BP&R March 2015 by BP&R Magazine

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bp&r march 2015

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www.britishplastics.co.uk EDITORIAL

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

SALES

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

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

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Mark Blezard T: +44(0)1244 680222 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (01244) 671074 © 2015 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.

Putting the UK’s manufacturing strengths on the political agenda

t the EEF’s annual conference last week, the media scrum surrounding the keynote speakers from Westminster showed the importance of keeping manufacturing on the political agenda. The urgency to sustain the renaissance of late and ensure the UK capitalises on the opportunities posed by the impending technological revolution put the issues of funding and investment, productivity and skills high on the agenda. You could put a cigarette paper between the pledges of the two speakers, Ed Miliband and Matthew Hancock, who both championed the cause of the ‘backbone of the UK economy’, its manufacturers.

In these times of mixed feelings, however, it is comforting to see firms such as Nifco UK reap the benefits of the ongoing investment and success of the country’s automotive industry, with its recent success in winning the tender to produce a thermoplastic component for Ford’s next-generation, low CO2 engine, reportedly worth in the region of £50million. Not only this, but the contract will create in the region of up to 50 new jobs in the North-East of England. Now if that’s not encouragement for Government to invest and back the sector, I don’t know what is.

At the EEF’s annual conference last week, the media scrum surrounding the keynote speakers from Westminster showed the importance of keeping manufacturing on the political agenda

Enjoy the issue. Leanne Taylor, Editor

But despite the promises of future support, it would seem that business confidence in the plastics industry is somewhat flat lining. According to findings from the British Plastics Federation’s latest survey of business conditions, confidence surrounding expectations of sales turnover, profitability and investment intentions over the next twelve months has waned, with firms citing the volatility of the international political situation and its potential affect on raw materials prices, as well as the outcome of the General Election, as causes for concern. Despite this, the overall performance of the industry remains robust, according to the Federation’s Director-General, Philip Law, who identifies some of the key messages from the findings in his column on page 50.

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THE BIG STORY Reinforcing the supplier-distributor-customer relationship through technical know-how

lastics raw materials distributor, Plastribution, says that it has increased the size of its technical team to cope with an increased demand for its services. Created to consolidate the technical support it provides to its customers and suppliers, the scope of service that the team currently offers is now extensive, ranging from material selection to regulatory compliance. Established to offer a ‘one-stop-shop’, providing extended technical guidance and advice to Plastribution’s customers throughout the manufacturing process, the technical team says it has not only added value to customer relationships, but also helped cement the dynamic between the supplier, customer and distributor. “By offering sound technical advice across a number of areas, covering the initial design through to the end of the manufacturing process, we are helping the complete supply chain make the right choices,” explained Dan Jarvis, Plastribution’s Technical Manager. Plastribution’s technical support covers a wide range of services including:

REGULATORY AND COMPLIANCE The monitoring and supply of all relevant documentation for regulatory issues including, but not limited to: REACH, RoHS, MSDS, WEEE, WRAS, food contact, medical compliance, California 65 proposition, conflict minerals. Plastribution can also advise businesses of their obligations regarding these issues.

EFFICIENCY The company is able to help with choosing the right products and additives to improve cycle time and energy efficiency. Alongside industry partners, it can also advise on process/ machine optimisation to get the best cycle time without sacrificing component quality.

MATERIAL CHOICES

TROUBLESHOOTING

Material selection is critical to product performance. Plastribution’s breadth of experience means the company can provide advice on the best material for the job, as well as assisting businesses to meet their ongoing requirements, such as physical performance, cost, design and regulatory constraints.

If you are having issues with components, whether they are visual defects, physical defects, processing issues, drying and handling issues, practical advice can be given on the best methods to eradicate the problems by process or material improvements.

PROCESSING ADVICE With carefully selected industry partners, Plastribution can help choose the right machine type and size, as well as tooling, ancillaries, storage and handling equipment.

IDEA TO COMPONENT From an initial sketch to production components, the technical team can help make ideas a reality by providing advice on the correct material, design considerations, manufacturing methods, project costs, prototype tooling and finished component manufacture.

TRAINING AND DEVELOPMENT Plastribution is proactive in the provision of training to the industry, covering polymer basics, process optimisation and the economics of the polymer supply chain.

RE-SHORING The company is well equipped to support OEMs who wish to transfer manufacturing of plastic components, assembles and sub-assemblies back to the United Kingdom. This includes technical support and assistance with supply chain management ensuring smooth repatriation of your manufacturing. WWW.PLASTRIBUTION.CO.UK

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contents

PLASTICS &RUBBER

march 2015

on the cover REINFORCING THE SUPPLIER-DISTRIBUTORCUSTOMER RELATIONSHIP Plastics raw materials distributor, Plastribution, has increased the size of its technical team to cope with an increased demand for its services. Created to consolidate the technical support it provides to its customers and suppliers, the scope of service that the team currently offers is now extensive. SEE PAGE 4

26 ]FEATURE PVC Dr. Brigitte Dero writes exclusively for BP&R on how the PVC industry has moved closer towards its sustainability goals since the implementation of Vinyl 2010

REGULARS

INDUSTRY NEWS

MATERIALS

MACHINERY

BUYERS’ GUIDE

SOFTWARE

NEWS FROM THE FRONTLINE

32 FEATURE ROTOMOULDING

New machine is the crystal ball for production engineers

EDITOR’S LETTER

Putting the UK’s manufacturing strengths on the political agenda

18 FEATURE AUTOMOTIVES

Opening the door to innovation in lightweighting technology: Leanne Taylor speaks to JSP on its part in the BMW i8

22 FEATURE

PURGING COMPOUNDS

Experts at Chem-Trend explain how next generation compounds and processing aids provide efficient manufacturing

35 FEATURE

TECHNOLOGY AND SOFTWARE

Leanne Taylor reports on Industry 4.0 and what it means for plastics

45 FEATURE

RECLAMATION AND RECYCLING

Going full circle: Mike Maxwell explains how retailers can create value by closing the loop

