BP&R March 2013

British Plastics

and Rubber

bp&r

THE MONTHLY MAGAZINE FOR BRITAIN’S POLYMER PROCESSORS

MARCH 2013

High-performance engineered plastics Static: The invisible influence

Plasma coating under normal pressure

3D Printing: Behind the hype

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

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

ART

Award has designs on

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

UK Plastic INnovation SUBSCRIPTIONS From architecture that puts the promote all that design in plastics stands ‘space’ in space-saving design and for,” said Keith Pinker, the Master of The lighting styles that are akin to a stellar Horners Company. explosion, to life-changing prosthetic Previous winners have showcased a limbs, futuristic automotives and a whole broad range of industries, including the host of ‘oh-so-now’ ‘birthing baby’, a medical products that are device for maternity “The calibre of paving the way for wards, the ‘Cycloc’, an entrants year-after- innovative device for modern living and defining a generation year demonstrates its space-saving bike storage (think Trunki, Tangle uniqueness and how as well as the the Teezer et. al.), UK ‘Durakerb’ lightweighting vital it is to promote kerbing system, which plastic product design is an exciting, won a contract to supply all that design in important and hugely plastics stands for” the London 2012 lucrative industry.

Olympics.

Keith Pinker In order to promote The closing date for the talent, creativity and entries is 27th July, with entrepreneurship of UK plastics design, the winner being presented with their this month sees the launch of the 2013 award in October. More information Worshipful Company of Horners’ Award about the design award, as well as the for Plastics Design and Innovation, Bottlemakers award for exemplary design believed to be the oldest plastics design in plastic bottles, jars or hollow award in the world, which champions and containers, is available at celebrates the very best of plastic design. www.hornersaward.co.uk. So if you have The award encourages excellence in a product worthy of entry, or know UK expertise, with entries being judged someone who does, don’t miss the on their design innovation, commercial opportunity to shout about the UK’s potential and success, environmental enviable plastic product design. advantage and UK content. “The calibre of entrants year-after-year demonstrates Enjoy the issue, its uniqueness and how vital it is to Leanne Taylor — Editor

T: +44(0)1244 680222 E: subscriptions@rapidnews.com

PUBLISHER Mark Blezard T: +44(0)1244 680222 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (10 times/year) by Plastics Multimedia Communications Ltd, Unit 2, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44(0)1244 680222 F: +44(01244 671074 © 2013 Plastics Multimedia Communications Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

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

Associated organisations

THE BIG STORY New easy-moulding nylon to replace metal in cars New Radilon A RV500RW 339 NER is a nylon 66 with 50 percent glass fibre from Radici Plastics in Italy, available in the UK through Plastribution, that moulds easily while offering new opportunities for metal replacement.

With the use of plastics in cars expected to continue to rise considerably, the new material extends metal replacement opportunities and allows moulders to produce components that are not only lighter – and thus more environmentally friendly – but more complex, with multiple integrated functions.

Enhanced Performance When testing Radilon A RV500RW 339 NER against a competing 50 percent glass-filled nylon 66, property improvements can be observed across the board. Measured at 23°C, tensile strength of the new grade reached 260 MPa, a 12 percent increase over the other material tested. Strain at break was also about 12 percent better at higher temperatures (150°C). Tensile strength at weld lines was reported to be 20 percent higher than the competing 50 percent glass compound.

Results of notched and un-notched Charpy impact test results showed that Radilon A RV500RW 339 NER is up to 30 percent tougher than the other material tested. Other important characteristics of automotive structural materials are high-speed stress-strain properties. Radici’s tests show that the stiffness and energy absorption of the Radilon A compound are greater than for competing compounds at all load application speeds. These improved dynamic properties make this material particularly suitable for applications such as engine mounts and gearbox housings.

A chart showing the tensile strength of the material

The material exhibits significant improvements in fatigue limits compared with competing grades, and a noticeable advantage in creep resistance, which is critical for applications such as valve covers and oil cups, because these components are subjected to a constant load for their entire useful life, and maximum oil tightness is always required.

Easy to Mould

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Production tests conducted by Radici reveal that the material processes almost exactly like the standard glass-filled nylon 66.

During its development, particular attention was paid to the material’s mechanical properties when it was exposed to high processing temperatures for prolonged hold times.

Through the introduction of Radion A RV500RW 339 NER, Radici is bringing to market a material that can be moulded at temperatures about 300°C in order to maximise weld-line strength without polymer degradation.

The chart indicates that the tensile strength of the material, with and without weld lines, does not change for melt temperatures of up to 310°C and barrel hold times of up to six minutes.

One of the first commercial applications to benefit from the new material is a gear-shift cable reaction bracket, previously made in aluminium, that has been developed by the Italian moulder Sila Holding in collaboration with Radici. The switch from aluminium to Radilon A RV500RW 339 NER resulted in the component weighing 30 percent less and becoming 20 percent cheaper to produce.

Further Information: www.plastribution.co.uk

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on the cover

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High-performance High-per formance engineered plastics engineer

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bp&r BRITISH PLASTICS &RUBBER

contents MARCH 2013

on the cover New easy-moulding nylon to replace metal in cars New Radilon A RV500RW 339 NER is a nylon 66 with 50 percent glass fibre from Radici Plastics in Italy, available in the UK through Plastribution, that moulds easily while offering new opportunities for metal replacement.

See page 4

3 EDITOR’S LETTER Award has designs on UK plastic innovation

10-15 FEATURE TEMPERATURE CONTROL UK start-up gets a cool boost with 90 percent energy savings

20-23 FEATURE Thermoplastics Update New polycarbonate grades for furniture are clear winners

24-27 ]FEATURE

From the Front Line

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RECLAMATION AND RECYCLING 32 Engineering Materials

38

Injection Moulding

40

Currency Corner

43

SOFTWARE

43

BUYERS’ GUIDE

44

Anti-Counterfeit Understanding the landscape of innovation

29-31 FEATURE STATIC CONTROL Static: The invisible influence

34-36 FEATURE 3D Printing

16-19 FEATURE

REGULARS

26

3D Printing: Behind the hype

PLASMA Plasma coating under normal pressure

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INDUSTRY

news Helping to promote positive perceptions of polymers UK universities are once again playing host to science and teachers from across the country in order to promote plastics and rubber technology and encourage its place in the classroom.

Bookings for the 2013 Polymer Study Tours, which are held at the Universities of Manchester, London Metropolitan and Edinburgh Napier, are now being taken.

Over the previous 25 years, more than 2800 teachers have taken advantage of the opportunity to attend the course, which, thanks to the sponsorship of companies and industry bodies, is free to all participants.

The courses are organised under the aegis of founder sponsor, the Worshipful Company of Horners Educational Trust.

The IOM3 helps to promote the course and manage the delegate administration and the BPF offers financial management and sponsorship via individual BPF Groups.

The course gives delegates the opportunity to enhance their knowledge of plastics and rubber technology and provides sources of material relevant to the modern curriculum.

Any companies or BPF Groups wishing to sponsor the Polymer Study Tours can also get details from the website below.

BPF members are encouraged to publicise the Tours to their local secondary schools.

Teachers get real experience operating processing equipment

Further Information: www.polymer-teachingresources.com

FROM THE FRONT LINE This month, Philip Law, Public and Industrial Affairs Director at the British Plastics Federation, writes for BP&R on what has been a Davis added: “this will be an uphill period of high profile activity for the organisation, which saw struggle.” television appearances as well as a political meeting.

Davis dismissed Iron's pressure for a

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This has been an extremely busy period had been launched earlier in the day. Irons of high profile activity for the BPF. In a has developed a lesser-known career as a single week the Federation was featured on maker of documentary films with an television twice and also managed to environmental twist. secure a meeting with the Chancellor of the In the 10-minute interchange, Peter Exchequer, George Osborne.

Davis was able to explain the industry's Firstly, Bang Goes the Theory, a BBC1 increasingly impressive record in bottle science magazine programme, explored recycling and how further progress can be the relationship between plastics and made through improvements in the quality society and benefited from a considerable of the used plastics streams emerging from body of information provided by the BPF, together with interviews with Product Safety Committee Chairman, Chris Howick, and BPF Member, Chris Dow of Closed Loop Recycling. We provided the BBC's research and production team full briefing on innovative products, the benefits of plastics and our take on some key issues, particularly food Peter Davis (left) featured on a Channel 4 contact safety. On this occasion I programme to debate plastics waste think we were able to have some influence.

Local Authority Materials Reclamation The highlight of the month was BPF Facilities. He added that much rests on the Director General Peter Davis participation willingness of Local Authorities to in a Channel 4 News feature on March 4th standardise their collections, a point which in debate with film actor, Jeremy Irons, over Irons concurred with. But with all political the green paper on plastics waste, which parties emphasising localism agendas,

plastic bag tax, pointing to their reuse and recyclability. He was also able to explain to Irons the functioning of the Producer Responsibility Compliance schemes, which raise a levy on packaging manufacturers to support recycling. Irons was unaware of this.

Less heady but probably more important, a BPF team eyeballed George Osborne when he visited one of his constituents, Albis Plastics, in Knutsford.

Albis’ Managing Director, Ian Mills, had set the meeting up to discuss the BPF’s Document, ‘The UK Plastics Industry: A Strategic Manufacturing Sector’.

BPF President, Philip Watkins, joined Peter Davis in pressing our concerns about future security of energy supply and costs, adding that that much more Energy from Waste capacity could meet 10 percent of our energy needs from unrecyclables. They asked for VAT on ‘green deal’ plastics products to be reduced to five percent, the cancellation of future fuel duty increases and further reductions in corporation tax.

They told the Chancellor that we wanted to see more measures to stimulate house buying by first-time buyers.

Further Information: www.bpf.co.uk

INDUSTRY

news British company makes first ever 100 percent recycled plastic cups Invicta Plastics Ltd, the British design and mould specialist that invented the plastic ruler, states it has beaten global competition to create the world’s first rigid, food-safe products from 100 percent recycled plastic bottles (PET), lids and milk cartons (HDPE).

The company says the breakthroughs have taken almost four years of research and millions of pounds of investment in the new technology.

Coca-Cola, a client of Invicta Plastics for over 50 years, is said to be amongst the first brands to test these new products, whilst Coca-Cola Enterprises, Greenpac and retail giant, Asda, are all said to be working with Invicta to explore the potential of these processes for point-of-sale products and merchandise.

CEO of Invicta Group, the Countess of Onslow, said: “Never before have regular plastic drinking bottles, bottle lids and milk cartons been given a new life, such as becoming high quality low cost injection moulded cups, plates and tablewear, toys and marketing products, fashion accessories and socially responsible educational equipment in every colour without some sort of virgin polymer or stabiliser added – until now.

“We trialled and tested hundreds of recycled materials sourced in the UK, Europe and the USA and created two new processes that we have called rPETable and rNEWable. These processes were developed keeping in pace with the rapid technical improvements in recycling and recycled material production in the last three years.

“It is our mission to work with major brands to spread the word, help protect the world’s natural resources, save our customers and the consumer money and reduce carbon footprints - in many cases by one simple switch: swapping virgin polymers for one of a wide choice of high quality recycled plastics including rPET and rHDPE.” Invicta says it is the intention that rPETable and rNEWable will grow globally with like-minded partners who work with major brands - and to do this, the company is seeking partners in order to expand.

Liam Knowles, Sales and Marketing Director at Greenpac UK, said: “We were the first to create a product using Invicta’s rPETable process - and now that every test has been passed to prove that these products are rigid, durable and food safe, it’s realistic to say that no business should ever need to use a single virgin polymer again for this type of product.

“This puts Britain years ahead of other injection moulders.

The processes make moulding in recycled materials very cost effective and can lower carbon footprints significantly. They also radically reduce resource depletion because they can be recycled time and time again. We now need more brands – big and small – to commission products and merchandise using this process,” he continued.

With Reckitt Benckiser, Unilever, Hasbro and many major global drinks brands including Guinness among the longest standing clients of Invicta, the company says there are tremendous opportunities to promote rPETable and rNEWable to these brand giants.

Further Information: www.invictagroup.co.uK

rPETable and rNEWable are trademarks of Invicta Plastics Ltd

The new products are being trialled by some of the world’s biggest brands.

Credit: Stewart Goldstein

TEMPERATURE CONTROL

www.quick-mould-change.com

news New mould temperature control connectors eliminate spillage Stäubli has introduced a new range of compact multi-connectors for mould temperature control circuits that it says totally eliminates spillage and prevents any pollutants entering the system on connection or disconnection.

Stäubli, the specialist in connection technology, has added a new multiconnector to its wide range of products specifically designed for the plastics market. Designated MCI 209, the new design is a compact, flat faced multicoupling capable of connecting up to 10 separate mould cooling circuits. The flat faced design is said to eliminate any spillage on connection or disconnection, improving safety by preventing the risk of leaking high temperature or water glycol fluids making floors slippery, as well as minimising the consumption of heat transfer fluids. Stäubli states the design also ensures no ingress of contaminants into the circuits that could affect the performance of the cooling fluid and increase the maintenance required on the system.

