a conference review Words: Dr Sally Beken, Technology Expert at the Knowledge Transfer Network (KTN)

// Materials Technical //

Blog This month, polymer expert and technical blog author, Dr Charlie Geddes,‘clears’ the myths about ABS and looks into how changing the chemical composition can affect its properties

The event in Manchester was well attended

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In association with Hardie Polymers – www.hardiepolymers.com

ubberCon 2014 was hosted in mid-May in the historic home of the global rubber industry, Manchester. The event was a resounding success, with over 220 delegates from 24 different countries, three parallel sessions and a poster exhibition.

Holding the event in Manchester had historic significance due to it being the location where Thomas Hancock and Charles Macintosh first built their joint factory to produce waterproof clothing in 1825. Hancock also lays claim to the first patent of vulcanisation in the world, as well as the invention of the internal mixer. Both these achievements happened while Hancock was based in Manchester.

Organised by IOM Communications Ltd on behalf of the Rubber in Engineering Group of the Institute of Materials, Minerals and Mining (IOM3), the event ran over two days and the main themes were ‘Advanced Engineering and Modelling of Rubber’ and ‘Materials Developments’.

Plenary speakers included Keizo Akutagawa of Bridgestone Corporation (Japan), who discussed the potential developments in rubber materials over the next decade, Professor Mark Warner of the Cavendish Laboratory at the University of Cambridge, who gave the Rubber Foundation Lecture on Liquid Crystalline Rubbers and Gerard Nijman, Senior Product Development Engineer at Apollo Global R&D Centre (the Netherlands), who talked about the challenges and latest developments in the tyre world.

Over 60 papers were presented at RubberCon 2014 on topics covering rubber materials at a microstructural level; rubber materials subjected to a range of static, dynamic, timedependent or cyclic loading conditions; failure of rubber products; and the manufacture of rubber products, including the rheology of polymers during mixing.

Under the ‘materials developments’ theme, novel polymers – or fillers and additives that can enhance performance – were discussed. Insights into the detailed mechanisms of filler reinforcement were covered and smart elastomer systems were highlighted. The conference also covered recycling initiatives and engineering solutions to meet tomorrow’s legislation.

For further information on the programme or speakers, as well as contacts for rubber engineering in the UK, you can contact the Knowledge Transfer Network’s Technology Dr Sally Beken on: sally.beken@ktn-uk.org

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further information: www.iom3.org/events/rubbercon2014

Transparent ABS can be a clear winner Mentioning transparency in the context of ABS moulding materials can raise a few eyebrows because ABS is normally taken to be opaque and indeed the vast majority of grades of ABS are opaque.

ABS is a two-phase system, which can be considered as small rubbery particles dispersed in a rigid thermoplastic matrix of styrene-acrylonitrile copolymer (SAN). The SAN provides stiffness and the rubber particles provide impact resistance.

One feature of a two-phase system is that light gets scattered as it passes from phase to phase, resulting in very low light transmission levels. It is possible to minimise scattering of light and maximise transmission if the two phases have similar refractive index values.

Manufacturers of ABS soon discovered that incorporating methyl methacrylate (MMA) monomer into the SAN rigid phase and tinkering with the composition of the rubbery phase resulted in matched refractive index values and hence high transparency could be achieved.

Of course, tampering with the chemical composition has a knock-on effect on other properties. Clear ABS (strictly speaking MABS) cannot compete with the impact resistance of impact grades of ABS nor the heat resistance of high heat grades of ABS. However clear ABS can outperform polystyrene, SAN and PMMA for impact resistance and has similar heat distortion temperatures. Polycarbonate can outperform clear ABS for both impact resistance and high temperature performance but clear ABS scores well for stress crack resistance and processability, with good melt flow characteristics.

Typical applications include domestic goods, cosmetic packaging, medical components and sports and leisure goods.

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

“World’s first” seven-component mould gets its teeth into production Zahoransky has delivered a sevencomponent injection mould to Schiffer, a German moulder of toothbrushes and dental care products. The mould-maker claims that this is “the first sevencomponent mould ever built worldwide.”

The 16-fold injection mould has two injection stations and one loading and removal station located on the outside.

Two different materials in the same colour

A 3D graphic of the mould and some of the channels

mould making and tooling

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are processed in the first station, while two different TPEs are used in the second station. One of these is injected in four different colours, a design feature implemented owing to the fact that the toothbrushes are retailed in four different colours. The use of the seven-component mould means that Schiffer does not need to perform colour changes. Zahoransky even claims that toothbrushes produced during the day could be in supermarket storerooms by the evening.