WWW.BRITISHPLASTICS.CO.UK

years | tie-bar-less

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INDUSTRY | NEWS

NIFCO UK SECURES £50M FORD AUTOMOTIVE DEAL Car parts manufacturer, Nifco UK, has announced that it has won its largest ever contract. The Eaglescliffe plastics manufacturer, which produces parts used in car engines and interiors, has revealed that it has won a contract that could be worth as much as £50million with automotive giant, Ford. Nifco was awarded the multi-year deal following a competitive tender process that saw the firm go headto-head against companies from the UK and around the world. The contract will see Nifco produce a complex thermostatic control assembly for a next-generation low CO2 engine. Work will start immediately with engineers from Nifco working with Ford’s product development teams. It is expected the new deal will secure up to 50 new jobs for the region, added to the 295 jobs that will have been maintained and secured since 2012. Mike Matthews, Managing Director and European Operations Officer, said that the contract was a hugely significant win for the company. “We are absolutely delighted to have won this contract with Ford,” Matthews commented. “The scope and size of the deal is unprecedented, and is made even more significant by the fact we have managed to displace

Mike Matthews said he is “absolutely delighted” with the deal, which is on an “unprecedented” size and scale for Nifco

competitors from right around the world. It is further proof of just how far Nifco has come, and the way in which the close relationships we build with our clients are helping us to better understand their business and the ways in which we can support them. “The jobs this will secure and the “THE SCOPE AND impact it will have locally is such a boost, and we’re thrilled to have SIZE OF THE DEAL IS been chosen to deliver it.” UNPRECEDENTED, AND The contract is another positive IS MADE EVEN MORE boost for the company, which has SIGNIFICANT BY THE FACT an order book that is full for the next five years. WE HAVE MANAGED TO Chancellor of the Exchequer, DISPLACE COMPETITORS George Osborne, said: “Our FROM RIGHT AROUND long term economic plan for the THE WORLD.” North East is all about building on the area’s strengths, like manufacturing and backing businesses that are growing and creating jobs. Nifco’s continued success, along with its new contract with Ford, is fantastic news for the North East” WWW.NIFCOEU.COM

Victrex is continuing to invest in cutting-edge technological leadership in advanced polymers. Credit: Victrex

VICTREX TO INVEST MILLIONS IN NEW POLYMER INNOVATION CENTRE IN NORTHERN ENGLAND UK-based producer of high-performance Polyaryletherketone (PAEK) polymers, Victrex, has announced it is to construct a major Polymer Innovation Centre in northern England. Financial assistance for the project has come in the form of £1.3 million in grant funding from the UK government’s Regional Growth Fund, subject to satisfactory due diligence, which recognises the vital, rapidly accelerating importance of high-performance polymers in the global marketplace. “This boost from the UK government’s Regional Growth Fund is great news for Victrex, in enabling our company to continue pioneering the market for high-performance

POLITICIANS URGED TO SUPPORT ‘BEATING HEART’ OF UK ECONOMY Two of the UK’s leading industry groups are calling for politicians to support the UK’s manufacturing industry and growing businesses in order to ensure long-term stability. During the EEF’s annual conference, Terry Scuoler, the organisation’s Chief Executive Officer, said that future prosperity of the manufacturing sector was down to Government providing the right conditions to secure future success of both the sector and wider economy through productivity growth and rebalancing.

polymers well into the future,” said David Hummel, Chief Executive of Victrex. In a fast-moving market, which thrives on continuous advances in Research & Development, Victrex says the planned Polymer Innovation Centre will increase capacity to turn lab concepts into real-world solutions and processes that can sustain mass production. The facility will enable the scaling up of new products and applications to full commercialisation for Victrex’s global customers. The project is expected to help in the creation of over 80 direct and indirect jobs over the next 10 years and could ultimately see a total £16 million investment. WWW.VICTREX.COM

“Manufacturers are committed to securing the future success of the industry,” said Scuoler. “If the case for manufacturing has been made then I call upon the next policitical party to invest and support these leaders of growth — the manufacturers We need to support a flexible workforce that is the envy of EU partners, continue to invest in R&D and invest in the UK’s infrastructure.” Elsewhere, the Head of the CBI, John Cridland, is calling on the Chancellor to use his final Budget before the General Election to prioritise measures which will create more growth opportunities for

WWW.BRITISHPLASTICS.CO.UK

medium-sized firms – while staying the course on the current fiscal reduction plans. With the economic recovery well-established, the CBI is urging the Chancellor to take action that will help support business investment and exports, providing long-term stability, certainty and simplifying the tax system – all to support ambitious UK firms. “Although the economic recovery is well-rooted and bearing fruit, we still need a Budget that locks-in the successes from this Parliament and spends funds wisely on those areas which will keep growth on track,” said Cridland.” WWW.EEF.ORG.UK

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The Worshipful Company of Horners has announced that this year’s plastic design competitions are now open for entry. The institution runs annual awards for ‘Plastics Design and Innovation’ as well as ‘Bottlemakers’, all celebrating and encouraging UK design expertise, creativity and innovation. “Last year we again saw a record number of entrants all demonstrating high levels of innovation and exemplary creativity in design,” Raymond Layard, the Master of The Horners Company, said of the awards. “The calibre of entrants year-after-year demonstrates their uniqueness and how vital it is to promote all that design in plastics stands for.” Last year’s winners were revealed at Interplas, the UK’s biggest plastics exhibition, and were awarded to DRFP Ltd and Endo Technologies’ ‘Propoints’, a dental application, and M+H’s ‘Braille Tubes’, featuring a new method

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Vehicles manufactured in the UK have been assigned a very special mission – to help 007 evade the enemy in the latest James Bond movie. Jaguar Land Rover has announced this week the lineup of vehicles set to feature in SPECTRE, the 24th in the series of James Bond films, including the Jaguar C-X75s, Range Rover Sport SVRs and Defender Big Foots. The Jaguar C-X75, produced with a carbon fibre chassis for lightweighting, will feature in a spectacular car chase sequence through Rome alongside the

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of printing Braille characters directly onto plastic packaging, respectively. There have been a number of past winners of both competitions that have gone on to receive much commercial success as a result of their success, including the ‘Cycloc’, the ‘Beehaus’ and the ‘Durakerb’ lightweight kerbing system, which won a contract to supply the London 2012 Olympics. Winners of both competitions will be presented with their awards during the Annual Banquet of the Worshipful Company of Horners, on 1st October 2015. Anyone wishing to enter can find out competition specifics and entry requirements, as well as application forms, by visiting the website, WWW.HORNERS.ORG The deadline for entries for both competitions is Friday, 24th July 2015.