Ensuring safe and effective connections is of prime importance and the MCI 209 range is said to incorporate a fool proof keying system that prevents connection errors and eliminates any risk of cross connection; the robust locking system ensures circuit integrity. Stäubli says all circuit connections are made by one simple action, reducing the time to change moulds. The optional proximity

The MCI 209

switch ensures safe working practices are maintained by providing direct indication that the plates are securely together. A parking plate provides the additional benefit of protecting the machine side plate during a tool change and improving safety by retaining loose hoses.

Stäubli states MCI 209 is suitable for both new and existing injection moulding machines and moulds, as well as other

applications where fluid circuits need to be connected and disconnected without any spillage, for example in the medical and pharmaceutical markets. CAD files of the new connector are available on request.

Further Information: www.staubli.com/en/connectors

Email: connectors.uk@staubli.com

The Adcooler reportedly saved Signal Plastic Components 90 percent in energy costs

Case Study: UK start-up gets a cool boost with 90 percent energy savings Process cooling specialist, IsoCool, has supplied an energy saving cooling solution to start-up injection moulder, Signal Plastic Components, which it says has resulted in a dramatic overnight saving of 90 percent on previous costs.

Installed in September 2012, IsoCool’s Adcooler adiabatic dry cooler was provided on a 12-month interest free loan to Signal Plastic Components, a company that is expanding rapidly after a successful first year in business.

Signal Plastic Components currently operate six presses at its factory in Washington, Tyne and Wear, where it manufactures plastic injection mouldings for a variety of industries. Historically, these machines were cooled to the required 20°C by a traditional refrigeration chiller, which was specified and installed by another cooling company. However, high energy costs quickly led Managing Director of Signal Plastic Components, Alan Franklin, to question the efficiency of the system.

“My expertise is in plastics manufacturing, not cooling, but even I could see that the running costs were too high,” he said.

IsoCool reviewed Signal Plastics’ existing set up, including the type and positioning of the system and proposed replacing the chiller with the Adcooler, an intelligent adiabatic dry cooler that switches automatically between dry and wet bulb operation according to the ambient temperature and humidity, in order to maximise the efficiency of the cooling system.

“Essentially, the Adcooler functions as an air blast cooler during low ambient conditions, providing up to 100 percent direct air cooling, and an adiabatic cooler when the ambient is higher than the set point temperature,” explained Nigel Hallett, Managing Director of IsoCool. “As a result it is far more efficient than a traditional chiller, which has a much higher installed power.”

Signal Plastic Components installed the Adcooler and said that results were immediate. The recent cool weather meant that the Adcooler ran in free cooling mode immediately, consuming only minimal power to run the fans. “As soon as we switched the Adcooler on our cooling costs went down by over 90 percent,” said Mr Franklin.

“We’re saving over £500 a month on energy bills at the moment, which makes a big difference to a small, growing company,” he continued. “We’ve been able to invest back into the business, and thanks to being more cost-efficient, enjoyed a brilliant last quarter – we won some really big automotive contracts, moved to bigger premises and employed more staff.

In fact, we’ve already taken another free-standing chiller from IsoCool to work with a special application that requires mould cooling below 10°C.” Further Information: www.isocool.ltd.uk

TEMPERATURE CONTROL

Tel: 01952 671918

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TEMPERATURE CONTROL

www.quick-mould-change.com

news

Frigosystem expands and develops chillers for plastics processors Frigosystem, an Italian supplier of temperature control equipment for heating, cooling and chilling of water, oil and air, says it is continuing to develop and enlarge its range of products in order to increase energy savings and product life.

One such development is the improved Raca Plus Energy chiller, which has new features that the company claims sets it apart from its competitors.

The new Raca Plus Energy series employs scroll compressors and uses new technology aluminium micro-channel condensers that are said to ensure a premium level of efficiency. This solution also allows the reduction in the volume of refrigerant gas by 40 percent in

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Frigosystem has expanded and developed its range of chillers

comparison to traditional copper/aluminium coils as well as improving the resistance against galvanic corrosion. Micro channel coils are easy to clean as they can be washed with a highpressure sprayer without bending the fins.

The product range has also been extended and now starts from 50kW up to 1,200kW cooling capacity and comes with multicircuit and multicompressor systems that may be specified with or without reservoir or pumps. Efficiency has reportedly been maintained while increasing the ambient operating temperature range from 43°C to 45°C. Frigosystem states these chillers may be specified with dual water circuits providing both chilled and cooled water circuits while utilising a common return.

The company says all Raca Plus Energy and Raca E chillers may further be specified with free cooling to further improve energy savings.

Miriam Olivi, Sales Manager of Frigosystem, supplier to UK distributor Intelicare, said: “Our range of Raca Plus Energy chillers set themselves well apart from other chillers having been developed for the heavy duty cycle requirements and precise temperature control of the plastics processing industry, unlike some chillers on the market today, which have evolved or been extended from chillers primarily developed for air conditioning applications where such duty cycles and temperature control are much less demanding.”

Further Information: www.intelicare.co.uk

Email: connectors.uk@staubli.com

news Ticona employs hot water technology for temperature control Conventional wisdom suggests hot oil is a preferred temperature control fluid for injection moulding, but Ticona, the engineering polymers business of Celanese Corporation, states it has found that processors can use hot water systems to achieve superior heat transfer performance suitable for high-temperature resins such as its semi-crystalline polymer, Fortron polyphenylene sulfide (PPS).

“We have repeatedly observed that commercially available, high pressure hot water technology provides sufficient heat transfer, which ensures optimum uniform tool heating for moulding highperformance materials like Fortron PPS,” said John Farrell, Global Leader Processing Labs, Ticona. “In addition, Ticona polymer processing teams in the

Americas, Europe and Asia found that water systems are a cleaner, safer and better environmental choice for efficient mould temperature control.”

Ticona processing engineers validated the moulding of Fortron PPS with various hot water systems, including units from Wittmann Inc. and SINGLE Temperature Controls Inc. Using typical ISO conditions for moulding Fortron PPS, they compared traditional systems and evaluated the characteristics of the different heattransfer fluids.

“We looked for improved heating of injection mould tooling considering the challenges using hot oil,” Farrell said. “Our teams confirmed the heat transfer of water is better than oil and can achieve the appropriate crystalline content of a higher-performance thermoplastic such as Fortron PPS.”

Specifically, Ticona said its processing teams determined that water-pressure heaters are better at controlling temperature, as water is a superior heat transfer medium than oil, which often needs to be 37.77°C hotter to achieve the same temperature as water; superior to electrically heated tools, as cartridge heaters transfer heat into the tool and part, but have only passive cooling, which can lead to poor process control and part variability; and also, that they are cleaner and safer than oil systems as water is inexpensive, can be easily disposed of and does not degrade when exposed to air.

TEMPERATURE CONTROL

Tel: 01952 671918

Further Information: www.celanese.com/ticona

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TEMPERATURE CONTROL

www.quick-mould-change.com

news Continued development of cooling Wittmann Battenfeld unveiled the latest expansion of its Tempro series of temperature controllers at Fakuma 2012 and is set to reveal further development at K 2013.

Wittmann states its three newest models, the Primus C120, the Tempro Plus D and the Tempro with variotherm functioning, represent leading technological edge for temperature control in the plastics industry.

The directly cooled Tempro direct C120 temperature controller was developed in response to the industry’s demand for directly cooled controllers and Wittmann states the unit has become popular with plastics processors over the past few years. The company now offers many variants of the Tempro direct C120 in regards to different pumps and different heating and cooling capacities.

The dimensions of the new unit are said to be the same as of the Tempro primus C90 and it therefore meets the requirements of a compact beside-thepress unit. Wittmann states it can be used at temperatures of up to a maximum of 120°C, with a standard heating output of 9 kW and a maximum delivery rate of 200 l at 2.4 bar operating pressure. It is suitable for all applications where high cooling performance and high delivery rates are both required.

ICS launches range of thermoregulators for hygienic conditions

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ICS Temperature Control has launched a range of thermoregulators and temperature controllers with an IP65 rating. Said to feature the latest touch screen technology, the C7 Advanced Controller offers recipe control, temperature, flow and pressure trending, selectable languages and data logging which can be saved to an SD card for validation requirements.

The products, which are manufactured in the UK under the brand name ICS Tricool Thermal, have reportedly been developed for hygienic and hose-down

Wittmann Battenfeld is set to unveil further expansions to its range of temperature control equipment at K 2013

The development of plastics markets and the new applications that go along with it make new demands on peripheral equipment and developers at Wittmann say higher temperatures for controllers have yet again increased. The pressurised models (140–180°C) of the high-end appliance series Tempro plus D are, therefore, now available with an optional heating output of 16 kW per temperature control circuit. Tempro plus D appliances are equipped with a dimensioned 5.7" LCD colour screen as standard. Various buttons on the display are freely

configurable so that the data required in each case can be retrieved exactly as desired by the operator.

In addition, the Tempro plus D Vario is now available. Here, the cavity temperature is measured via a thermal element thus allowing for heating up and cooling the cavity to a defined temperature. Heating time and cooling time are determined anew for every cycle, thus increasing the stability of the process.

Further Information: www.wittmann.co.uk

ICS has launched a new range of temperature control equipment

areas across a range of industries. All units are manufactured to ISO 9001 and ISO 14001 accreditations.

The range includes water heaters, oil heaters and pressurised water heaters, with capabilities ranging from 9-48kW and temperatures up to 160°C for water and 350°C for thermal oil which is said to

reduce heat up time by as much as 30 percent.

ICS says it has specifically designed the units so they can be tailored to manufacturers’ needs and if necessary, designed to communicate with higher-level machines or line controls through a wide range of electronic interfaces.

The Tricool units provide precise temperature control by distributing water through a closed circuit that maintains the temperature of the contents of jacketed vessels within a very tight tolerance.

Further Information: www.icstemp.com

news

Email: connectors.uk@staubli.com

The new Turbomiser chiller from Cool-Therm

Case Study: High efficiency chiller delivers hot energy savings Bristol-based cooling specialist, Cool-Therm, has announced that it has installed a new Turbomiser chiller at a flexible packaging manufacturer in order to maximise energy savings.

CoolTherm states the new, high-efficiency Turbomiser chiller, installed at Amcor Flexibles Winterbourne, operates on virtually frictionless magnetic bearings, to deliver lower power consumption and reduced carbon emissions.

It is believed to be the first chiller of its kind to be installed in the packaging sector.

During the project, Cool-Therm worked closely with staff at Amcor to replace one of the existing chillers at the site, after it had reached the end of its operational life.

Cool-Therm has worked with Amcor Flexibles Winterbourne for more than 20 years, installing and servicing three large chillers delivering the continuous chilled water required by the plant’s plastics extrusion machines.

Cool-Therm states the new Turbomiser chiller, installed alongside two existing McQuay centrifugal chillers, operates around the clock, all year round, maximising savings.

Andreij Duma, Operations Director at Amcor Flexibles Winterbourne, said: “Cool-Therm anticipated a 20 to 25 percent energy saving with the introduction of Turbomiser. However, the performance over the first six months looks even better than this, and the latest figures show a saving of just under 50 percent.”

Ken Strong, Managing Director of Cool-Therm, explained: “The period of use so far covers the warm season. We would expect even better efficiency still during winter. Here, Turbomiser can operate at lower condensing temperatures where the efficiency advantages are greatest.”

The ‘sweet spot’ for Turbomiser is considered to be 25 to 60 percent of load, where, due to its operating characteristics versus conventional chillers, energy efficiency for the delivered cooling capacity is maximised. Turbomiser is equipped with integral inverter drives, enabling very fine incremental adjustments to be made to precisely match chiller output to cooling load.

Cool-Therm states it is now working to fine-tune the cooling system to deliver further energy savings to customers.

TEMPERATURE CONTROL

Tel: 01952 671918

Further Information: www.cooltherm.co.uk

Twin-circuit heating and cooling unit launched Manufacturer of temperature control equipment, Tool-Temp, has launched a new model, which it says is ideally suited to moulders in the plastics and rubber industries.

The new TT13502E twin-circuit heating and cooling unit offers a temperature range from 10°C to 90°C and has two independent water circuits with two seal less pumps, stainless steel water tanks along with two 6kw heaters and 8kw of cooling capacity.

Tool-Temp states the new unit, manufactured in Switzerland, would suit many applications from running a small injection moulding cell to controlling the mould and tanks on a polyurethane rubber system.

Further Information: www.tool-temp.net

The new TT13502E

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New partnership in plasma treatment solutions for plastics Vetaphone, a manufacturer of corona and plasma treatment solutions for plastics, has announced a new partnership with the French-based company, Coating Plasma Industrie.

The flexible packaging industry has seen a considerable growth in specialised films over the past few years, and Vetaphone states its commitment to support the packaging industry and maintain its reputation has led it to team up with Coating Plasma Industrie.