The system links the mould in-line with the downstream production process and through to seven injection units, which had to be connected to the mould in an extremely tight space. The availability of several material feeds, the different processing temperatures of the various materials and the close spacing between the different nozzles at the same cavity needed to be taken into account. The moulding was performed by a sixcomponent machine from Engel, while a seventh injection unit from Boy was integrated into the production process.

Mold-Masters supplied the hot runner technology for the application. The system features a two-part soldered runner.

Instead of having just straight channels, these runners have as many as three melt levels with curves and turns incorporated.

This design uses the principle of natural balancing, as well as a uniform thermal profile and a relatively low construction height.

Seven-component toothbrush mould showing the four separate colours

Zahoransky says that this technology allows two or more melt flow channels to be integrated into a single runner. The design also allows six or more materials and colours in a single runner.

The group states that though complex, multi-component moulds are the most cost-effective solution for applications where identical products are to be moulded in different colours. further information: www.zahoransky.com

Mouldmakers can use the chiller/TCUs to test and build better moulds before they’re shipped, says Frigel

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Press-side cooling benefits not just for moulders anymore Mould makers can now utilise the benefits of advanced cooling technolgy to test and build better moulds before they’re shipped, and provide customers with a higher level of service and satisfaction as a result, according to process cooling specialists, Frigel.

Where temperature control technology is traditionally used alongside the process machine to deliver high turbulent flow throughout the mould for more uniform and precise cooling, more and more mouldmakers have begun to use the technology to their advantage when designing and building moulds.

“A high-performance chiller/TCU provides the ability to test each mould to determine the exact flow rate and temperature that will enable it to produce the highest quality part with the lowest cycle time, regardless of the materials used,” said Al Fosco, Frigel North America.

“The parameters can also be tested and calibrated to ensure the mould will prevent scrap. The key benefit is quality

control before the mould is shipped. It’s a practice that saves money for mouldmaker and moulder alike.”

Frigel says for mouldmakers, a chiller/TCU can enhance their role as mould experts, as well as strengthen their role as a value-added partner through knowledge of machine-side technology and the ability to offer advice for optimum settings that improve mould performance.

“The advantage to moulders is the ability to consistently produce quality parts with increased throughput and less scrap based on testing and the ability to make necessary adjustments, all of which points to satisfied end-customers and improved margins,” Fosco concluded. further information: www.frigel.com

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New coat in Meu s ed e ject burger’s or p pro ins with duct ra ng g6 t oler e: DLC ance

Rock solid: DLC coated ejector pins with g6 tolerance launched Manufacturer of standard parts for tool and mould making, Meusburger, has broadened its product range with DLC coated ejector pins.

The DLC (diamond-like carbon) coating increases both wear resistance and corrosion resistance

of the ejector pins, says Meusburger, whereas their excellent dry-running properties make them suitable for use in cleanrooms. In addition, the g6 tolerance enables the pins’ easy and trouble-free installation in the mould. further information: www.meusburger.com

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New thermal insulating sheet for moulds launched HASCO has launched new thermal insulating sheets for external insulation to prevent the heat from escaping from heated injection and compression moulds.

The new ‘Z1215’ sheets have been specially developed for moulds that are subject to a high level of thermal stress.

Moulds can be fully insulated using this thermal insulating sheet, says HASCO, which is made of high-temperature plastic.

The sheets are placed against one side of the mould, with their honeycomb structure forming insulating air chambers, ensuring considerable energy savings both during the heating phase and throughout the injection moulding process. Thermal equilibrium is rapidly achieved in the mould, permitting maximum process reliability and shorter cycle times. further information: www.hasco.com

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Portugual’s Engineering & Tooling Cluster: An Introduction If America is famed for having a Starbuck’s on every corner, then the district of Marinha Grande in Portugal could certainly put forward a similar claim for having as many mould makers. From 1945 until the present day, the industry has thrived on the exportation of its produce abroad, and can now claim to be one of the biggest manufacturers of moulds in the world, exporting over 90 percent of production.