Aston Martin DB10. The C-X75 vehicles have been built in collaboration with Williams Advanced Engineering facility in Oxfordshire, England. Jaguar says carbon fibre, drawn from motorsports technology and used in the chassis, creates an incredibly lightweight, yet rigidly strong structure. Super-fine fibres made from pure carbon are woven into fabric sheets that are then carefully impregnated with a resin and baked into shape with a combination of heat and pressure. WWW.JAGUARLANDROVER. COM

Sales of Nampak’s Inﬁni bottle have reached one billion

Comment: Innovation on the horizon with access to funding By Steve Shaw, Executive Director at RAPRA.

TO INFINI AND BEYOND: NAMPAK MAKES BILLIONTH SALE UK manufacturer, Nampak Plastics, has announced sales of its ‘Infini’ milk bottle have reached the one billion mark. The achievement has been reached in just over two years, with Infini being stocked on the shelves of several major retailers such as Marks & Spencer, Morrisons, Sainsbury’s, Tesco and Waitrose. “We are thrilled about the announcement of our billionth Infini bottle sold,” commented Eric Collins, Managing Director of Nampak Plastics. “It’s great to see the efforts of the whole team at Nampak highlighted by customer sales. It is clear that the Infini bottle is an innovative, sustainable and cost effective product – which, evidently, consumers enjoy.” Infini is, currently, the lightest and strongest bottle on the British market

and to has saved 34,000 tonnes of carbon and 16,000 tonnes of material per year since launching in 2012. Kevin Vyse, Primary Foods Packaging Technologist and Innovation Lead at Marks & Spencer, said: “Having witnessed Nampak continue to push the barriers around performance and sustainability over the last few years, it is great to hear of the announcement of the billionth Infini bottle sold. I’m looking forward to further hearing about the advances Nampak has planned for developing this groundbreaking product.” Nampak has secured a myriad of awards since the launch, including the DuPont Award for Packaging Innovation, Sir Peter Parker Award for sustainable business leadership and, most recently, The Cream Award’s prize Judges’ Award for Packaging Innovation. WWW.EU.NAMPAK.COM

RAPRA has highlighted the advice and funding schemes available for SMEs bringing new products to market during a dedicated event held in Telford recently. The ‘Effective Routes to Innovation’ conference was designed to provide businesses with information and advice regarding proof of concept, market research, R&D, prototyping and testing in order to facilitate the process of bringing new products to market. The event was attended by speakers from Pera Technology, a new product development contractor, as well as Warwick Scientific Services (WSS), a centre delivering scientific services and testing facilities based at the University of Warwick. Marina Roberts, Regional Manager for the North West from Pera Technology described the journey of taking an initial idea through to a market launch. She also reconfirmed to the audience that financial support is available for new product development at a national and European level. Horizon 2020 is the new Research and Innovation programme from the European Commission and has a dedicated budget to supports SMEs. Dr Mark Barnett of WWS delivered a presentation entitled, ‘Helping Technology Businesses with Research and Development’ and gave delegates examples of the types of project that could be undertaken at WSS. Dr Barnett also gave an insight into the Innovation Vouchers Scheme that offers SME’s up to two days of free project work with WSS, enabling them to gain access to the vast amount of expertise and equipment that WSS has within its organisation. WWW.RAPRA.ORG

RAPRA’s ﬁrst event of 2015 focussed on innovation and funding for SMEs

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AUTOMOTIVES | NEWS

RACING START TO 2015

FOR UK AUTOMOTIVE MANUFACTURERS

anuary marked the 35th consecutive month of rises in the UK car market, with new car registrations at their highest level since 2007. The amount of exported THE UK’S AUTOMOTIVE cars to China INDUSTRY LOOKS SET increased seven-fold TO CONTINUE WHERE IT since 2009, LEFT OFF IN 2014, WITH thanks to RECENT FIGURES RELEASED substantial BY THE SOCIETY OF growth in the MOTOR MANUFACTURERS wider Asian AND TRADERS (SMMT) market. “Economic INDICATING A POSITIVE growth in Asia OUTLOOK FOR 2015. LEANNE over the last TAYLOR TAKES A LOOK AT five years has THE SECTOR’S STRENGTHS seen demand AND WHAT IT MEANS FOR for new cars accelerate THE SUPPLY CHAIN. massively,” explained Mike Hawes, Chief Executive at the SMMT. “The British car industry’s success in the region is down to the quality of our globally competitive products built with our engineering excellence and our highly skilled workforce. The strength and importance of the UK automotive sector to the UK economy is self-evident.” These figures have been complimented by recent announcements from some of the biggest automotive companies of investment intentions in their UK sites, including Bentley, which has pledged £800 million to projects at its headquarters in Crewe, Cheshire, and