Vetaphone states this partnership brings Coating Plasma Industrie’s experience and knowledge of the chemistry of plasma together with Vetaphone’s industry knowledge to ensure customers get the highest quality and most effective plasma surface treatment system on the market.

The Enhanced Atmospheric Surface Improvement (EASI) Plasma technology is said to provide a wide range of benefits for the coating and converting processes, such as nano coating, anti-fog properties, low surface ageing and higher dyne levels. It reduces production costs by eliminating the need to use expensive primer, while at the same time making the end film a much thinner and higher quality product.

Vetaphone states there is a great potential for saving resources and getting a superior surface by employing EASI-Plasma.

Further Information: www.vetaphone.com

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VE1G-A EASIPlasma Treater Station with quick-change electrode cartridges

Plasma monitoring in action (Credit: IKV)

PLASMA

news

Spectroscopic plasma monitoring investigated at IKV Deposition of thin-layer barrier coating on plastics for barrier improvement is a state-of-the-art technology. To support online quality management of plasma processes, the Institute of Plastics Processing (IKV) at RWTH Aachen University is investigating the use of spectroscopic plasma monitoring.

Plasma emissions are strongly associated to process parameters such as pressure, applied power and gas flow.

However, scientists at the IKV say when looking at complex or rapid processes there is still a lack of viable and reliable industrial quality management systems. In these cases, establishing a temporal link between process variables and plasma properties is a crucial factor in order to obtain quality-related data in real-time.

Based on the optical emission spectroscopy (OES) spectroscopic plasma monitoring can survey the plasma process in real-time and thus the treatment or coating processes. The advantage of this technique is its ability to monitor different process information, e.g., the condition of the processing chamber, like the degree of contamination the expected layer

properties, such as barrier properties, scratch resistance or wettability or the reproducibility of batch processes.

With this in mind, a plant control system based on programmable logic controller (PLC) has been developed at IKV. In close collaboration with Plasus Ingenieurbüro, the ‘Plasus Emicon’ system was integrated into the plant control system via Profibus DP. IKV states all available process data can therefore be collected and analysed simultaneously along with the measured plasma emissions, so that preventive action can be taken even in complex and rapid processes. Time and expensive sample checks are reduced to a minimum by continuous in-process performance monitoring.

Further investigations on process monitoring, for example automatic acquisition of process homogeneity in large area coating processes, are in progress.

Further Information: www.ikv-aachen.de

PLASMA Treating the sealing groove of an automotive component with atmospheric plasma before sealant application to ensure good adhesion is achieved

CASE STUDY: Why plasma surface treatment is sparking interest in the automotive manufacturing industry Plasma is commonplace and nothing new, but its use is sparking interest amongst companies in the automotive sector for its benefits during the manufacturing process.

Creating and using plasma in a controlled environment and the impact it can have on many manufacturing applications is what sparks much interest for companies, especially when it can help reduce costs, improve efficiency and ensure process consistency.

Plasma surface modification equipment is available in two industrial configurations; in vacuum plasma chambers that can process large volumes of parts in a single operation and in atmospheric plasma nozzles that can be fixed and are ideal for extruded parts, or robot mounted for parts with more complex geometries or where selective treatment is required.

Dyne Technology Ltd. recently supplied Wipac Ltd, a design and manufacturing company that specialises in high technology exterior LED lighting headlamps and rear lamps for the world’s most prestigious car makers, with an atmospheric plasma system for improving the adhesive bond strength of its rear lighting chrome plated plastic embellishers.

Wipac required the production solution to be efficient, cost effective and flexible. The engineers at Dyne Technology developed a solution that it says met all three of these key criteria, enabling Wipac to treat the embellisher prior to application of a double sided adhesive tape before fixing it to the rear lighting cluster. By employing a robot mounted PlasmaTEC Atmospheric Plasma unit, Wipac now has the process control and flexibility it required. The robot ensures accurate positioning of the plasma nozzle throughout the entire surface treatment cycle, thereby guaranteeing a consistent plasma application. The flexible production cell allows for the future integration of additional process equipment.

The robot-mounted atmospheric plasma system supplied by Dyne Technology has proved to be a great success with Wipac Limited. Dave Benton, Wipac’s Manufacturing Director said: “The production system installed has improved the adhesion of our materials and therefore the overall quality, reliability and performance of our products.”

Another recent automotive manufacturing installation was a high technology vacuum plasma system to surface-treat the Polypropylene upper body components for a very high profile UK automotive company. The interior trim mouldings required surface treatment prior to glue application and bonding of the leather trim.

Working together with the engineers at Dyne Technology, the solution was to use a vacuum plasma unit to modify the surface, i.e. increase its polarity, by placing low surface energy plastic components in the highly active environment that exists inside a vacuum plasma chamber to increase the material’s polarity.

Internal view of the highly active environment of a vacuum plasma chamber

The capacity of the vacuum plasma chamber installed is nearly 1m³, and with two large internal treatment trays, Dyne says the unit can treat a complete upper body car set in one go, with a treatment time of 35 seconds. The installation of the ‘VacuTEC’ Vacuum Plasma Chamber has given the company the ability to take complete control of the process in-house, without the need to use external suppliers to treat parts prior to build, reducing costs, eliminating the risk of damage during transit and ensuring process consistency and security. The vacuum plasma process has eliminated the need for high temperature flame treatment with all of its associated dangers, safety considerations and the costly automation that goes hand-inhand with flame torch treatments.

Further Information: www.dynetechnology.co.uK

PLASMA FEATURE

Plasma coating

under normal pressure Nanocoating with atmospheric pressure plasma enables substances tailored specifically to the application to be deposited deep down into the nanostructure of the material surface. An award-winning jet-technology creates a highly effective functional coating that confers completely new surface characteristics on the materials. Inès A. Melamies writes for BP&R to further explain the technology.

The process is based on the Openair plasma jet technology developed by Plasmatreat GmbH in Steinhagen, which has been used throughout the world for almost 20 years. This system is characterised by a threefold action: it activates surfaces by selective oxidation processes, discharges them at the same time and brings about microfine cleaning of materials such as metals, plastics, ceramics and glass. A particular feature of this technology is that the plasma is potential-free, which greatly increases the range of possible applications. The intensity of the plasma is so high that processing speeds of several 100m/min can be achieved. It also offers economic benefits: the jet systems are designed for in-line integration by the user, i.e. they can be integrated directly into a new or existing production line, and they are compatible with robotic systems.

Plasma coating under normal pressure In addition to the functions described above, this plasma system is also used for functional coating (Fig. 1). Until recently this coating process could only be performed under vacuum.

Plasmatreat, in close collaboration with the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Bremen, has spent the last few years developing an innovative process called PlasmaPlus, which for the first time enables a nanocoating to be applied to material surfaces under normal

Fig. 2: The PlasmaPlus system Graphic: Plasmatreat

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Fig. 1: Locally selective plasma coating under atmospheric pressure: the chemical composition can be varied according to the application to obtain the best results for a variety of different materials. Photo: Plasmatreat

atmospheric conditions. In recognition of its work in developing this simpler, far quicker and more cost-effective process, the company was granted the Industry Award 2012 in the “Production and Mechanical Engineering” category. Fraunhofer researchers, Dr. Jörg Ihde and Dr. Uwe Lommatzsch, received the Joseph von Fraunhofer Prize at almost the same time.

At the heart of the process is a plasma nozzle that conceals a highly complex coating system (Fig. 2). The process is environmentally friendly, needing nothing other than compressed air, electricity and a precursor, which is added to the plasma to create the coating. Due to the high-energy excitation in the plasma, this compound is fragmented and deposited on a surface as a vitreous layer (Fig. 3). The chemical composition can be varied according to the application to achieve the best results on a variety of different materials.

The unique advantage of PlasmaPlus compared with other systems is the locally selective coating technique. Layer deposition can be targeted with millimetre accuracy to a precisely defined location. The use of a plasma jet enables the coating to be applied in this highly targeted manner, which makes efficient use of resources. Processes can be controlled in such a way that coatings which confer different functions, such as adhesion and anti-adhesion, or for example corrosion protection, can be applied using the same nozzle (Fig. 3). This means that only very small quantities of coating material are required, and very varied materials or material combinations can be applied.

Christian Buske, CEO and President of the Plasmatreat Group, points out another important advantage: “The processing speed is extremely high. For example, a 100Nm-thin coating can be deposited in milliseconds. Under vacuum it would take around one to two minutes and localised selection would not be an option.”

Water and dirt repellent The company’s plasma coating process currently makes it possible to create hydrophobic surfaces that repel water. Surfaces treated in this way are also dirt-repellent and self-cleaning without requiring any mechanical cleaning action.

Barrier coatings Barrier or diffusion coatings created using plasma are an important focus of research. They are considered a reliable protection for food, beverage and medicinal packaging and provide an effective barrier to carbon dioxide, oxygen and water. They can be applied to all types of plastics and enable the production of barrier films or PET bottles with a CO2 barrier.

Medical devices The PlasmaPlus process can already be used to apply photocatalytically-active titanium-dioxide coatings. When exposed to sunlight and moisture, these coatings have a selfcleaning and germicidal effect. This application is of particular interest for coating medical and sanitary products since it allows manual cleaning intervals to be extended or omitted altogether.

Another Plasmatreat research topic is the deposition of antimicrobial coatings containing silver.

PLASMA FEATURE

Research goals and applications

Fig. 3: The image shows a crosssection through an approximately 100 nm thick PlasmaPlus coating (SEM 50,000x magnification).

Photo: Saint-Gobain

Fig. 4: PlasmaPlus in-mo uld coating and in-mould regeneration .

Photo: Plasmatreat

Advanced Polymer Testing

2C-injection moulding Plasmatreat is also intensively researching and developing techniques to improve rubber-to-metal and plastic-to-metal bonding in hybrid injection moulding. This involves applying nanocoatings with active adhesion to the metal surface, then moulding the plastic component onto the surface. In the future, depositing adhesion-promoting coatings with the PlasmaPlus process will provide an alternative to solvent-based primers in automobile manufacturing.

Release coating inside the steel mould The plasma ant-adhesion coating developed by Plasmatreat has been successfully used as a universal release treatment for injection moulding tools for the past two years. It provides exceptional release characteristics for a variety of different polymer and rubber-based mould materials. This anti-adherent effect is due entirely to plasma polymerisation on the mould surface. Thanks to this environmentally friendly process, wet chemical release agents are no longer required, nor is it necessary to demount moulds for re-coating, since old coats no longer have to be removed. New coatings can now be applied directly to the mould in situ. (Fig. 4)

The cost-effective starter instrument for quality assurance DSC 203 F3 MaiaÂŽ Differential Scanning Calorimeter

Nanocoating of 3D components It is also possible to apply atmospheric plasma coatings to complex 3D components using the PlasmaPlus process based on Openair plasma technology. The coating material even reaches areas that are difficult to access like deep groove geometries or undercuts. This makes it possible to completely coat populated circuit boards on or under the components.

Summary PlasmaPlus nanocoating under atmospheric pressure allows for substances tailored to specific applications to be deposited deep into the nanostructures of the material surface. This produces a highly effective functional coating and gives the materials completely new surface characteristics. The ability to manufacture products with selectively functionalised surfaces has added an entirely new dimension to innovation capability.

Further Information: www.plasmatreat.co.uk

NETZSCH Gerätebau GmbH Tel: +44 (0)1902 306645 uk.thermal@netzsch.com www.netzsch.com/n17326

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THErMOPLASTICS

news AEROSPACE Thermoplastic sheet for heightened performance in the air To help global aerospace customers comply with increasingly stringent standards for flame-smoke-toxicity (FST) performance of interior aircraft components, SABIC’s Innovative Plastics business has introduced new, extremely low heat release sheet for aircraft window shades.

SABIC states new Lexan XHR 5000 sheet is designed for multi-layer window shade systems requiring advanced FST properties and opacity. The solution is said to meet demanding safety requirements, as well as helping improve comfort in the cabin environment with a high-quality appearance and enhanced room-darkening properties.

SABIC’s says investment in advanced materials technologies for the aerospace sector demonstrates the company’s

SABIC’s Lexan XHR 5000 Sheet

commitment to helping aircraft OEM customers meet toughening regulations, greatly expand thermoforming design options, improve aesthetics and heighten the consumer flying experience.

“The new availability of Lexan XHR sheet can help our aerospace customers

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Further Information: www.sabic-ip.com

Plastic engine support

AUTOMOTIVE World's first plastic engine support in the new Mercedes GL Class Daimler is installing what is said to be the world’s first plastic engine support for the new, six-cylinder Mercedes GL Class, moulded using Ultramid A3WG10 CR, a highly reinforced specialty polyamide from BASF. Compared to the previous aluminum support, the plastic part is said to offer improved acoustical properties, better thermal insulating characteristics and a definite weight advantage, while being

solve their most pressing FST, design and performance needs and marks the debut of a new industry standard that will clearly make major contributions to the future of aircraft interior design,” said General Manager at SABIC, Jack Govers.