But what makes Portugal a key choice for the engineering and tooling industries and how is it continuing to thrive? The following article offers an insight. the lopment of ent ntinual deve o tm c s e ve in th vy re stry, hea To ensu du in s ld u o e m aining Portugues logy and tr e in techno is being mad

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he Portuguese Engineering & Tooling Cluster represents a dynamic industry that provides innovative and integrated solutions to a global market. The Cluster originated from a collaboration between Portuguese companies active in the moulds, special tooling and injection moulding industry, and is characterised by its highly developed infrastructure and ability to operate as a multidisciplinary partner, thanks to a strategic positioning in the development of complex and sophisticated industrial products.

The Cluster’s unique model of cooperation, innovation and internationalisation is recognised as an international benchmark. Ninety percent of its production is exported to 120 different countries around the world. Europe is the main export zone, although the economic relevance of the U.S.A, Mexico and Brazil is on the rise. The United Kingdom is now eighth in the ranking of Portuguese mould and tool exports.

Portugal has around 450 tooling companies employing approximately 8,000 workers in two main locations (Marinha Grande and Oliveira de Azeméis). It is internationally recognised as one of the top producers of precision moulds for the plastics industry, and is increasingly extending its value chain both up and downstream with specialised skills from design and engineering to the production of final parts.

The Cluster was formally recognised by the Portuguese Government in 2009 and is legally represented by POOL-NET – the Portuguese Tooling Network Association. The aim is to contribute to the sustainability of European industry, supporting product development in strategic areas (such as aerospace, automotive, medical devices, packaging, electronics, energy and the environment) and to promote the Portuguese Engineering & Tooling cluster internationally, under the brand ‘Engineering and Tooling from Portugal’. With companies working together under this strategy, Portugal has increased its competitiveness and market share worldwide.

An example of a mould for the automotive industry

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Plans for the future To support migration to these niche markets, the Cluster is a member of various European collaboration networks and is closely involved in R&D and innovation projects for the sustainable development of the industry. Further aims are to maximise core technologies (e.g. milling, turning and EDM) and to introduce new technical and technological skills into these strategic areas. This requires an effective transfer of knowledge and optimisation of R&D results, with engineering heading the list.

In fact, the Portuguese moulds industry invests heavily in technology and training. Portuguese companies are fully equipped to cut precision moulds – particularly tools involving multiple cavities, inserts and interchangeable parts. The Portuguese toolmakers have pioneered the application of new technologies that enable the use of in-mould labeling and decoration or multi-component products. Moreover, the Portuguese Engineering & Tooling Industry has embraced the use of ’smart tools’, which incorporate a wide range of electronic sensors, to provide added value for international customers.

Portugal’s Engineering & Tooling companies have gained international recognition for their skill in interpreting their customers’ requirements, building a reputation for versatility and advanced technology while also offering an excellent price/quality ratio. The Cluster offers solutions in all fields, streamlining innovation, helping customers to find new solutions, building reliability, precision and efficiency with special emphasis on trust and commitment as core values. further information: www.toolingportugal.com/EN

mould making and tooling

Providing flexibility and fully integrated service Portuguese tooling companies offer a fully integrated service consisting of an extended value chain with specialised skills and competences, ranging from design, engineering and prototyping to mould manufacturing (including specialisation in large-sized and precision and micro moulds), special tooling, injection and assembly of products and components – closing the loop from design to final product.

For the majority of these companies, the automotive industry is the major market, accounting for approximately 70 percent of production, although many are diversifying into other areas such as packaging, energy and the environment, aerospace and medical devices.

Portugal’s moulding week promotes EU collaboration and industry development An event held in Portugal last month to promote the country’s engineering and tooling competencies saw some five agreements for collaboration made with other European plastic clusters.

The new agreements, which aim to encourage international cooperation, the exchange of information and business opportunities among members, were made between Pool-net, Portugal’s tooling network association, and Clusterland – Austria; Plastipolis – France; Proplast – Italy; Veneto Nanotech – Italy; and AVEP – Spain.

The ‘Moulds Event 2014’, held from 23rd – 27th June, presented seminars, conferences, workshops, B2B meetings, and exhibitions looking at innovation, evaluation of market trends and technologies as well as providing a networking platform for attendees to launch new projects and business.

The weeklong event, held every two years, is organised

by Pool-net along with CEFAMOL, the Portuguese Association for the Moulds Industry and CENTIMFE, Portugal’s Technological Center for the mouldmaking, special tooling and plastic industries.