Jaguar Land Rover, which is investing some £1.5 billion in its Solihull plant to develop its lightweighting technologies. This is of course excellent news for plastics companies throughout the supply chain looking to benefit from these opportunities. Luke Hampton, Supply Chain Development Manager at the SMMT told the industry that UK plastics manufacturers should prepare to break into, develop and capitalise on the opportunities seen within the UK automotive industry. “Some of the biggest automotive companies see the UK industry as ‘the place’ to manufacture,” Hampton said. “There is massive opportunity coming for suppliers up and down the supply chain.” This was echoed by the findings of a report from the Automotive Council published late last year, which highlighted a fresh £2 billion growth opportunity for UK component suppliers thanks to the unprecedented period of success being enjoyed by UK automakers. The report assessed the ‘reshoring’ potential for ‘upstream’ automotive suppliers and identified a realistic aim to increase the local content from its current figure of around a third of all components to around 60 percent. Some of the projects involving the UK’s cuttingedge polymer and composite

technologies have already been flaunted at the automotive industry’s biggest events in 2015. In January, the North American International Auto Show in Detroit saw UK manufacturers steal the headlines, including confirmation of Jaguar’s first SUV, the F-PACE, that will benefit from aluminium architecture and lightweighting technology, as well as the US debut of the Oxford-built MINI Hatch, which went on sale in the UK in early 2014, following a £750 million programme to continue MINI’s manufacturing legacy in the UK. It is this heavy investment in new vehicles and models that saw a slight dip in UK car output in January, although the month’s mean performance was 16 percent higher than 2009. The outlook for 2015 remains steadfastly positive with output expected to pick up throughout the year. “Vehicle manufacturers have invested heavily in the UK in recent years to bring new models and technology to our factories,” Hawes continued. “The slight dip in output in January is as a result of this investment as major UK car manufacturers begin production of new models. As production ramps up throughout the year, we expect to see the sector’s output increase.” WWW.SMMT.CO.UK

The MINI Hatch appeared in its hottest John Cooper Works trim for the ﬁrst time in Detroit

Driving material change

MAZDA TO USE NEWLY DEVELOPED BIOPLASTIC IN SUMMER 2015 LAUNCH Mazda Motor Corporation has developed a biobased engineering plastic suitable for both interior and exterior automobile parts that will be used in its vehicles from as early as 2015. Mazda has been proactively developing biomass technologies for a number of years. Now, under the ‘Biotechmaterial’ name, the company says it has come up with the automotive industry’s first high strength, heat-resistant and plantbased bioplastic for interior parts as well as the world’s first biofabric for seat upholstery made entirely from plant-derived fibre. To be suitable for exterior parts and the harsh environmental factors to which they are exposed, bioplastics need to be exceptionally weather, scratch and impact resistant. The automaker says it has now, in conjunction with Mitsubishi Chemical Corporation, succeeded in making the

Providing mate

material suitable for exterior parts as well. It was achieved by optimising the composition of a highly mouldable and durable new bioplastic base material with additives and colouring agents (patent pending), and enhancing moulding specifications. Mazda says this will enable it to produce parts that are as durable as conventional painted ABS plastic parts, yet feature a higher-quality finish and associated design advantages such as mirror-like shine and colour quality. The new bioplastic will help Mazda decrease its environmental impact, as being made from plantderived materials, it curbs petroleum use and with it CO2 emissions. As the bioplastic can be dyed and does not require painting, it also reduces emissions of volatile organic compounds (VOCs). This bioplastic will be first

WWW.BRITISHPLASTICS.CO.UK

used for interior parts on the all-new Mazda MX-5, to be launched in late summer 2015, before finding its way onto exterior components of other production models. Mazda displayed prototype Mazda Biotechmaterial parts made from the bioplastic at Eco-Products 2014, an environmental technology exhibit in Tokyo. WWW.MAZDA.CO.UK WWW.MITSUBISHICORP.COM Mazda says the new biobased engineering plastic will help it reduce its environmental impact

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STREET-LEGAL ABARTH FINDS ITS RACING SPIRIT THANKS TO PLASTICS Polycarbonate glazing solutions and coating technologies from SABIC have been put in the spotlight during the launch of the new production model of a super-fast racing car. The front fixed windows of the new, street-legal Fiat Abarth 695 Biposto, which include built-in sliding panels, are made from SABIC’s ‘LEXAN’ resin, a PC material, and ‘EXATEC’ coating technology. The fixed front windows with sliding panels are features straight from the world of racing and are applied to the Biposto to “help transfer the racing experience of the Abarth brand to the on-road car market”. SABIC says this was feature was only achievable using its EXATEC coating, as it is the one solution available in the industry today that meets European regulatory requirements for transparency, scratch and abrasion resistance for PCbased vehicle windows. The Abarth 695 Biposto (which means “two-seater” in Italian) heralds back to the original super-fast Fiat Abarth from 1964 and is the road-going reinterpretation of the Abarth 695 Assetto Corse, which competes on racetracks throughout Europe. The EXATEC glazing system involves applying protective coating layers on the LEXAN resin-based windows. First, a hard coat is applied to the thermoplastic windows to ensure resistance to sunlight UV exposure. A glass-like plasma coating is then applied over the hard coat, which delivers an advanced level of protection for scratch and abrasion resistance. SABIC says this not only enhances the weatherability of the hard coat layer, but delivers the performance necessary to meet regulatory standards. “It is rewarding for us at SABIC anytime one of our customers is able to achieve ambitions that would not otherwise be possible without our materials,” said Scott Fallon, General Manager, Automotive, SABIC’s Innovative Plastics business.

NEW POLYCARBONATE ROOF IS SMART ADDITION TO VEHICLE A heat-absorbing panorama roof made of shatterproof polycarbonate has been added to the latest edition of Smart’s ‘fortwo’ vehicle to form an extended windscreen. The roof system, made with Makrolon polycarbonate from Bayer MaterialScience, is the world’s largest injection-moulded, transparently coated car roof with an infrared absorber. The new roof is designed to bring more light into the interior of the vehicle, enhance the driving experience through temperature regulation as well as reducing weight compared to glass.