Testing by an independent laboratory demonstrated that thermoformable Lexan XHR 5000 sheet complies with the Federal Aviation Administration’s (FAA) flammability requirements under the FAR 25.853 regulation, and smoke density and heat release requirements under the Ohio State University (OSU) 65/65 standard.

Supplied as a white-pigmented cap layer over a black base, LEXAN XHR 5000 sheet is engineered as a robust yet lightweight substrate to be laminated with decorative films and then thermoformed.

able to withstand the same load. The part, which supports the engine with the aid of the engine mounts, is moulded from Ultramid A3WG10 CR, a speciality polyamide that has been optimised for high mechanical loads.

BASF states the plastic engine support being used by Daimler is not only 30 percent lighter and considerably quieter than its aluminum predecessor, but it also has a beneficial effect on the service life of the engine mounts.

Further Information: www.basf.com

Compounder develops range for hot and cold water contact European thermoplastic compounder, LATI, has spent several years developing engineering plastic compounds to replace metal in items intended for contact with hot and cold drinking water.

In 2009, the group’s PA66-based structural compounds (tradename Latigloss) obtained certificates of suitability for contact with water according to the WRAS (hot and cold water), NSF 61 (hot and cold water), ACS, KTW, and W270 standards.

This encouraged the extension of the water contact product portfolio, according to the group. In particular, LATI has now concentrated on expanding its range of plastics for contact with hot water, an application where polyamide 66 has some limitations.

The base resin for the new range is aromatic polyamide (PPA). Compared to PA66, LATI says that PPA provides resistance to hydrolytic and extractive action of hot water, even during prolonged exposure. Natural moisture absorption is said to be very low, even at high temperatures. This allows the PPA to keep its mechanical properties when immersed, reducing the risk of leaks or failure due to the typical swelling of wet polyamide.

LATI says that all of its compounds are developed to replace metals, hence they feature substantial structural reinforcement made of 40-60 percent glass fibre.

LATI submitted the full Latigloss 57 F2 product range in the ‘natural’ and ‘black’ versions to the aforementioned certification bodies. Results reportedly showed that Latigloss 57 F2 is best suited to contact with cold and hot drinking water up to 85°C. The compound was shown to combine low residue values with good resistance to fungi and algae growth.

Potential applications for the range include valves, mixers, tanks, taps, connecting parts and all parts in continuous contact with cold and hot drinking water, says LATI. The certifications allow safe use throughout Europe, as well as the USA.

THErMOPLASTICS

HOUSEHOLD

The new thermoplastic compounds can be used for parts in contact with drinking water

Further Information: www.lati.com

DISTRIBUTORS UK Distribution agreement for Polyamide 6 and 6.6 compounds from Turkey UK polymer distributor, Longfield Chemicals, has signed an exclusive distribution agreement to market the polyamide 6 and 6.6 compounds produced by Turkish compounder, Epsan Plastic.

The agreement, which applies to the UK, currently covers distribution of the full range of polyamide compounds including the Eplamid, Eplon and Epimix brands, along with a comprehensive range of industrial quality grades.

“Longfield Chemicals will supply the complete range of Epsan Plastic’s high performance compounds for companies in the UK. As our brand and product range expand, so does our need for outstanding distribution partners,” said Global Sales Manager, Arda Efe. Epsan specialises in the production of high performance polyamide compounds and currently has two plants located in Turkey as well as distributors throughout Europe.

21 Further Information: www.longchem.co.uk www.epsan.com.tr

bp&r

THErMOPLASTICS

news MEDICAL Teknor Apex gets ISO-13485 certification for medical elastomer plant in UK Teknor Apex’s facility for manufacturing its ‘Medalist’ medical thermoplastic elastomers (TPEs) in Oldbury, West Midlands, has achieved ISO13485 certification, meaning a huge boost in supplying the European market.

The company states its UK plant can now produce TPEs with the same properties as those from the USA, making it a single source for multinational customers and extending its international supply capabilities.

ISO-13485 is an international standard for quality management in medical manufacturing. The facility in the UK has passed the final audit and is expected to achieve full certification by the end of the current calendar quarter, according to Stef Hordijk, Strategic Market Manager for the Thermoplastic Elastomer

Teknor Apex’s facility for manufacturing its ‘Medalist’ medical thermoplastic elastomers (TPEs) in Oldbury, West Midlands, has achieved ISO-13485 certification

Division of Teknor Apex. A Medalist production facility in St. Albans, VT, USA obtained ISO-13485 certification in 2010.

“Certified production of Medalist TPEs in the UK helps Teknor Apex to save transit time and shipping costs in supplying the EU market, and it enables us to offer European customers compounds that provide the same properties as those from the USA and meet the same exacting standards,” said Mr. Hordijk. “The startup of a second production facility for Medalist compounds increases our capability to serve as a single source of material for companies that manufacture internationally at multiple locations.”

ISO-13485 specifies systems for consistent compliance with regulatory and customer requirements and includes provisions for risk management, sterile

PACKAGING

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New PP grade puts in a cool performance Borealis, a provider of chemical and plastics solutions, has launched a new grade of transparent polypropylene (PP), which it says will provide a step-up in performance and processing sustainability for frozen food packaging.

Based on Borealis Nucleation Technology (BNT), new Borpact SH950MO is said to feature a unique combination of transparency and good drop impact properties in low temperatures. Borealis states its performance is enhanced by higher flow (melt flow rate of 40) and better processability with improved stiffness (1050 MPa) compared to its predecessor, Borpact SG930MO. The company states improved properties and better processing efficiency bring benefits and cost savings throughout the packaging value chain.

Borealis’ PP grade is said to be ideally suited to frozen food packaging

Developed primarily for packaging of deep freeze products such as ice cream, frozen desserts and other frozen food items, Borpact SH950MO is also said to be an excellent choice for broader consumer packaging and housewares when the combination of good impact performance and transparency is a top priority.

manufacturing and traceability. The comprehensive implementation programme required for ISO-13485 certification requires focusing of the entire compounding operation on processes and procedures that maximise the safety and reliability of the compounds supplied to medical device manufacturers.

Developed for device manufacturers, ISO-13485 is not an essential standard for a compounder. Teknor Apex states Medalist elastomers are already fully compliant with regulations for medical uses and meet stringent standards for biocompatibility and purity.

Further Information: www.teknorapex.com

Borealis states the higher flowability of the new grade enables converters to use lower processing temperatures, which, in combination with BNT, support energy and cycle time savings.

One of the key aspects of the new grade is said to be the opportunity to benefit from its improved properties to downgauge material use. The high flowability and improved stiffness, both compared to the standard random PP grades, enable the use of thinner walls and more complex designs without compromising product properties or processing performance.

“We have invested in creating a next generation grade with improved processability and end product performance that takes the lead in supporting the sustainability and differentiation requirements of the thin wall consumer packaging market,” commented Rainer Höfling, Borealis Vice Presdient of the Moulding Business Unit.

Further Information: www.borealisgroup.com

DSM launches new material grade for plastic LED packages DSM has introduced ‘Stanyl ForTii LED LX’, an LED (Light Emitting Diode)-specific grade of Stanyl ForTii high temperature polyamide with halogen-free flame retardant grades as a material solution for LED packages (the plastic body).

DSM states the material has been developed in response to increased sales of LED packages driven by the switch to LEDs for LCD (liquid crystal display) backlighting and by developments in the lighting industry.

The company says LED manufacturers are looking for materials that deliver high reliability, enabling smooth, high volume production and excellent light output. Highflow Stanyl ForTii LED LX is a mineral-filled grade, and DSM says its excellent UV resistance sets a new standard for LED packages. The new material reportedly delivers a good reliability performance over time and, more specifically, high initial reflectivity, as well as excellent mechanical strength.

DSM states its high flow properties make it suitable for use in high-cavity tools.

This enhanced reflectivity of Stanyl ForTii has an immediate effect on the LED

LED LX solution for LED packages.

DSM launches Stanyl ForTii

ELECTRICAL and ELECTRONIC

package light output and is said to enable LED suppliers to improve their key specifications.

According to DSM, Stanyl ForTii LED LX outperforms competitive PPAs thanks to its specific polymer structure. High reliability and LED lifetime are further enabled through its excellent adhesion to silicones and epoxy encapsulates as well as the metallic lead frame, avoiding chip degradation due to moisture or air diffusion through interfacial delamination phenomena.

LEDs with high power densities make thermal management the key focus area in LED lighting design. Without appropriate thermal management, LEDs will gradually lose brightness, change their color spectrum over time and present higher

failure rates.

Stijn Meijers, DSM Global Segment Manager for Lighting, said: “DSM is strongly committed to the lighting industry. This is demonstrated by our growing portfolio of material solutions for lighting, developed for a wide range of high-performance applications such as highly reflective grades for LED packages or thermally conductive grades to enable improved thermal management. By using our industry-specific material portfolio, our customers are able to gain a number of significant benefits including greater efficiency, weight saving, higher flexibility in manufacturing, and a smaller carbon footprint.”

Further Information: www.dsm.com

fr NA om Ne S Sty w an ro d lut Z Y io LA n R

ALBIS

BRINGING GREAT PRODUCTS FROM GREAT SUPPLIERS TO YOUR DOOR Full technical and development service Local stockholding Your expert materials advice partner Next day delivery 25 kgs to full trucks

ALBIS (UK) Ltd. · Parkgate Industrial Estate Knutsford · GB-Cheshire WA 16 8XW Phone: +44/(0)1565/755 777 · Fax: +44/(0)1565/755 196 albisuk@albis.com · In Ireland: ireland@albis.com · www.albis.com

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ANTI-Counterfeit AND IP

Taggant technologies are a masterbatch security additive

news Combating counterfeiting with multiple levels of taggant security Microtrace, a provider of custom and ready-to-use anti-counterfeiting identification and authentication solutions, has announced the availability of multiple taggant solutions for incorporation in a single product for a higher level of security.

Taggants are microscopic or nano materials that are uniquely encoded and virtually impossible to duplicate—like a fingerprint. In the plastics industry, taggants are used to authenticate genuine injection moulded, extruded and rotationally moulded products.

“We have been seeing advancement in determination level and skill set of counterfeiters,” said Brian Brogger, Vice President of Microtrace. “The best

defense against counterfeiting is a multi-level programme. Not only should your product have multiple security features in different areas, but each feature should be multi level.”

Microtrace developed the Molecular Taggant for the plastics industry, which it says is a unique class of chemistries designed and synthesised specifically for the substrate or material they are incorporated into. Added at trace levels, the Molecular Taggant is said to be completely invisible and undetectable in

the final product. According to Brogger, development will continue this year with additional product releases and enhancements.

Further Information: www.microtracesolutions.com

New masterbatch is as foolproof as fingerprints The Gabriel-Chemie Group has launched a new additive masterbatch that it says will combat the losses faced by the plastics industry through product counterfeiting, which it estimates is “billions of Euros”.

Maxithen ProTec4 is said to represent a unique security system that can prove the origin of products exactly and cannot be copied. The special masterbatch is said to provide plastic products with an unmistakable code that demonstrates a clear proof of its origin.

The masterbatch is manufactured to an individual code for each product, which the company states are as unmistakable as a genetic fingerprint. This makes it impossible to exactly replicate an employed pigment in order to copy the product protection. The individual security pigments can reportedly be verified using a specially programmed detector. GabrielChemie states the use of different codes means that even different product batches can be identified.

Maxithen ProTec4 can be also used to monitor the production process. By

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directly communicating with the machine during processing, an overdose or underdose of additives or colour pigments can be ruled out.

Further Information: www.gabriel-chemie.com

New patent court to be established in London Business Secretary, Vince Cable, has announced the creation of a new patent court to be based in London, which will mean companies looking to defend or enforce their patents across Europe will only need to go to one court once, instead of fighting their case in each European country.

The new court will form a ‘one-stop shop’ for companies wanting to protect their business ideas in Europe and will be up and running from 2015. The Business Secretary said establishing the new court and system will offer significant savings for businesses.

Commenting on the agreement, Vince Cable said: “The decision that London should host this new court shows not only the confidence in our legal sector but also the strength of the UK's intellectual property regime. Agreement on a unified patent regime is a good result as it will mean defending a patent across Europe will now be much simpler.

“The agreement will help our inventors who can in future spend more time on research and development, producing new ideas and less time filling in forms and defending their patents in court. We estimate benefits to the UK of around £200m a year.”

The single patent package is said to guarantee a simpler system for companies registering new business ideas in the EU. Currently, British inventors can protect their invention either through the UK Intellectual Property Office or, if they are looking for wider protection for a number of countries, by applying to the European Patent Office.

These patents must then be validated in the respective countries bringing in costs for translation and administration. With a new single patent, businesses could make savings of up to £20,000 per patent in translation costs alone and many saved hours of form filling.