The focus of the event in 2014 was on the cluster’s strategic markets, which include automotive, aeronautics, energy and environment, electronics, packaging and medical devices, and it attracted some 800 participants representing 13 countries (Portugal, Spain, Italy, France, Germany, Finland, United Kingdom, Netherlands, USA, Belgium, Slovenia, Canada and South Africa).

Moulds Event 2014 attracted 800 participants

The week included a number of technical conferences

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news Flexible automation for medical device manufacture Flexible automation is key to meeting the demands of the medical device manufacturing industry, according to the director of Leicester-based ATM Automation.

Sabir Hirji says that as components become more complex, volumes increase and competition between manufacturers of similar products or devices necessitates changes in production, traditional, dedicated automation solutions can be limiting. “Whilst fast and efficient, this approach has limitations in output, as the machine will have been designed to operate at a fixed speed, and this type of machine generally lacks flexibility for additional or new product types,� Hirji explained.

New medical devices, drug delivery and diagnostic test systems have influenced the technologies used within medical sector automation. As these products become more complex, the

number of individual operations needed to complete an assembly often increases, as has the number of different technologies used in production. “Supplying automation into the medical sector today is not just about adhering to the stringent regulatory standards and procedures,� Hirji continued. “The ongoing development by manufacturers in new generation products means that they are seeking far greater levels of flexibility and future-proofing within their production systems.�

Changes within the manufacturing process have an impact on almost every part of an automated system, including the mechanisms and methods used to feed the individual parts to the machine. “Whilst traditional vibratory bowl feeders perform well for single variant products, re-tooling these systems for additional products can sometimes mean compromises in performance and reduced uptimes due to time lost changing tooling for the different component types,� said Hirji. “Vision guided robots, however, offer the flexibility needed to cater for multiple part variants, and the latest generation compact 6 axis robots, and Delta-type robots, are extremely fast. Combining these types of robot with machine vision and a flexible feeding system means that the robot can locate and pick parts

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presented in different positions and orientations, as well as identify and handle multiple part variants.�

This concept also offers additional benefits at the proof of principle and prototype stages of a project, says Hirji, by allowing handling, assembly and cycle time trials to be conducted, using what is effectively production-level equipment.

The flexibility offered by robots also mean that any other automation elements used as part of the overall solution, for example rotary indexing tables, can if required, incorporate several component or variant specific fixtures. This enables multiple part types to be produced within the same system without the need for any tool changes, as the robot will use the appropriate fixture for the part being produced at the time. “This cellular, or modular approach, offers a number of benefits to the manufacturer, including greater ‘elasticity’in the process in the event of stoppages and the flexibility to change quickly from one part variant to another.�

This concept is also said to make scalability more easily achievable, when production volumes need to increase to meet market demand. further information: www.atmautomation.com

Global medical polymer market to reach USD 17.05 billion by 2020, report suggests The global market for medical polymers is expected to reach USD 17.05 billion by 2020, according to a new report.

Grand View Reseach says increasing substitution of conventional materials such as glass and metals in medical devices by high performance polymers such as PVC and polypropylene, coupled with growing demand for medical devices from the fast developing Asian healthcare market, is expected to drive medical polymer demand over the next six years.

In addition, the growing geriatric population is expected to further boost the demand for polymer-based devices in minimally invasive surgeries resulting in increased demand for medical polymers.

Devices and equipment were the largest application markets, accounting for over 2,000 kilo tonnes of medical polymer demand in 2013, the report finds. Growing medical tourism, due to low-cost labour and advanced facilitates in emerging healthcare destinations is expected to have positive impact on the market over the forecast period. The extensive use of medical polymers in medical packaging applications accounted for 2,271.3 kilo tonnes of demand in 2013. further information: www.grandviewresearch.com

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Boosting Innovation in Medical Product Development A new micro moulding technology said to be ideally suited to the demands of medical device OEMs, or sectors where precision is key, has been developed that uses ultrasonic vibration as the plastic melting agent.

The new technology has been developed

by Barcelona-based micro moulding expert, Ultrasion SL, in order to produce smaller and more complex parts whilst achieving both material and energy savings compared to the traditional micro injection moulding process.

The recently introduced Sonorus 1G ultrasonic micro moulding machine uses no barrels, screws, and heater elements and has The technology has been designed for smaller and more complex medical device manufacture

a small footprint of 1.8 metres tall by less than a metre wide and deep.