Above: The new street-legal Abarth ﬁnds its racing spirit with help from SABIC’s LEXAN resin and EXATEC coating Right: The front ﬁxed windows of the new, street-legal Fiat Abarth 695 Biposto, which include built-in sliding panels, are made from SABIC’s ‘LEXAN’ resin, a PC material, and ‘EXATEC’ coating technology

“In this case, our EXATEC coating technology proved vital to the task of creating a road-ready racing car without compromising the design. This vehicle is another in a line of good examples of what PC glazing can do to help automakers’ develop and deliver lighter, better performing and differentiated vehicles for their customers.” WWW.SABIC-IP.COM

Manufactured by Munich-based automotive supplier, Webasto, the technical highlight of the roof system is said to be its ability to absorb solar energy and prevent the interior from becoming too hot. This is achieved using infrared absorbers integrated into the granules of the polycarbonate panels. The infrared absorption, which prevents infrared rays from entering the vehicle, also leads to reduced fuel consumption, says Bayer, as there is less need to use the air conditioning system to regulate the interior temperature. The Makrolon AG2677 material is extremely impactresistant, weatherproof and lightweight, with a roof made of polycarbonate reportedly up to 50 percent lighter than a glass equivalent. The new roof is designed to bring more light into the interior of the vehicle

The plastic panel on the new Smart fortwo weighs 9.8 kilograms, which Bayer says both reduces fuel consumption due to the low weight and also influences the car’s driving dynamics, as it shifts the vehicle’s centre of gravity further down. The roof is manufactured by means of two-component injectioncompression moulding. Besides the transparent Makrolon AG2677, Bayer’s black-coloured polycarbonate ABS blend, Bayblend T95 MF, is used as the second component. This, says Bayer, enables the integration of additional functions such as screw bosses on the bottom side of the roof. Attached to them is an adjustable fabric roller blind used to control the brightness of the interior. A coating layer makes the panorama roof resistant to scratching and weathering influences. WWW.MATERIALSCIENCE.BAYER.COM

Driving material change

Providing mate

Opening the door to innovation in lightweighting technology Words | LEANNE TAYLOR

educing weight by approximately 22 percent and improving crash performance, leading global automotive supplier, Magna International, used ARPRO to develop a DRIVING SUSTAINABILITY, complete new door PERFORMANCE AND WEIGHT panel carrier for the REDUCTION, JSP, THE BMW i8. The vehicle’s MANUFACTURER OF ARPRO, upward swinging doors are a visual highlight, so A LIGHTWEIGHT EXPANDED consequently the structure POLYPROPYLENE BEAD FOAM of the panel required a MATERIAL, HAS DELIVERED A strong, yet lightweight, UNIQUE FIRST IN AUTOMOTIVE material to ensure the INTERIOR DESIGN BY ENABLING A doors met the demands NEW APPLICATION FOR THE DOOR for both performance and aesthetics. PANELS OF THE BMW I8. HERE, ARPRO’s ability to reduce BP&R LOOKS IN MORE DETAIL weight, reduce tooling AND THE PROJECT AND SPEAKS investment by a reported EXCLUSIVELY TO THE COMPANY 50 percent and provide BEHIND THE INNOVATION. insulation of the door panel, along with integration of the cable channels and switches, has proven fundamental to the use of a scissor door design for the first time in

RO material The door panel carrier uses ARP

a series-production vehicle. The material has already been widely used in BMW models, including structural applications such as seat benches in the X5/X6 and the 5 Series seatback. “Every gram saved by the ARPRO door panel means less environmental impact, while ARPRO’s energy absorbing capacity enables crash pad functionality, despite small pack space and the constraint of a complex, aesthetic design,” explained JSP President and Chief Executive Officer for Europe Middle East and Africa, Paul Compton. The development of the door panel was revolutionary, so testing at JSP’s ‘eureka’ bespoke moulding facility in Germany was rigorous, overcoming a number of challenges. The engineering process was particularly complex because of the multi-functional requirements in the one component. ARPRO needed to provide stability, structure and strength, as well as the integration of components including trims, loudspeakers and switches, as well as heat and sound insulation, in a very thin wall. This was coupled with the overarching necessity for perfect tolerances appropriate to a premium car. Compton said equally challenging was the moulding tool, as the radical design required multiple iterations to achieve perfection. “Increasing automotive sustainability and producing a door that opens with ease and style is a great achievement, especially as the technology didn’t exist when we started this project,” Compton continued. “Our part in the BMW i8 project has been recognised and has now led on to other exciting developments that will see car production take great strides forward in the near future.”

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Q: How does the structural composition of the ARPRO material beneﬁt its use in automotive applications, particularly from the perspective of safety? A: The structure of the material is closed-cell. It is this microscopic characteristic that predicts its macroscopic behaviour. Each cell is like ‘a balloon that can be squeezed, but not popped’. ARPRO’s behaviour in compression (impact or safety applications) therefore is to squash linearly up to ~80 percent along the axis of impact and then return to shape, also able to withstand secondary impact. This is why ARPRO has been found to be useful in multiple protection-type applications. Key to this is its resilience to impact and ability to incur multiple impacts without affecting its function. This is one of the key differentiators between ARPRO and other materials.

The sporty BMW i8

Q: Carbon ﬁbre is something that is talked about a lot in terms of its beneﬁts for use in automotive, however, it is currently too expensive for use in mass production. How does ARPRO material compare in terms of cost? A: ARPRO is a familiar material and uses processes adaptable to mass production – these are partly the reasons for the growth in applications, but it has other valuable characteristics too such as thermal insulation and recyclability; it even has benefits in crash performance as it is completely isotropic – unlike carbon fibre, it doesn’t matter what direction ARPRO is impacted. There is always a perception that some technologies are more expensive than others, but really it’s about suitability. It depends on the desired performance characteristics as to whether the expense is a concern. ARPRO will deliver crash performance regardless of the impact direction at a value that is suitable to mainstream series vehicles. Q: How long was the process from concept to completion with the BMW i8 project? A: Although we worked directly with BMW on the i8, our customer was the Tier 1, Magna. The challenge was achieving multiple, often conflicting specification targets, adapting the process to optimise the solution. The full length of the project was a function of the whole application, but the ARPRO part development, though complicated, was achieved quickly using our dedicated facilities in the eureka laboratory. From initial designs from Magna through to the first prototypes, the turnaround was approximately three months. However, as this was a unique first not only for us but for Magna and BMW, the whole process was a learning curve and we are proud to now offer new innovations thanks to this partnership with Magna.