Further Information: www.ipo.gov.uk

The best product you have never seen Addmaster, a UK-based supplier of additives for plastics, states that its product verification system for polymers is being used daily behind some of the world’s most famous brands as counterfeit products are estimated to cost the global economy billions.

Easy to incorporate and invisible to the naked eye, the company states Verimaster can be added to any polymer with no loss to physical or optical properties and tested with Addmaster's detection tools to prove its authenticity.

Grades are now said to be available that allow detection to be carried out at source with the unique sensors (pictured) or via laboratory-based tests that can detect multiple signatures.

Addmaster states Verimaster is particularly effective in protecting manufactured plastic products from counterfeiting, as it’s easy and cost effective to add as a masterbatch, compound or within the polymer feedstock.

“When up to 20 percent of prescription drugs and over 550,000 aircraft parts are thought to be counterfeited each year, it shows that nothing is off limits to copycat producers,” said an Addmaster spokesperson.

ANTI-Counterfeit AND IP

news

Further Information: www.addmaster.co.uk

Addmaster’s unique system is used for detection

Industry Insight: Disposing of counterfeit goods the environmentally friendly way Malcolm Odlin, Purchasing Manager at Luxus, discusses how to prevent environmental impacts when disposing of counterfeit goods.

As counterfeiting inevitably intensifies in our tough economic climate, the problem of how to responsibly manage this issue presents an additional challenge for manufacturers. Not only do they need to consider effective disposal, preventing counterfeit products entering the market, but they must also satisfy environmental concerns too.

There are a number of routes to market for counterfeit products including the internet, car boot sales and street markets, which can all provide easy access for an unwary public. Recent figures provided by the EU Commission confirmed that European Customs intercepted 15 billion Euros worth of counterfeit goods in 2010, with a massive 85 percent originating from China.

Luxus offers a confidential plastics waste recycling service for the safe and secure destruction of either counterfeit or

manufacturer’s surplus goods, allowing as much as we possibly can to be reengineered back into new compound. The remainder is used in our own recycled products.

Our on-going partnership with waste management and recycling company, Yorwaste, for example, enables us to effectively prevent their client, a major international food, beverage and confectioner, from being at risk from counterfeiting.

As the client’s waste broker, Yorwaste is responsible for the safe management of their waste; in this instance the waste is surplus moulds used for the manufacture of its well-known confectionery brands.

The solution is for their effective re-sale direct to us as part of our confidential waste management service generating additional revenue for the client.

When the moulds arrived with us they are shredded, granulated and then reengineered back into new granulate for our own compounding division. This

Malcolm Odlin, Purchasing Manager at Luxus

provides a safe, responsible and cost effective solution for the client preventing the moulds falling into the wrong hands without any harm to the environment in the process.

The client benefits from the peace of mind that there is no risk of the moulds ending up in China with the potential for poor quality copies being produced and shipped back here.

Further Information: www.luxus.co.uk

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FEATURE

Understanding the

landscape of innovation The development of new products and processes in a dynamic industry such as plastics requires a great deal of technical and commercial expertise. In order for a new innovation to be successful, however, account must also be taken of legal requirements, particularly those of the world of intellectual property (IP). Here Robert Gleave, IP Consultant, and Jackie Maguire, CEO, of Coller IP, a company specialising in commercial IP management, valuation and commercialisation, write for BP&R about what businesses should know.

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The plastics and rubber industries are continuously looking to invest in new such as China and India for intangible assets. Such identification of all innovations to drive future growth. However, example, some foreign the valuable intangible assets in a company in the drive to develop new, innovative companies have encountered can be done internally or by calling in products and get them to market, ensuring difficulties in when trying to outside specialists to undertake an audit that every aspect of intangible, as well as prevent others using their IP, often and landscaping exercise. tangible assets, is addressed is sometimes because reproduction of goods and Next, a company needs to ensure that neglected. designs historically has been how protection is as watertight as possible.

With up to 80 percent of a company’s business is done in those countries.

Obtaining patents for innovative value now typically deriving directly from Employees may sometimes not even developments and inventions gives an intangible assets, including intellectual know that such reproduction is individual or organisation the rights to stop property, it is vital that companies not only forbidden. others from making, selling, licensing, ensure they are not infringing the IP rights An example is American plastic distributing or otherwise profiting from your of another, but also that they have table manufacturer, Lifetime Products invention for a limited period of time in adequate protection around their own Inc., who last year won its first victory in exchange for a public disclosure of that designs, products and processes. Cheap its patent litigation in Chinese courts. The invention. If an organisation is trading, or and counterfeit versions of products Shanghai First Intermediate Court ruled planning to trade, internationally, the issue appearing on the market can deprive a that Chinese competitor, Bestem, infringed of protecting intellectual assets across the company of income and may damage its on one of Lifetime’s Chinese patents. globe can be quite intricate. Wherever reputation.

However, the company and Bestem Companies should are still in dispute over other understand the difference claims. between the various forms of However, there is ground for intangible assets. These comprise optimism. INTIPSA (International IP intellectual property (IP), Strategists Association) of which intellectual capital (IC) and Coller IP is a founder, has recently intellectual assets (IA). Intellectual published a new report on the IP Property includes the patents, regime in China.* It concludes that trademarks, trade secrets the role of IP and its enforcement copyright and so on that are used in China is much more advanced to protect inventions, a brand than most people realise: “IP law name and products and services. in China is of a high quality by Intellectual Assets include the global standards and the quality, people or knowledge-based cost and timeliness of the “rights” assets of a company - for Fig. 1: A chart showing the rate at which patent (patents and trademarks) granted example, key skills, know-how and applications relating to masterbatch technology to foreign firms under Chinese law processes - i.e., the lifeblood of a have been filed since 1993. The data shown is for compare well with the rest of the business. Finally, Intellectual US, European and International applications world. Enforcement of patent Capital means the way a company (Figures for 2011/2012 are incomplete due to the delay rights is much cheaper and faster does business, for example between application and publication) than in most developed countries. through relationships, branding, The courts, including the IP positioning, contracts and Tribunal of the Supreme Court, are reputation. All three categories handing down some very sophisticated possible a company should register its IP have a value. judgements, although the ability to enforce rights in its key geographical markets.

There are three principal steps to think varies in different parts of China.”

Contract terms are important, for about when it comes to intangible assets.

One area where the plastics and rubber example, to stop employees taking ideas to These are understanding their nature, industries are continuing to innovate is the a competitor and particularly where including their value; next, protecting them; collaborations with third parties on products field of plastics additives and masterbatch and finally, ensuring you know how to technology. The global masterbatch market are concerned. They should include exploit them in line with your business provisions for obligations of assignment and is now predicted to reach $8.25 billion by strategy going forward.

2017. This growth has been driven by The first task is to undertake a thorough cooperation as well as confidentiality. significant innovation that has enabled the Attitudes to IP protection vary widely audit of all of the intangible assets in the use of plastics for an ever-increasing range from country to country. Although the organisation. This includes not just patents, of applications. The level of research and situation is improving, in some countries trademarks and designs but the wider

development within this sector is reflected by the rate of filing of new patent applications. Figure 1 shows the number of new applications relating to masterbatch technology filed each year during a twentyyear period. This analysis shows a recent rebound in activity with the number of new applications in 2011 more than double that seen during 2009.

In an innovative industry it can be difficult to spot the areas of key technological advance and to steer a path that avoids the potential for infringement of third party rights.

Understanding the relative position of products, processes and machinery to competitor patents is important for business decisions relating to investment in innovation, development of a new product or sale, or acquisition of a business.

One way of understanding competitive position is the generation of a patent landscape, which can help a company in the process of evaluating its IP. In simple terms, the landscape is formed through an analysis of the most frequent words and phrases within a focussed set of documents. Returning to our example of masterbatch technology, a landscape is shown in Figure 2 for patent families filed during the last ten years. In general, patent families positioned closely on a landscape can be considered to be related technically and the contours show areas of high patenting activity.

The masterbatch technology landscape shows innovation in a wide range of applications for additive masterbatches, for example improving electrical conductivity, producing biodegradable polymer products and process improvement. The landscape also shows that companies continue to develop new technology for colour masterbatches and rubber compositions. A good IP analyst will work with closely with a business to focus on the key information required from the landscape to help facilitate business decisions. Specific ‘contours’ within the landscape may be analysed in detail to highlight significant innovations in a specific technical area and the landscape can be analysed for the patent holdings of key competitors, work around strategies and acquisition targets.

Once assured that all necessary protection is in place, individuals and

companies from startups to the largest corporations can ensure they are in a good position to focus on what is important to them – developing their inventions and growing their business without the distraction of IP theft or legal challenge.

FEATURE

In order for a new innovation to be successful account must be taken of legal requirements, particularly those of the world of intellectual property (IP).

* INTIPSA Briefing Note: Intellectual Property: China in the Global Economy – Myth and Reality. 1 ‘Masterbatch – A Global Strategic Business Report’ Global Industry Analysts, Inc

Further Information: www.collerip.com Fig. 2: Patent landscape showing patent families related to masterbatch technology which have been filed in the last 10 years (output from Thomson Innovation). The activity of some of the major patent holders in the landscape including Clariant, Evonik and BASF are represented.

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Case Study: Static control helps plastics industry ‘ion’ out problems As static electricity is a problem that often goes undiagnosed and causes manufacturers costly headaches in terms of lost production and product rejects, Buckinghamshire-based SMC has developed a range of products designed to measure, control and remove it.

Product launched for static elimination in gravimetric blenders Arrowquint, a UK-based company that specialises in static control solutions, has designed a new product that could help overcome the problems associated with static charge when using materials handling equipment.

Gravimetric blenders and hopper loaders often have optical level switches that can become contaminated by dust or fines in the granulated material, which then sticks to the window through static charges. This blocks the window and prevents proper level control, which may result in either an intermittent or a continuous feed into the moulding machine.

In order to overcome this, Arrowquint has designed a small (8mm dia) flexible electrode which can be readily inserted into a blender or hopper loader to blow low pressure ionised air into the granulate around the level switch, eliminating the static charges and preventing the contamination.

STATIC CONTROL

news

Further Information: www.arrowquint.co.uk

SMC's IZS31 bar-type ionizer

SMC states products in its ‘Ionizer’ range deliver effective remedies to cure static electricity, leading to reduced production costs, improved performance, increased efficiency and improved safety. Such a solution from the Ionizer range was successfully implemented for an SMC customer that specialises in water bottle manufacturing.

Plastics, along with rubber, have a tendency to produce static electricity as they act as insulators and can hold a charge rather than act as conductors of electricity. In this instance, plastic bottles were charged with static electricity during the fabrication process, causing costly problems for the manufacturer once they joined the transport line. The static charge being stored in the surface of the bottles caused them to repel each other and lose their vertical positioning, leading to the production line being shut down while the bottles were manually re-aligned.

Although the customer did have a static removing device in place, it wasn’t capable of removing the static charge in the time set by the production process, which requires a high-speed transport system. SMC provided a solution with its bar-type ionizer, the IZS31, which the company says has a proven track record of removing static electricity extremely quickly. In this case, the IZS31 neutralised the static charge within the time set by the application.

SMC states the result has transformed the water bottling plant’s production efficiency, removing disruption to the process and the need for human intervention.

Further Information: www.smcpneumatics.co.uk

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STATIC CONTROL FEATURE

Static: The invisible influence Problems with static electricity are increasingly common in the plastics industry; affecting production, reject rates and even health and safety. Here, Stewart Gordon-Smith, Export Sales Engineer at Meech International, manufacturers of static control, air technology and web cleaning systems, writes for BP&R on how to identify problems with static and how best to control it.

Static is a common phenomenon and one that the majority of us encounter on a daily basis, whether that is through the rubbing of a party balloon on our hair and sticking it to a wall, or touching a object which gives us a short, sharp shock. It is an occurrence that has a real, yet fleeting affect in our day-to-day lives.

However, despite this knowledge of static in everyday life, its effect within industries such as plastics and converting has only become visible in recent years.

As machinery speeds have increased and an expanding number of synthetic materials have been developed, the negative effects static can play in industry have become apparent.

Static electricity causes productivity, quality and safety problems throughout industry: in the form of electrostatic attraction or repulsion, it generates dust contamination and product misbehaviour; as an electrostatic discharge it gives shocks to operators, starts fires and destroys electronic components.

Static electricity

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Many factors affect the generation and maintenance of static including humidity, the type of material, repetition and change in temperature. Plastics, in particular, generally maintain static charges for a long time due to their high resistivity, so it is common for problems with static to occur in this industry. Whenever the raw structure of a plastic material is changed, the process will manifest an electrostatic charge, which invariably leads to static problems on the production floor.

As health and safety legislation has tightened, and consumer expectations and the increasing need for efficiency and cost-savings on the production floor have grown, a need has emerged to resolve these static problems. And to meet this demand, innovative solutions have been developed, often tailored to meet specific requirements.

Companies such as Meech recognised these issues many years ago and came forward to educate and offer solutions for the ‘static problem’.