The machine has a dosage system that delivers the correct quantity of standard pellets for every shot direct to the mould. The production cycle begins with the mould already closed and dosed with raw polymer at room temperature. The material is then contacted by an ultrasonic horn or “sonotrode” which is lowered, and as well as melting the polymer forces the material to flow into the mould cavities. The sonotrode then returns to its original position, and the cycle begins again.

“Ultrasonic micro moulding technology is outstandingly precise, uses no heaters, and the process means there is no material residence time, and no material degradation which are huge issues in micro manufacturing applications,” explained Enric Sirera, Sales Director at Ultrasion SL. “Also, as energy is only imparted for a split second when the ultrasonic horn contacts the raw polymer to induce melt, the technology uses up to 90 percent less energy than traditional micro injection moulding.”

What is radically different about ultrasonic melting, according to Ultrasion SL, are the differences in melted material characteristics produced, and the knock-on effect that this has for various other process developments and product design.

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“The key is that ultrasonic melting reduces the viscosity of melted plastic, this being a biproduct of the ultrasonic agitation itself, and the fact that the new sprue concept in the Ultrasion technology means that it behaves as an energy director as well as part of the ejection system. The energy director orientates the waves in the flow direction, therefore the molten material and waves travel together toward the cavities, reducing the viscosity of the polymer,” continued Sirera. “It’s all about applying a high intensity mechanical vibration that transmits energy directly into the polymer molecular structure resulting in a very fast and efficient melting ‘inside-out’ rather than ‘outside-in’; typically how melting occurs in injection moulding via electric heaters.”

The company says in real terms, this particular characteristic of the ultrasonic moulding process means that 15 mm long parts with wall thicknesses of 0.075 mm are easily attainable. Achievable tolerances are as tight as 0.01 mm. This reduced material viscosity also means that the moulding pressures required are much reduced over traditional micro moulding technologies, meaning it’s possible to use delicate and precise core pins and insert configurations that would break under normal pressures. further information: www.ultrasion.com

Sumitomo (SHI) Demag’s ISO 7 activeCell, a self-contained injection moulding cleanroom, as used by Carclo Technical Plastics (CTP).

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Sumitomo (SHI) Demag Plastics Machinery (UK) Ltd Accent House · Triangle Business Park Stoke Mandeville · Bucks · HP22 5BL T: +44 (0)1296 739500 F: +44 (0)1296 739501 E: sales.uk@dpg.com www.sumitomo-demag.co.uk

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Static control for cleanroom moulding is just what the doctor ordered Contamination attracted by static is a major issue in a cleanroom-manufacturing environment

W

hile injection moulding is highly effective for both manufacturing, labelling and packaging applications, users of the technology need to take into account the fact that static electricity can have an effect on contamination control by attracting dust and dirt that can have an adverse effect on the overall Demand for cleanroom conditions quality of a product.

Businesses in a in injection moulding processes large number of has expanded exponentially in sectors, including recent years as growing numbers food and of medical and pharmaceutical electronics, and manufacturers come to rely on the particularly medical technology to meet the and requirements of the European pharmaceutical, are Medical Devices Directive. Stewart forced to dispose of Gordon-Smith, Export Sales any products Engineer at Meech International, affected by dust or looks at how controlling static in dirt, making it essential that they the cleanroom can help eliminate prevent this in order costly contamination. to avoid costly waste. This is why they perform injection moulding applications and packaging processes in contamination-free environments.

While the food industry is concerned with brand protection, avoiding perishing and ensuring that a product’s image isn’t tarnished in the eye of the consumer, the medical and pharmaceutical sector is obviously more concerned with contamination control from a sanitary point of view. The presence of even the smallest amount of static charge can attract fibres and small specs of dust to products that need to be kept sterile, such as catheters, stents, scalpels, syringes and hypodermic needles.

There are a series of eventualities that need to be taken into consideration when addressing the issue of static in the medical and pharmaceutical sectors. For instance, in the case of a number of small medical components, the accumulated static charge is actually greater than the weight of the product itself, which in turn can cause them to stick to the surface of the moulding components. If the moulding tool closes with the product still attached to the tool face, the product could be noticeably damaged and have to be disposed of.

Another example can be observed during the packaging and storage phases. When a statically charged product is placed in a plastic bag following the moulding stage, there is a risk that the charge on the product will fail to neutralise for as the length of time that it’s contained within the sealed plastic environment. As a consequence, the charge will cause the packaging to attract contamination onto its outside surface. Furthermore, once the plastic bag has been opened, an even higher degree of the contamination will be instantly drawn to the product.