costly than injection moulding tools and it was more efficient when developing prototypes and the i8 panel. The i8 panel also had to meet specifications on weight reduction and the use of ARPRO and its tooling was perfect for validating innovative new technologies. The new ARPRO tooling also allowed us to implement changes and adaptations with ease and develop a frame and eventual part that would meet and exceed challenging specifications. This tooling therefore met the weight reduction by reducing the door set by 4.5 kilograms. Q: Is the automotive industry the main focus area for development of ARPRO materials at the moment? A: There is still massive potential for further penetration in automotive, but ARPRO has myriad opportunities in many industries. By dint of scale, the automotive industry will always be a focus area, given the properties delivered by ARPRO and especially now that lightweighting is such a key area of innovation in the sector. Other application areas, though not as large, are also growing fast, however; HVAC heating, ventilation and air-conditioning as an example, is growing on the back of a similar drive towards improved energy efficiency in buildings and therefore the physical properties and manufacturability of ARPPRO is creating massive application development. WWW.ARPRO.COM

Q: ARPRO was created in the early 1980s, how has it developed from the product it was then to the product used in the BMW i8? A: The fundamental characteristics and performance of ARPRO exist within all the grades available, even in the new grades that are developed. Since the 80s, development has been material, technology and application based: many more grades in terms of specific applications, target BP&R CAUGHT UP moulded density colours; lots of WITH ROB PLUSKA, and processing and parallel TECHNICAL SUPPORT technologies created MANAGER FOR ARPRO for particular solutions; more than both of MATERIALS, TO FIND and these things – growth OUT MORE ABOUT THE in new uses for the BMW PROJECT, HOW material provoking broadening of ARPRO MATERIAL HAS huge the industry across CHANGED SINCE ITS the world. ARPRO is DEVELOPMENT AND manufactured and in all the major WHERE JSP’S FUTURE used economies.

Q: Can you expand on the design and development process behind the mould tool for the door panel? A: ARPRO tooling replaced existing parts that Magna already had, however this investment of new tooling was less

PURGING COMPOUNDS | NEWS “HARDEST WORKING” NEW PURGING COMPOUND SAVES TIME AND MONEY, STUDY SHOWS A new purging compound launched late last year by the Dyna-Purge division of Shuman Plastics has proven its effectiveness through an independent study. The ‘Dyna-Purge D2’ compound is said to deliver ease of use through an innovative scrubbing formulation and wider processing temperature range, making it an ideal solution for injection, extrusion, compounding, and blow moulding applications. “An independent study on new Dyna-Purge D2 demonstrates that it is more effective than mechanical (abrasive) and chemical purging compounds, resulting in faster cleaning and less downtime,” explained Tim Cutler, Vice President of Dyna-Purge. According to Cutler, the product is the hardest working purge compound in the company’s product line-up and is able to do the heavy lifting other commercial purging compounds can’t handle. Dyna-Purge D2 features “triple action” technology that thoroughly cleans and removes material from the screw and barrel as well as the tool or die. With a temperature range of 350°F to 625°F (177°C to 329°C), Cutler says it is effective at purging virtually all resins with “consistent and reliable” results.

“Dyna-Purge D2 saves time and money as it lowers purging costs and scrap rates. And it’s so easy to use with no processing adjustment or mixing required,” Cutler concluded. A copy of the recently completed, independent study is available by visiting: WWW.DYNAPURGE.COM

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Purging and peace of mind JS: The answer can take many forms, depending on personal or company priorities. The factors include performance, speed, cost (or a balance of the three), as well as ease of use, versatility of product, regulations (food contact etc.), safety and operator convenience WITH EFFICIENCY (smell, ease AND PRODUCTIVITY of disposing of purge), and A KEY FOCUS FOR finally, re-use/ PLASTICS PROCESSORS, reclaim/ BP&R ASKED JOHN disposal.

STEADMAN, DIRECTOR AT MIDDLESEX-BASED AQUAPURGE, HOW REGULAR PURGING CAN ELIMINATE SOME OF THE MOST COMMON, AND COSTLY, PROBLEMS FACING COMPANIES.

What are the beneﬁts of regular purging?

JS: Aside from establishing consistency in colour and material there are also many side benefits to a regular purging practice. Firstly, regular purging succeeds in removing carbon/ pigment build-up from the compression and metering zones (this is where it generally builds up) and will also help to keep the screw geometry standard. This is normally a forgotten point when companies are validating machines and processes for high-spec jobs. Secondly, it is valuable to have a product in your toolbox that will make certain strip downs obsolete. Regular purging can pre-empt these and all manner of nasty surprises, bringing regular and ongoing peace of mind. Companies that do not deploy a settled programme of purging generally leave manufacturing processes open to situations that create poor product and trigger conflict within operational staff.

How can using purging compounds improve manufacturing eﬃciency?

JS: There are many valid reasons for using a purging agent. Chief among these is that production facilities and their supporting resources (direct and indirect labour) are expensive commodities, which only get paid for if the machines are producing saleable product. When you study production efficiency via processes such as continuous improvement, you discover that there is nothing more wasteful than making finished product that needs to be scrapped. Finished product contains all the expensive factors of production – but is of no value. You can’t even recover the polymer value as regrind. Every moulding that comes off your

machine is your value-added. If it is good, your customers pay for it, but if it isn’t, your company pays.