What happens when static occurs in the plastic industry?

As static is generated, process lines begin to mis-feed as products made of synthetic material such as polyethylene, polypropylene and polystyrene misbehave, and the opportunity for contamination of the final product increases dramatically.

Add to this the increased potential for serious damage and injury to operators as a consequence of electric sparks generated within explosive environments, and the need to control static levels becomes a fundamental aspect of the production environment. Contamination can spoil finishes of painted products in storage with abrasion issues, and cause rejects in the food, pharmaceutical,

Static can be both problematic and beneficial during production processes

automotive and medical industries where quality is of utmost importance.

Over time, the applications and benefits for static elimination and generation have become increasingly diverse. Below are a couple of specific examples of how static elimination, or generation technology, can now be applied.

Consider the food and drink industry: a common need for static elimination occurs on a bottling line. First plastic is heated to blow or injection mould the bottle, and then it is cooled dramatically.

The cooling process itself generates a huge amount of electrostatic charge.

Without static elimination equipment in place, highly-charged bottles would start to stick together, causing line stoppages (loss of production) and mis-feeds; they would attract contamination in the form of dust, making them hard to glue and label, and unacceptable to fill with dust on the inside. As quality of this product is paramount this simply cannot be allowed to happen, so this scenario leads to increased production costs, with additional cleaning at the pre-filling station.

When static is present, belt conveyers are prone to bottles falling over. This can result in damage, increased scrap rates and lower product yield. Static charges on mouldings may cause them to stick to the conveyor belt, resulting in the product falling onto the floor, not in the collection

Static charge can cause disruption to the manufacturing process

Causes of static during the production process

bin. As mouldings fall into the collection bin the ‘battery effect’ can result in a huge charge being accumulated. This causes a high level of dust attraction and operator shocks. It’s even been known for static to malfunction the electronics in a process line causing it to start to run backwards.

On the other hand, introducing static into a production line can be beneficial: consider synchronising static generation technology with a die cutter on a plastic bag line, a tiny application of static can be applied to the edges of a punched hole. By pinning the area surrounding the handle

closed, the static charge effectively prevents the bags from inflating. Further along the line, static is applied to fix the bags tightly to each other as they are wound into rolls. As a result, the overall size of each roll can be reduced by as much as 30 percent, permitting huge savings in subsequent transport costs.

Despite the invisible nature of static, without the equipment developed to control it, the manufacturing industry couldn’t maintain its health and safety standards and the levels of productivity and profitability that it currently does. In the future, we can expect process line

speeds to increase further and become more automated, and the range of materials to expand further. As they do, it will be up to experts in this field to be on hand to offer unique solutions and provide the necessary services to ensure that standards continue to be met with ease.

Further Information: www.meech.com

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RECLAMATION AND RECYCLING

news Plastics industry shows support for new Green Paper on tackling waste The European Commission has published a Green Paper on plastic waste to launch a structured discussion about how to make plastic products more sustainable throughout their life cycle and reduce the impact of plastic waste on the environment.

Environment Commissioner, Janez Potočnik, said: “Managing plastic waste is a major challenge in terms of environmental protection, but it's also a huge opportunity for resource efficiency. In a circular economy where high recycling rates offer solutions to material scarcity, I believe plastic has a future. I invite all stakeholders to participate in this process of reflection on how to make plastic part of the solution rather than the problem.”

Potočnik said that plastic is often perceived as a cheap and disposable material in our “throw-away” society, and therefore recycling rates are low. He added that the Green Paper underlines the key role that plastic plays in many industrial processes and applications, and the potential economic gains of higher recycling rates.

The Green Paper on plastic waste aims to launch a structured discussion about how to make plastic products more sustainable throughout their life cycle

“As the world population grows and natural resources become scarcer, recycling plastics will be an alternative to the exploitation of virgin resources,” he said. “To speed this change, better framework conditions are needed to support eco-design and environmental innovation, with waste prevention and recycling factored in to the design of plastic products.”

Current EU environmental legislation doesn't specifically address the particular challenges posed by plastic waste. The Green Paper aims to collect facts and stakeholders' views on the impacts of plastic waste and a way of mitigating them through a European strategy.

The consultation, which includes 26 questions, will last until the beginning of June 2013. The result will feed into further policy action in 2014 as part of a broader waste policy review, which will look in particular at the existing targets for waste recovery and landfill as well as an ex-post evaluation of five directives covering various waste streams.

The European plastics industry has welcomed the Commission’s Green Paper on Plastic Waste as a catalyst for joint action amongst different key players to achieve the vision of ‘Zero Plastics to Landfill by 2020’.

“The review of the Landfill Directive in 2014 offers an opportunity to make a step-change in the EU's resource efficiency policy,” explained Dr Wilfried Haensel, Executive Director of PlasticsEurope. “The inclusion of a landfill ban on plastics waste in the Directive will stimulate the plastic recycling sector and will make more plastic waste available for efficient energy recovery to produce electricity and heat. This ultimately leads to the creation of jobs and helps Europe to be less dependent on energy imports.”

Speaking at the Waste Free Oceans conference held in Brussels on March 7th, EuPC’s Managing Director, Alexandre Dangis, also welcomed the launch of the Green Paper. “At times when future polymer sourcing for European plastics converters remains unpredictable, and uncertain, there is a clear need to optimise the collection and sorting of plastics waste in order for the plastics industry to be more resource efficient,” he said.

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Further Information: www.eea.europa.eu

Further Information: www.hahnkunststoffe.de

Parent company Hahn Kunststoffe GmbH is investing in the UK market

RECLAMATION AND RECYCLING

Hahn Plastics announces substantial investment into the UK Hahn Plastics, a European manufacturer of recycled products made from mixed plastic waste, has announced significant investment plans in the UK. Hahn’s recycled plastic products are widely used in the construction, industrial and agricultural markets across Europe for their stronger performance and environmental benefits over traditional materials such as wood and concrete.

The German-based parent company, Hahn Kunststoffe GmbH, has invested in a 45,000 sq. ft. state-of-the-art production and warehousing facility at Salford, Manchester. The UK operation will engage in stocking, distributing and manufacturing an extensive range of Hahn’s patented recycled plastic products.

Hahn states this commitment will enable UK customers to enjoy better access to its extensive range of 1,500 product lines, in more colourways and with better stock availability, quicker delivery and great after sales service from a local workforce. In addition to the existing ‘Hanit’ family, the UK operation will offer an added high-spec formulation, ‘Hanplex’, which is appropriate where applications require a more robust material.

Hahn’s UK Sales and Marketing Director, Paul Harris, commented: “As the demands towards sustainable materials in construction go from strength to strength, the local investment in stock, production facilities, and jobs here mean that we are best placed to serve today’s market demands and continue innovating the next generation of construction materials.

The huge range of standard products available from stock means that there is a real alternative to the use of traditional materials in many applications.”

Managing Director, Stephan Seibel, added: “Hahn Kunstoffe GmbH is delighted to be investing in the UK, following export sales success to date. We have experienced great demand in the UK market in recent years, from all sectors of industry and agriculture. We hope to underpin our commitment in the market by providing a greater level of service by local stock holding and manufacture.”

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3D PRINTING

news CASE STUDY: Rutland Plastics harnesses multi-material and small batch moulding capability through SYS 3D printing A UK-based plastic injection moulder that has invested in 3D printing for design and prototyping says it has become a valuable tool in retaining existing business and developing relationships with new customers.

Oakham-based Rutland Plastics invested in an Objet Connex 350 3D printer from SYS Systems Ltd of Foston, Derbyshire last year and states that over the last six months it has produced some 100 different printed models up to 342mm by 342mm by 200mm in a single cycle.

“The process is useable not only to mimic the final manufactured part, create finely detailed, functional and durable prototype and sample components but also for us, to provide a very cost-effective customer service solution,” said Steve Ayre, Managing Director of Rutland Plastics.

“With the Objet Connex 350 3D printer we can use its multimaterial capability to create finely detailed truly functional models and prototypes. We are also developing a process for very small batch runs of plastic injection mouldings by printing a mould tool cavity and saving the cost of a conventional steel or aluminium tool. Most important, and giving us a major customer advantage, we are able to deliver a significant reduction in leadtime that speeds concept to production,” Ayre continued.

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Typical 3D printed components at Rutland Plastics on its Objet 350 printer supplied by SYS.

Rutland states there are two key areas where 3D printing is producing very practical aids to production and prototyping at its 32,000 sq. ft. facility. Firstly, there is the small batch injection moulding service in development where mould tool cavities are 3D printed to produce short moulding runs and trials that offset the need for costly initial steel and aluminium mould tools. Here the cavity is placed in one of Rutland’s standard bolsters to produce an injection moulded part.

Secondly, according to Ayre, the flexibility of the 3D printing process to enable different materials to be selected or blended from the 50 or so material types, grades and colours has been invaluable, enabling the blending of different mechanical properties involving rigid, flexible and transparent materials in the same 3D print run/build cycle.

“The resulting ‘composite’ material can have totally different specific values for tensile strength, elongation to break, cope with different heat deflection temperatures and even a variety of Shore A scale values. This means we can easily simulate customers’ needs for polypropylene, ABS, transparent, high temperature and a wide range of rubber-like materials between Shore 40A to 95A,” commented Rutland’s Design Engineer, Simon Grainger.

Rutland Plastics says it is able to produce wall sections on models as thin as 0.6mm with general accuracy levels of 0.1mm on the Objet machine, while larger models can be created by simply joining together two or more prints.

According to Ayre, the 3D printer has to be the type of critical ‘tool’ for use in any moulding business that wants to be progressive and seeks to have more customer involvement and hence on-going growth won against offshore competition.

“The printer is a valuable tool in support of our ‘design for manufacture’ involvement with customers – an area that has

proven so beneficial in retaining existing business and developing relationships with new customers,” said Ayre.

“3D printing helps to give confidence to the client and provides the ideal support with any presentations the new product would need to be involved with,” Ayre concluded. www.sys-uk.com www.rutlandplastics.co.uk

Plastic replaces metal in 3D printed medical device The use of plastic to replace metal in an external orthopaedic support has enabled a two-year-old patient to use her arms with help from a 3D printer.

The Wilmington Robotic Exoskeleton (WREX), an assistive device made of hinged metal bars and resistance bands for children with underdeveloped arms, is normally fabricated on a CNC system, however, it was too heavy and large for the young patient to use, so a Stratasys 3D printer was used to print a smaller and lighter plastic version of the device.

The research designer behind the device 3D printed a prototype WREX in ABS plastic, where the difference in weight

3D PRINTING

The 3D printed WREX

Typical exploded assembly of 3D component for moulding produced at Rutland Plastics

allowed him to attach the smaller-sized version to a plastic vest for the patient to wear.

The 3D-printed WREX is said to be durable enough for the patient’s everyday use and the design flexibility of 3D printing lets the research designer continually improve upon the assistive device, working out ideas in CAD and building them the same day.

For further information on the Stratasys range of 3D printers contact Mark Tyrtania on 01295 672515 or email markt@laserlines.co.uk.

Further Information: www.laserlines.co.uk

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3D PRINTING FEATURE

3D Printing: Behind the hype James Woodcock, Group Editor across TCT, the magazine for the additive manufacturing and professional 3D printing industry and www.prsnlz.me, the hub for the 3D printing and personal manufacturing community, writes exclusively for BP&R on the benefits and advantages of the technology for the plastics industry.

In my role I am lucky enough to get to see some pretty impressive facilities across the UK, Europe, USA and beyond. People making everything from hearing aids and dental aligners to Nascar engines and parts for planes. The most impressive thing about these places is often the decidedly low-key nature of the buildings that house the processes, and the companies that run them. From 20th floor design micro-studios in the heart of a big city to sheds in towns to small industrial estates in the middle of nowhere — they’re all hiding a ‘secret’.

That secret is that away from the hype of mainstream coverage exists an ecosystem of established 3D printing technologies that are adding value across the design, prototyping and manufacturing supply chain worldwide. Far from being an overnight sensation or ‘the next big thing’ 3D printing (or additive manufacturing) is now 30 years old. From the outside it may appear that not much has changed since the commercialisation of the first 3D printer, a stereolithography machine, in 1986.

Nothing could be further from the truth.

Quite apart from the fact that multiple technologies now exist for processing multiple materials (and sometimes more than one material at a time), it is the depth to which 3D printing is embedded in almost every major industry that really surprises.

Plastics processing systems have historically led the way in terms of uptake and use and metals systems are still in relative infancy.

Four main classes of 3D printing polymer processing technologies exist, all of which have the same fundamental modus operandii — to create parts layer-by-layer from ‘sliced’ digital models: Stereolithography (SL) The first ‘3D printer’ to make it to market was developed by Chuck Hull, founder of 3D Systems Corporation. In the SL process liquid photo-polymer resin is hardened by application of a laser that traces the image of each layer onto the surface of a vat of resin. Once the layer is complete, the vat drops, covering the hardened layer with fresh liquid resin, after which the process starts again. A range of materials are available, including biocompatible materials and materials for wind tunnel testing.