What some fail to realise is that the sterile blister packaging is every bit as important as the product inside, since even the most minimal source of contamination will result in the item being rejected. In fact, the most frequent source of contamination within a cleanroom environment is actually the operative. Eyelashes, strands of hair and skin follicles are all bp&r capable of being attracted to the packaging’s surface by static

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lutions can be Static-control so arge nate unwanted ch employed to elimi

charge, ultimately leading to the product’s rejection.

For these reasons there needs to be an awareness of the effects and repercussions static charges can have on both productivity and product quality, as well as a range of ionising solutions that meet the ever increasing demands of the businesses operating within the medical sector. By employing pulsed DC static control equipment, a long range ionising system removes and controls the static charges, while the product cools to meet ambient temperature. If air assisted ionising systems are used in this process, a possible side effect is that the airflow may redirect airborne contamination towards the mould’s surface.

Pulsed DC has the ability to create an ionising field large enough to not require air assistance.

For the sanitation-conscious medical and pharmaceutical industries, every possible step must be taken to eliminate possible sources of contamination. The use of injection moulding in packaging to prevent contamination and counterfeiting of sterile equipment and pharmaceuticals is one such step, but static elimination and control is a vital element of maintaining sterile conditions and it is important not to underestimate the savings it can deliver. further information: www.meech.com

machinery

Engineering Passion

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news UK auto supplier to save â€œÂŁ20,000 plus a monthâ€? with new machine A UK-based automotive parts specialist says the arrival of a new plastic injection moulding machine equipped with a bespoke two shot unit will save it over ÂŁ20,000 a month and eliminate a production headache.

DMS Chromium, which supplies the automotive trade with a range of chromium-plated plastic injection moulding products, has invested in a Romi-Sandretto EN 380 to replace a 400tonne machine bought at auction.

The company handles many vehicle components which need a chromium front face but no chromium on the back because clips need to be heat welded. In one instance the company needed to produce 15,000 speakers and had to hand paint out the chromium which took nine people, working over three shifts, to complete.

“This was proving a real cost burden.

I developed a new moulding tool and Romi-Sandretto agreed to adapt this machine which handles two different plastics simultaneously,â€? commented Chris Sharpe, Managing Director of the Kidderminster-based company. “It not only saves us ÂŁ20,000 a month, allowing us to recoup the additional sum we paid for the turnkey solution within three months, but it will also create a raft of new sales opportunities,â€? Sharpe added.

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further information: www.sandretto.co.uk

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software directory manufacturing management directory

Machinery sales forecast set to be exceeded

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ith half of the year already behind us, it seems that now is a good time to take stock. Talking with members, it appears that the UK plastics industry is enjoying a very good 2014 so far. At the end of last In his column this year, 550 injection moulding units, month, Nigel Flowers, valued at around £80 million, were Chairman of the forecast to be sold in 2014. It appears that this was a PMMDA, talks conservative estimate. From machinery sales, discussions with PMMDA members, robots breaking the we seem to be on track to exceed law and “signing off 700 units, 30 percent more than the paperwork”. the initial projection. This makes it the highest level of investment we, as an industry, will have experienced in the last decade. All of this is a very positive sign for the injection moulding industry moving forward.

Levels of investment in automation are also on the increase, both for new and existing moulding machines. However, one area we should all be mindful of is maintaining CE compliance. With the Supply of Machinery (Safety) Regulations 2008, amended in 2011, it became mandatory for a complete robotic cell to carry a CE mark.

The directive also stated that whoever created the final installation – whether integrator or end-user – was responsible for obtaining this certification.

Many companies are unaware that the onus for CE marking their robotic injection moulding equipment has shifted. As a result, they may be breaching the law. Our duty, as the suppliers of equipment, is to reduce the complexity and ensure clients understand the ins and outs of compliance to ensure that they’re not exposing themselves to financial penalties.

Wrapping things up, following the amicable split from the PPMA earlier this year, the PMMDA has spent the early part of 2014 getting the ‘paperwork’ in order. Representing 27 members across all sectors, I can say with utmost confidence that the PMMDA remains the voice of UK polymer equipment suppliers. Knowing that the committee remains committed to ‘your PMMDA’, and is working hard to deliver the benefits and services that you demand, it is now time to move forward and capture the business opportunities. further information: www.pmmda.org.uk

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It seamlessly integrates with Epicor Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

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

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 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).

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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.