polymers; and reduced screw throat depth in compression and metering sections, leading to an altering of the melting characteristics of the screw How should a processor use purging and barrel and the creation of differing in the treatment of heat sensitive processing conditions for the same job materials? at different times. JS: Careful treatment is essential Typically, there are two ways in which when moulding heat-sensitive carbon is created. Firstly, when there material masterbatches or polymers is a slow build-up of carbon over an at temperatures close to their higher extended period of time end processing limits. caused by normal running, These materials are periodic stoppages or more likely to cause machine faults. This type the carbon problems of degradation historically mentioned previously. has been very difficult to Generally, these remove as it builds up in materials are designed very fine, hard layers. With to be heat stable for the onset of new highly the residence time filled purging compounds in the barrel during this problem can now be normal production at cured effectively without a range of processing strip-down. Secondly, a temperatures. However, rapid degradation of heat there are areas in the sensitive material resulting Steadman hn Jo screw, barrel and nozzle from machine stoppages that are typically ‘dead zones’, where either during a shut down or a break the flow of material is greatly reduced, down. A practice of regular purging compared with the rest of the system. can tackle and pre-empt both of these This can cause premature degradation situations. of these materials, showing itself as brown streaks in the component. More WWW.AQUAPURGE.COM seriously, it can affect the physical properties, but give no visual indication that this is happening. Ineffective clearing of these heat sensitive materials on shutdown can also cause degradation, due in part, because the standard shutting down procedure – purging with a stable polymer such as polyethylene – invariably leaves a skin of the heat sensitive material on the equipment. This material then burns during machine shut down or start up, and shows itself as black specks scattered throughout the component.

How does a processor know which is the best purging compound?

How can regular purging help avoid problems associated with carbon? JS: Carbon can reduce a polymer processing machine’s productivity. When the viscosity of the melt is altered by changing the material, processing conditions or masterbatch colour or dosage level, a certain amount of previously degraded material can be loosened from the equipment. This typically shows itself as specks or – in more severe cases – streaks in the component. This can result in several problems, such as carbon deposits on the internal parts of equipment that are not completely smooth; reduced physical properties in dark coloured components; corrosion of metal parts due to the discharge of acidic fumes from the degradation of some

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Purging compounds are used for cleaning the cylinder of injection moulding machines or extruders

PURGING IN PRACTICE: HOW NEXT GENERATION COMPOUNDS AND PROCESSING AIDS PROVIDE EFFICIENT MANUFACTURING

olour changes in particular are known to be a critical aspect in the manufacture of components made of thermoplastic materials. All residues must be removed from the moulding machine, otherwise they can be incorporated into the material, resulting in colour contaminations. Such ‘ghost colours’ AS THERMOPLASTIC MATERIALS sometimes manifest FIND HOME IN AN INCREASING themselves a NUMBER OF INDUSTRIES, THE number of hours STANDARDS AND REGULATIONS after completion TO WHICH THEY MUST ADHERE of the cleaning process – an event BECOME MORE DEFINED. WHILE that in many cases THE PRODUCTION CHALLENGES ARE results in lengthy SIMILAR IN ALL INDUSTRIES, THEY machine downtime MUST BE ADDRESSED INDIVIDUALLY periods. This is ACCORDING TO THE SPECIFIC a concern when THERMOPLASTIC MATERIAL, producing automotive components as well PRODUCTION PROCESS AND as for applications END USE. HERE, EXPERTS FROM in the food industry, CHEM-TREND WRITE FOR BP&R such as in the ON THE IMPORTANCE OF PURGING production of caps COMPOUNDS AND PROCESSING and closures. In AIDS IN ENSURING EFFICIENCY addition, specific regulations relating to AND PRODUCTIVITY IN EVERY food safety have to be MANUFACTURING PROCESS. observed in the food industry. The general requirements in all kinds of industries are increased productivity, reduction of machine downtime, reduced scrap rate and increased quality levels. Processing aids, in particular purging compounds, play an important part in addressing issues such as those mentioned above.

Two practical examples Purging compounds in the automotive industry Especially in high-quality branded products, streaks or discoloration is unacceptable. A renowned German automobile manufacturer was faced with this challenge in the production of the centre console for its new electric cars, which is made of thermoplastic polymers using the injection moulding process. Discoloration occurred not only immediately after the colour change, but also after some time had lapsed. Following a detailed analysis of the production process, Chem-Trend’s experts were able to present a solution to this issue with the application of Lusin Clean G300. In a multistage process, the hot runner and cylinder were cleaned using the white cleaning compound. After the cleaning process was completed, colour changes no longer caused discoloration of the components. Purging compounds in the food industry Purging compounds that are used in the food industry are required to be permitted for use in applications where direct contact with food cannot be excluded. Processing aids such as purging compounds must be in compliance with the regulations of the U.S. Food and Drug Administration (FDA) and the European Plastics Regulation 10/2011. One example from the food industry where processing aids play an important role is the manufacture of caps and closures for beverage packages. Here, colour or material changes can often lead to high scrap rates. Chem-Trend’s newly developed Lusin Clean 1060 was designed to solve this problem. This high-efficiency purging compound has been specifically developed for the cleaning of screws, cylinders, nozzles and hotrunner systems of injection moulding machines

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for parts made of polyolefin. It rapidly and thoroughly removes residue from injection moulding machines and is therefore particularly suitable for frequent colour or material changes. In addition, the new purging compound removes black spots, carbon residue and cracked materials. It consists of high-grade plastics with high-efficiency cleaning additives and can be used at processing temperatures up to 290 degrees Celsius. For all types of thermoplastics challenges – from different applications to various thermoplastic materials – there is a solution. Cleaning compounds developed specifically for their respective process allow for efficient machine component cleaning that reduces reject rates and downtime. With the selection of a compatible compound, users report savings between 30 and 70 percent in cleaning costs depending on the application. Often underestimated: Further important processing aids Alongside purging compounds, manufacturers can also benefit from additional processing aids that can contribute to increased productivity. These products include release agents, lubricants, cleaning granulates, mould cleaners and anti-corrosion agents. Release agents not only prevent part sticking, but also help to improve surface quality and avoid stress cracking. The key factor in this regard is the product’s robust and durable release effect, as well as its good temperature resistance. It is important to use an injection moulding tool lubricant that provides long-lasting lubrication and soft running and thus removes the need for time-consuming tool re-lubrication. The lubricant should also not become encrusted or form any hard residues. In addition, the base oil should evaporate as little as possible, since an inadequate lubrication film could cause moving parts to seize up. Moreover, lubricant deposits on plastic components can ruin a tool. Here, too, the product