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Fused Deposition Modeling (FDM) Here solid plastic is melted and extruded layer-by-layer into the final shape.

FDM can process ABS meaning strong parts that better emulate an injection moulded piece. The layer-by-layer approach can cause weakness in certain planes (something that affects all 3D printing systems), depending on the orientation of the build. Other materials include ULTEM and polycarbonates in a range of colours. The FDM process is the inspiration for a vast majority of the low-cost consumer 3D printers now available.

Polymer Jetting Jetting technologies deposit a UVcurable resin in the form of tiny droplets, much like a 2D inkjet printer does with ink onto paper. A UV lamp behind the print head immediately cures the resin. This technology allows ABS-like materials, bio-compatible materials and printing with materials of differing properties within the same build.

Different polymers can also be mixed on the fly to create differing properties across a build.

Selective Laser Sintering (SLS) Powdered polymer is sintered by a laser, which traces the geometry of each ‘slice’ onto the surface. Once sintered the bed drops and fresh powder is deposited on top allowing the process to continue. A variation of the theme, Selective Heat Sintering, uses rapidly heating resistors that scan close to the surface of the powder as the energy source instead of a laser. SLS machines predominantly process Nylon materials but the scope is rapidly expanding to include PEEK and PEKK for medical applications.

The greatest value for most users of 3D printing technology still lies in the prototyping phase where 3D printing can drastically reduce development times when used in-house or through one of the numerous service bureaux. Indeed the question tends to be not ‘should I use 3D printing’ but ‘how should I use 3D printing’.

While FDM-style machines are available for around £1000 or less, the truth is that these systems will not be sufficient for professional use. The lowest-cost professional FDM systems start at around £6000 but with significant limitations on materials and build size. SLA, SLS and polymer jetting technologies are

considerably more expensive in terms of purchase price and materials, meaning that accessing this technology through a bureau service is generally most appealing to SMEs. When it comes to designing for the process it appears that the hype machine has worked its ‘magic’ here too. While even the major machine vendors may still persist with the ‘make anything you can design’ mantra, it tends not to be quite so simple.

Each 3D printing process has limitations. In fact each process has dozens of limitations, some specific to that process but some that apply to all 3D printing processes. While it is true to say that there are fewer design limitations for 3D printed parts than for say injection moulding, machining or casting, it is also true to say that 3D printing-specific limitations really do exist. What these are and how to overcome them is beyond the scope of this piece, but it is something to bear in mind when assessing the technologies (and the salesperson’s spiel).

Another seldom mentioned factor that is worth mentioning is part finishing. Almost every promotional video shows an operator removing a clean, ready-to-use part from the machine. Again, real-life is a disappointment here with every process requiring at least some part finishing when the build has finished. For SLA and polymer jetting this includes support removal, cleaning and further curing; for SLS excess powder must be removed and the part cleaned; for FDM supports need removing (either by breaking them off or by dissolving soluble support material) and a degree of polishing may be required.

So, who’s actually using this technology today? The medical industry is one area that 3D printing is growing in acceptance both for modeling and for direct interventions.

The automotive and motorsport industries are also a hotbed of 3D printing innovation, with Formula 1 particularly invested in the technologies. From wind tunnel testing to aerodynamic parts on the real-life cars, plastics 3D printing is everywhere in F1.

If you’re after more insight about how the hype surrounding 3D printing is both skewing perspectives and opening up exciting new opportunities you can check out an excellent blog piece from industry insider, Joris Peels, on the TCT website: http://mytct.co/joris1 Further Information www.tctmagazine.com

ENGINEERING MATERIALS

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news Large-scale PPC Polyol run to create sustainable polyurethane from waste CO2 Novomer Inc., a sustainable materials company pioneering a family of highperformance polymers and other chemicals from renewable feedstocks such as carbon dioxide (CO2), has announced the world's first large-scale manufacturing run of polypropylene carbonate (PPC) polyol, producing over seven tonnes of finished product.

Novomer states the recently produced material, a 1,000 molecular weight PPC diol, will be used to accelerate product qualification and adoption in a wide range of conventional polyurethane applications including flexible and rigid foams, adhesives and sealants, coatings, and elastomers. Novomer is currently working closely with several major companies in various segments of the polyurethanes industry and this material will enable commercial scale testing of Novomer polyol.

Novomer polyols are designed to replace conventional petroleum-based polyether, polyester, and polycarbonate

Plastic makes light work of fixing broken bones Artificial bone, created using stem cells and a new lightweight plastic, could soon be used to heal shattered limbs, according to a new study.

The use of bone stem cells combined with a degradable rigid material that inserts into broken bones and encourages real bone to re-grow has been developed at the Universities of Edinburgh and Southampton.

Researchers have developed the material with a honeycomb scaffold structure that allows blood to flow through it, enabling stem cells from the patient’s bone marrow to attach to the material and grow new bone. Over time, the plastic is said to slowly degrade as the implant is replaced by newly grown bone.

Scientists developed the material by blending three types of plastics. They used a pioneering technique to blend and test hundreds of combinations of plastics, to

The Polyol uses waste CO2 as a significant raw material

polyols. The polyols are based on the copolymerisation of carbon dioxide (CO2) and epoxides and the resulting products contain more than 40 percent CO2 by weight. The use of waste CO2 as a significant raw material yields a product with an extremely low carbon footprint. In addition, since waste CO2 is significantly lower in cost than conventional petroleumbased raw materials, Novomer states polyol-manufacturing costs will be favorable compared to conventional polyols when produced at full commercial scale.

In terms of performance, Novomer's PPC polyol reportedly has a unique polycarbonate backbone that increases the strength and durability of polyurethane products. Incorporating these new polyols into existing formulations yields foams with higher tensile, tear strength, and load bearing capacity; adhesives and coatings with improved adhesion, cohesive strength, and weatherabilty; and elastomers with greater tensile and flexural strength.

“We are pleased with the results of this first run,” said Dr. Ron Valente, Novomer’s Vice President of Research.

“This campaign clearly demonstrates the robustness of our catalyst and manufacturing process and we are confident in the ability to move to a larger scale as demand warrants.”

Further Information: www.novomer.com

identify a blend that was robust, lightweight and able to support bone stem cells. Successful results have been shown in the lab and in animal testing with the focus now moving towards human clinical evaluation.

Professor Mark Bradley, of the University of Edinburgh’s School of Chemistry, said: “We were able to make and look at hundreds of candidate materials and rapidly whittle these down to one which is strong enough to replace bone and is also a suitable surface upon which to grow new bone.

“We are confident that this material could soon be helping to improve the quality of life for patients with severe bone injuries and will help maintain the health of an ageing population.”

Further Information: www.southampton.ac.uk www.ed.ac.uk

Artificial bone, created using stem cells and a new lightweight plastic, could soon be used to heal shattered limbs, according to a new study.

ENGINEERING MATERIALS

Scientists develop spray-painted plastic solar cells Scientists at the University of Sheffield have developed plastic-coated solar cells created using a process similar to spray-painting.

The method could potentially reduce the cost of solar cells significantly, meaning the technology could be provided to people in developing countries and perhaps one day be used on glass in buildings or car roofs.

Experts from the University of Sheffield’s Department of Physics and Astronomy and the University of Cambridge have created a method of spray-coating a photovoltaic active layer by an air-based process – similar to spraying regular paint from a can – to develop a cheaper An artist's impression of spraytechnique which can be coating glass with the polymer to mass produced. create a solar cell Professor David Lidzey from the University of Sheffield said: “Spray coating is currently used to apply paint to cars and in graphic printing. We have shown that it can also be used to make solar cells using specially designed plastic semiconductors. Maybe in the future surfaces on buildings and even car roofs will routinely generate electricity with these materials.

“We found that the performance of our spray coated solar cells is the same as cells made with more traditional research methods, but which are impossible to scale in manufacturing.

We now do most of our research using spray coating.

“The goal is to reduce the amount of energy and money required to make a solar cell. This means that we need solar cell materials that have low embodied energy, but we also need manufacturing processes that are efficient, reliable and consume less energy.”

Most solar cells are manufactured using special energy intensive tools and using materials like silicon that themselves contain large amounts of embodied energy.

Plastic, by comparison, requires much less energy to make.

By spray-coating a plastic layer in air the team hope the overall energy used to make a solar cell can be significantly reduced.

At present devices are coated onto flat surfaces; however there is said to be nothing to stop the coating of curved surfaces that could be used in a number of applications. The main restriction, however, is that at present such surfaces need to be very smooth.

Researchers say a downside to using the plastic as solar cell materials – needed for the spray technique – is that they are not

currently as efficient at generating electricity as cells made from silicon. The vast majority of solar panels found in the UK are made from silicon and are expected to last over 25 years.

It is unlikely that plastic cells will ever be this stable, but if the energy cost of plastic cells can be lowered enough they will become more effective than silicon over their life cycle.

Professor Lidzey added: “Increasing the energy conversion efficiency and lifetime of plastic cells are significant issues that many groups are working on. It should also be noted that the cost of silicon solar panels have reduced significantly over the last few years so plastic solar cells will have to catch up with these improvements.”

Further Information: www.polymercentre.org.uk

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news CASE STUDY System integrator takes risk out of complex plastics project Injection moulding equipment manufacturer, Sumitomo (SHI) Demag, has completed a challenge set by supplier of connectors and interconnect components, Molex Ireland, which has enabled the company to produce a new product to target a new market.

The complex project required the production of a two-shot rugged sealed connector made by Molex for pump manufacturer, Grundfos, enabling the group to target the industrial multicomponents rugged sealed connector market.

The new manufacturing process included two multi-cavity bespoke twoshot direct gate hot runner moulds (to make the connector cover and insert in a single mould process), management of 750 and 850 Glow wire materials with a strong bond to a second shot sealing material, plus a fast and efficient multicomponent 350 tonne injection moulding machine.

The two-shot rugged sealed connector made

by Molex for Grundfos

Molex states it chose system integrator, Sumitomo (SHI) Demag, as one of the technology partners for its previous experience in this type of application. “We were confident that Sumitomo (SHI) Demag could provide the right equipment as they had a successful installation base of multicomponent injection moulding equipment worldwide,” commneted Process Engineer, Donal Costello.

Sumitomo (SHI) Demag provided sample parts by borrowing a similar machine from an existing customer for a two-week period to run the unique moulds as well as sending the machine to the mould makers before it went to Molex. Sumitomo (SHI) Demag Managing Director, Nigel Flowers, said: “We were able to test the materials, fit the moulds, complete validation and commissioning

so that when the machine got to Molex all we had to do was install the system.”

Molex states Sumitomo (SHI) Demag provided a solution which took the project from an idea into production, providing a compact and flexible machine enabling it to target the new market. Donal continued: “This project involved a new customer, new product type and a new sector for Molex globally – we had to be 100 percent confident that our chosen partners could deliver a manufacturing solution that was both capable and reliable. Sumitomo (SHI) Demag, in conjunction with the other stakeholders Hofmann, Manner and John Goff, really helped us to de-risk the entire project.”

Further Information: www.demag-hamilton.co.uk

ADVERTORIAL

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Reduced take-out times for injection moulders is an important factor in increasing production rates Whenever a de-mould robot is introduced into an injection moulding process an increase in the overall cycle time is usually inevitable, the key to increasing production volumes is keeping this time to an absolute minimum.

By ensuring the end of arm tooling size is kept to a minimum, and by maintaining high rigidity with low mass on the support arms, the performance of the take-out system can be maximised.

DB-Automation Ltd, based in Leicestershire, UK, has become a world class manufacturer of high speed take-out robotics by using these techniques and others to deliver process improvements to an international client base.

Recently the team at DB-Automation designed and manufactured a bespoke multi-cavity take-out system for integration

with an 800 tonne injection moulding machine.

The system provided a cycle time saving of one second for the client in comparison to the existing equipment and this coupled with the technical support and training provided by the team has resulted in the system producing 200,000 parts per day.

The client’s satisfaction in the system has been demonstrated by the placing of a further order for another system after just two weeks of production.

For more information about how you could benefit from our services please contact us.

Further Information: www.db-automation.co.uk

A watertight partnership for Engel Engel Ausria has announced a partnership with Germanbased PMEfluidtec GmbH, specialists in fluid assisted injection moulding, for the development of water injection technology (WIT).

Engel states the water injection technology offered under its ‘watermelt’ label is used for the efficient and cost-effective production of long media lines and complex hollow parts such as handles, beverage crates and engine components via injection moulding. The injection of water into a cavity partially filled with plastic melt ensures even wall thickness distribution and smooth internal surfaces, even where part geometries are complex. Engel states other advantages include the economical use of raw materials and short cycle times.

“Water injection technology is a small but very interesting niche,” commented Michael Fischer, Sales Manager (Technologies) at Engel Austria. “Thanks to our partnership with the leading WIT specialist, we will also be able to offer customers around the world custom-made, state-of-the-art system solutions in the field of water injection technology.”