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buyersâ&#x20AC;&#x2122; guide

materials

equipment

mould release 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.

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ultrasonic welding

control systems and equipment quality monitoring control

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

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.

material handlinG InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

Dosing equipment

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

polymer distributors

vibration welding

ancillary masterbatch

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

extrusion systems chillers/temperature extruders and downstream controllers equipment Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

FOR SALE for sale/WANTED

Reheat Stretch Blow Moulding Machine (PET)

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

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granulators

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assembly

thermocouples

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

pulse staking H.T.E Engineering Ltd

Motan Colortronic Ltd

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Unit 9, St Ives Enterprise Centre, St Ives, Huntingdon Cambridgeshire, UK, PE27 3NP

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T: +44 (0) 1480 467321 M: +44 (0) 7435 967632 E: john@hte.ie W: www.pulsestaker.com

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

granulators

dryers/dehumidifiers

secondhand and reconditioned

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

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

infra red systems

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

mixing, feeding, drying Motan Colortronic Ltd

heating equipment

3d printing

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

Injection Moulding

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

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

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

materials handling and storage Buy and Sell Cable and Plastics Machinery

gravimetric/volumetric blending

LABORATORY machines

printing machines pad

Floatair tumble mixer 250kg capacity

Rapid Granulator type 4535/KV Please Contact:

T: +44 (0)1204 534414 E: sales@goodwinmachinery.co.uk W: www.goodwinmachinery.co.uk

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

hot runner systems DTL Machinery UK

screws and barrels

hopper loaders

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

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

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 â&#x20AC;&#x201C; market leaders in static control systems.

testing equipment

50mm x 24:1 Boston Matthews extruder 90mm x 24:1 Francis Shaw extruder

hopper dryers

hot runner controllers

Arrowquint Ltd

Presently Available:

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

static control

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

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

hardness - IRHD and shore MAPRA Technik Co â&#x20AC;&#x201D; BAREISS For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers.

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

World leader in Materials Testing Instrumentation Tensile|Fatigue| Impact Compression|Melt Flow Coronation Road, High Wycombe, Bucks HP12 3SY, UK Tel: +44 1494 464646

www.instron.com

49 bp&r

buyers’ guide mouldflow analysis

equipment

Contract cleaning Injection Moulding Extrusion

testing equipment inspection & measurement MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER For DOSS visual solution of Italy –Inspection & sorting machines for O’rings, Seals, Gaskets.

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

• • • • • •

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

services mouldflow analysis

parts & services

injection moulding

EXTRUSION FLOW ANAYLYSIS FLEMING Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in the flow simulation of: Extruder screws & spiral mandrel,flat spiral,profile, coathanger & coex dies Compuplast distributor Stop guessing start simulating Tel: +44 (0)1299 253300 www.flemingptc.co.uk

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

contact lisa montgomery 01244 680222

Main duties: l Sales of equipment and systems to end users, machinery manufacturers and dealers. l Conduct site surveys and assess customer needs for new installations or upgrades to current equipment. l Preparing system design quotations for customers. l Reporting sales activity to the UK Sales Manager. l Liaising with project team and service engineers.

Requirements: l Proven track record in sales OR engineering/production background and a willingness to learn. l IT skills in all Microsoft Office systems. l The ability to interpret customerʼs requirements. l Commercial awareness.

In return the successful applicant can expect a good salary, sales commission, company car, pension, medical insurance, life assurance and generous holiday entitlement.

50 bp&r

For a full job description and application please send a CV to James Panton, UK Sales Manager by email jap@kongskilde.com or by post at Kongskilde UK Ltd, Hempstead Road, Holt, Norfolk NR25 6EE

Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at

printers of plastic mouldings

To advertise in this space

Role: Northern Area Sales Manager responsible for developing new business/sales in the field of pneumatic conveying systems and waste extraction systems for the plastics, paper, packaging and recycling sectors.

EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.

printers

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

Due to continuing growth Kongskilde UK is looking to expand its sales force in the northern area of the UK. The ideal candidate will be living in either the Manchester or Newcastle area covering northern England and all of Scotland.

RECYCLING systems

CHOOSE THE NUMBER ONE.

testing/consultancy FLEMING Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in: Capillary rheometry FTIR DSC/TGA MFR/MVR Extrusion Pilot-scale blown film Line Instrumented impact Flow simulation Tel: +44 (0)1299 253300 www.flemingptc.co.uk

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

STAND G60