For 12 years, PMEfluidtec has been developing and producing systems for fluid-based injection moulding using internal pressure technology. Under the terms of the partnership, PMEfluidtec will be responsible for WIT systems and process and mould technology as well as service for WIT units; Engel will be responsible for adapting injection moulding machines, automation and peripheral units.

Further Information: www.engelglobal.com

By Order of S. D. Raithatha of Springfields Business Recovery & Insolvency Limited, Administrator of Schlegel Automotive Europe Limited

A RANGE OF RUBBER MANUFACTURING MACHINERY UTILISED FOR THE AUTOMOTIVE INDUSTRY TO INCLUDE: EPDM EXTRUSION LINES; HORIZONTAL & VERTICAL INJECTION MOULDERS; LABORATORY & INSPECTION; GENERAL ENGINEERING; MATERIALS HANDLING & WAREHOUSE EQUIPMENT ETC. (Subject to Availability)

INJECTION MOULDING

news

Online Auction

Plastic & Rubber Manufacturing Machinery: 6 x EPDM Extrusion Lines; 4 x Boy 22D Horizontal Injection Moulders (3 x 2004, 2008); 2 x Berghof Stork ST1600-250 Horizontal Injection Moulders (1989); 2 x Sandretto Serie OTTO 360 Horizontal Injection Moulders (1990); MIR MVP400-2800 Horizontal Injection Moulder (1997); 6 x Boy 22M Vertical Injection Moulders (2001); Various Mapelli 20-75-75, 20-120, 20-50-50, 35-170 Injection Moulders; Various LWB Steinl VCE-T 300/100 Injection Moulders (2002); 4 x Kinguawa Single Station Presses; 3 x Various Werner & Pfleiderer Hydraulic Presses (1989-1985); 3 x Grandwork Systems Ltd Splicing Machines (2006); Quantity of Various Industrial Automation & Robotec Peg Insertion Machines etc.

General Engineering: AB Arboga Radial Arm Drill; Charmilles Technologies & Elox Spark Erosion Machines; Pollard Mori Seiki MV 35/40 VMC; Mori Seiki SL-4T Turning Centre; 2 x Colchester Student Lathe; Tos SN32 Centre Lathe; 3 x Various Bridgeport Milling Machines; Various Shot Blast Cabinets, Grinders, Welders, Chop Saws, Band Saws, Drills, Workshop Benches etc.

Other Assets: 4 x Ingersoll Rand SSR ML-55 Compressors; Caterpillar DP25 Electric Counterbalance Forklift; Hyster 5.00D Forklift; Quantity of Pallet Trucks; Various Inspection Laboratory Equipment, Extraction Units, Spray Booths; Quantity of Office, Canteen Furniture and I.T. Equipment Throughout

To bid please go to: www.edwardsymmons.com or On View: Tuesday 19th March 2013, 9.30am – 4.30pm At: Beveridge Lane, Bardon Hill, Coalville, Leicester LE67 1TA Online Bidding Ends: Monday 25th March 2013, from 12.00noon Clearance: Tuesday 2nd April 2013 – Monday 15th April 2013, 9.30am – 4.30pm This is a full PPE site – visitors must wear adequate PPE at all times For further details, please contact: Jenni Pearce Email: jennifer.pearce@edwardsymmons.com Edward Symmons LLP, Charles House, 148/149 Great Charles Street, Birmingham, B3 3HT Fax: 0121 200 7630

41 Engel will adapt its injection moulding machines, automation and peripheral units to accommodate WIT

bp&r

UPDATE

PMMDA all shaped up and ready for progress This month, we introduce a new column written exclusively for BP&R by PMMDA Chairman, Nigel Flowers. This bi-monthly column aims to provide regular industry insight, updates and information from the association.

Recent market conditions have not only forced our industry to take a reality check, but they’ve prompted the PMMDA (Polymer Machinery Manufacturers and Distributors Association) to do the same too. The association, originally formed in 1966 by eight founder companies, set out to agree a range of standards for both UK manufacturers and distributors of foreign machinery and to prevent a proliferation of exhibitions. Fast forward forty plus years and with fewer than 40 members, it was clear that greater strength in numbers was needed to give us a better chance of being heard. The PMMDA therefore joined forces with the PPMA (Processing and Packaging Machinery Association) in 2010 making a combined total of 400 UK equipment manufacturers and distributors all with common goals and challenges to overcome.

A powerful group of associations, including vision, robotic, processing and packaging equipment suppliers, as the

newly appointed chairman of PMMDA, it was clear to me that a united front would result in greater benefits for our members; increased networking opportunities, cross fertilisation of ideas and, most importantly, a louder voice in Westminster with which to lobby government for support for the UK plastics industry and manufacturing as a whole.

Our recent alliance with the PPMA has been controversial for some and an inevitable sign of progress for others. A subtle re-branding process has enabled the association to retain its own identity yet benefit from a fresher logo, new marketing materials, a regular newsletter and a new website, resulting in more attention from prospect members and buyers than ever before. As in my own organisation, Sumitomo (SHI) Demag, I’m sure most member companies have been through their own personal reality check, reminiscing on the days where over 1,000 injection moulding machines a year were sold into the UK. Yet the UK still remains a strong and an innovative global supplier, particularly in the medical, automotive and high tech markets, and for us all to forge ahead in these markets, it’s advantageous to use a trade association and its services to help raise a business’s profile.

PMMDA Chairman, Nigel Flowers

A new profile-raising opportunity for PMMDA members and industry alike is the annual PPMA Group Industry Awards.

Amongst the 10 award categories, which celebrate manufacturing capabilities and achievements within all facets of the industry, including robotics, vision, processing and packaging equipment, there is an award for ‘Polymer Equipment Manufacturer or Distributor of the Year.’

Free for members and industry to enter by mid-March, the ceremony will be held on 4 June 2013 alongside the Total Processing & Packaging Exhibition (NEC, Birmingham) and is a great way to receive free publicity, heighten brand recognition and show thanks to staff and partner organisations.

Further Information: www.pmmda.org.uk

Cryogenics What’s it got to do with polymers?

This month’s update from the Rubber and Plastics Research Association (RAPRA) looks at the role Cryogenics plays in polymer science after a recent visit to Cryox in Didcot, Oxfordshire.

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We all think of Cryogenics as freezing someone until they can be resurrected or storing embryos, but there are a few surprising applications that do not immediately come to mind, such as freezing fish fingers! Other uses include medical MRI scanners, which depend on cryogenics to keep their superconducting magnets cold, as well as LNG or liquefied natural gas, which also depends fundamentally on cryogenics. Much science involves low temperatures - with less molecular vibration it is possible to ‘see’ more clearly inside material structures or get sharper signals from detectors.

Cryogenics is a growing area as science and technology push the boundaries of energy production and space exploration to name but a couple.

As the use of cryogenics becomes more widespread, the potential for the use of plastics becomes greater and the need to find new polymers becomes apparent.

Where do they come in? Well, in almost every application – wherever liquids are involved, there will be pipes and valves for a start – with seals for example. And materials which are wonderfully compliant (giving an excellent seal) at ambient temperature, may be as unforgiving as rock at cryogenic temperature, or may become brittle and shatter.

The low temperatures required are generally achieved using cryogens (liquid nitrogen boils at -196°C, liquid helium at -269°C, which is only four degrees above absolute zero or 4K on the Kelvin scale).

There is a growing amount of cryogenic material performance data available in the public domain, though

there still remain many gaps that call for testing to be carried out. There can also be hazards with already published data; in an area of technology which is still developing rapidly, hindsight puts some historical test methodologies in question and in some cases, material production processes may have gone through revisions resulting in minor changes, for example to impurities – with substantial effects on cryogenic performance.

With this in mind, RAPRA draws attention to Cryox and the STFC laboratories. STFC is the Governmentowned Science and Technology Facilities Council, and has far and away the biggest resource in the UK of cryogenic test facilities and low temperature technologists. Anyone with a cryogenic enquiry can use RAPRA’s enquiry form to seek assistance.

Further Information: www.rapralimited.org

Why exporting during a downturn makes business sense This month’s view from Smart Currency With the UK economy continuing to struggle, manufacturers are increasingly turning their sights to overseas markets to drive business growth and ongoing sales revenue. Just this month, a Midlands-based manufacturers network urged manufacturing firms to grow their export markets as a means of overcoming poor growth opportunities here in the UK. This makes a great deal of business sense, enabling firms to continue expanding their operations, retaining and even adding new staff while also increasing their brand awareness on an international scale – leaving them better positioned to take advantage of renewed opportunities at home once the economy picks up again.

Additionally, the fall in the value of Sterling this year means UK manufactured products are highly competitive price-wise in overseas markets.

This currency weakness is expected to continue for some time to come, given there is little hope of a resurgent UK economy any time soon. Indeed, there is plenty of speculation that the Bank of England will step in yet again to further devalue the pound through its Quantitative Easing programme.

When expanding overseas trade, firms must first consider the risks associated with international exchange rates. What may be profitable now could become a loss-maker in the months ahead if not properly planned in advance. But conversely, seemingly unattractive opportunities now can quickly become money-makers should the exchange rates move again.

It all comes down to preparedness to make the most of the options available to you. www.smartcurrencybusiness.com/BPRTreasury

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

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

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

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

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

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

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

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

Affordable systems available for all size of processor.

Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.

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

Call Lisa on 01244 680222 for details.

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buyer’s guide vibration welding

mould release

Branson Ultrasonics

materials

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

polymer distributors

temperature control

For Temperature Control Rental turn to the experts assembly hot plate welding colour masterbatch

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

COMPOUNDING

• FLUID CHILLERS • BOILERS • AIR CONDITIONING • HEATING • DRY COOLERS/ FREE COOLING

0800 026 4717 Rental Systems

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

wanted

pulse staking H.T.E Engineering Services Ltd Unit 9, St Ives Enterprise Centre, St Ives, Huntingdon Cambridgeshire, UK, PE27 3NP T: +44 (0) 1480 467321 M: +44 (0) 7435 967632 E: john@hte.ie W: www.pulsestaker.com

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

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

spin welding

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

1 mm Easysperse MicroPellets to 4 mm MaxiPellets.

Standards second to none.

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

ultrasonic plastics assembly systems

equipment

fastenings and fixings AEROSOLS

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

chillers/temperature controllers 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

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

CNC ASSEMBLY MACHINES masterbatch

Cannon Shelley UK agents for Belotti 5 axis CNC machines

ancillary

T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.belotti.com W: www.shelley.biz

control systems and equipment

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

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

thermocouples

extruders and downstream equipment

hot runner systems

hopper dryers

hot runner controllers

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

UK agent for Lyons Electronics.

GATE CUTTERS hopper loaders

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

infra red systems

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

dryers/dehumidifiers

printing machines pad

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

Energy Saving Dryers

granulators 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

injection moulding screws and barrels

heating equipment mixing, feeding, drying 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

extrusion systems LABORATORY machines

metal detection & separation 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

nozzles & nozzle tips

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

materials handling and storage

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

gravimetric/volumetric blending Motan Colortronic Ltd

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

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

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

To advertise in this space contact lisa montgomery 01244 680222

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buyer’s guide injection moulding

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

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

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

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

pad

testing/consultancy

WATER FITTINGS mouldflow analysis

testing equipment

Fleming Polymer Testing & Consultancy Unit 326 Hartlebury Trading Estate, Kidderminster, Worcs, DY10 4JB T: 01299 253300 E: enquiries@flemingptc.co.uk W: www.flemingptc.co.uk An independent ISO9001 accredited laboratory specilising in Rheometry, TGA, DSC, MFR/MVR, Pilot-scale blown film line, flow simulation, Consultancy.

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

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

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

DTL Machines We Buy / Sell all Makes, Age and Sizes of Injection Moulding Machines & Ancillaries Tool room machines and also complete factories / plants Factory Clearance Services Dismantling / Removal of obsolete plant and machinery T: 01925 596170 M: 07838138342 E: douglastrading@gmail.com Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com

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

World leader in Materials Testing Instrumentation

services ACQUISITION

Injection Moulding Business Wanted T/O between £100,000 and £1.5million.

Contact in the strictest confidence, Joe Reeve, Data Plastics Ltd Email joe.reeve@dataplastics.co.uk Phone 01993 700777

Tel: +44 1494 464646

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

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

mouldmaking

parts & services Contract cleaning Injection Moulding Extrusion

Tensile|Fatigue| Impact Compression|Melt Flow Coronation Road, High Wycombe, Bucks HP12 3SY, UK

tool making

• • • • • •

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

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

WANTED

printers printers of plastic mouldings 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

WANTED PLASTIC SCRAP We are looking to purchase LDPE post production scrap.

Can take over 100 Tonne a week.

Payment terms: COD T: 0121 328 5222 F: 0121 328 3555 E: sales@bsplastics.co.uk