should exhibit robust temperature resistance. In addition, the latest generation of release agents form a film on preform and film surfaces after the moulding process, thus minimising scratching during the downstream processes. Mould cleaners are used to remove residues and decomposition products from the mould. Targeted use of cleaners that remove degasifiers and oligomers leave the tool in an extremely clean state, thus enhancing the quality of surface characteristics. The advantage of solvent-free mould cleaners is that they reduce downtime “THE GENERAL REQUIREMENTS since they can be applied directly into the IN ALL KINDS OF INDUSTRIES heated mould. Regular ARE INCREASED PRODUCTIVITY, application of a longREDUCTION OF MACHINE lasting anti-corrosion DOWNTIME, REDUCED SCRAP RATE agent helps keep machine components as AND INCREASED QUALITY LEVELS. well as moulds in good PROCESSING AIDS, IN PARTICULAR condition.

PURGING COMPOUNDS, PLAY AN IMPORTANT PART IN ADDRESSING ISSUES SUCH AS THOSE MENTIONED ABOVE.”

Today’s processing materials are mainly solvent-free and avoid the use of silicone and halogens, thus making them environmentally conscious. Moreover, the fact that butane and propane use is avoided helps to enhance the safety of the manufacturing process. Processing materials that are used to manufacture food packaging must also meet the applicable food safety requirements and normally are certified in accordance with NSF H1/H2 and K1/K 3 category codes or Directive 2002/72/EC.

About Chem-Trend

Founded in 1960, Chem-Trend is a global organisation focused on delivering valueadded solutions to improve quality, reduce costs and boost the productivity of moulding and casting operations. With its series of Lusin products, Chem-Trend has designed a complete portfolio of processing aids for the manufacture of components made of all kinds of thermoplastics. WWW.CHEMTREND.COM Colour or material changes in the manufacture of caps and closures can often lead to high scrap rates

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MATERIALS | NEWS Bayer has added the expertise of TCG to its portfolio

The new distribution agreement will see TPS offer a range of lightweighting and innovative materials solutions from PolyOne to customers in the UK and Ireland

BAYER MATERIALSCIENCE BUYS COMPOSITE MATERIALS SPECIALIST TCG

TPS ANNOUNCES DISTRIBUTION OF POLYMER MATERIALS FROM POLYONE IN UK AND IRELAND Materials distributor, Total Polymer Solutions (TPS) has announced a new strategic collaboration with PolyOne to distribute its products in the UK and Ireland. The partnership will see Dublin-based TPS offering its clients a broad range of PolyOne’s innovative products and solutions, including those from its Specialty Engineering Materials, Colour and Additives and GLS Thermoplastic Elastomers businesses. “Our collaboration with PolyOne provides us with a platform of extensive products and expertise to support our clients in solving their toughest manufacturing challenges,” commented Ronan Kennedy, Managing Director of TPS. “Our customers benefit by complementing our own local expertise at TPS with the knowledge base in the PolyOne Innovation Centres, and capitalising on the global reach that PolyOne has.” Kennedy says that two products in particular from the new range have attracted considerable interest from its UK and Ireland customer base, namely ‘Therma-Tech’ conductive solutions and ‘NEU Specialty Engineered Materials’ for the healthcare industry. Therma-Tech conductive solutions can reach thermal conductivities up to 20 W/m.K in-plane (50 to 100 times greater 24

than standard thermoplastics and 20 percent that of cast aluminium) and have typical formulation densities from 1.65 to 1.75 g/cm3 (30 to 40 percent less than aluminium). These materials are increasingly being selected to replace aluminium to dissipate heat in heat sink applications in domestic lighting and automotive applications. Manufacturers are realising weight reduction, increased design freedom, and improved manufacturing efficiency. NEU Specialty Engineered Materials provide the healthcare industry with solutions based on TPU and other elastomers that offer design freedom, regulatory compliance confidence, and system optimisation. Specialty solutions include materials such as radiopaque and radiopacifiers; surface modified solutions and modifiers; antimicrobial materials; pre-coloured materials, and more, for applications such as catheters, endoscopes, fittings and other critical medical devices. Complementing the new collaboration is the appointment of a new member of staff at TPS. David Guthrie has been appointed to work directly with clients on materials identification and development, as well as tooling design optimisation and process efficiency. WWW.TOTALPOLYMER.COM WWW.POLYONE.COM

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Bayer MaterialScience has announced the acquisition of Thermoplast Composite GmbH (TCG) in order to expand its range of polycarbonate composite products. TCG, based in Nuremberg, Southern Germany, specialises in the production of thermoplastic fibre composites and Bayer says the takeover of the company gives it access to “innovative technology know-how” as well as “key patents and facilities”. Bayer MaterialScience is already active in the development and marketing of composite solutions based on polyurethane systems. “We are seeing significant demand and growth opportunities for composites made from thermoplastic materials such as polycarbonate,” said Dr. Markus Steilemann, member of the Bayer’s Executive Committee and Head of the Polycarbonates Business Unit. “By getting into the development and production of the corresponding composites, we want to become one of the driving forces in this industry. We expect promising opportunities above all in the IT, automotive and transportation industries, as well as in consumer goods, which would further strengthen our position.” Bayer MaterialScience plans to expand TCG’s production capacity and will retain all of TCG’s existing staff. Areas where it sees growth potential for polycarbonate composites include premium housings for the IT industry as well as automotive applications. “By acquiring TCG, we have now filled the last gaps in our processing technology know-how,” said Dr. Olaf Zöllner, Head of Polycarbonate Applications Development for Europe. WWW.MATERIALSCIENCE.BAYER.COM

In association with Hardie Polymers – www.hardiepolymers.com

// Materials Technical // NEW UV SWITCHABLE ADHESIVE CREATES PAIN-FREE PLASTER REMOVAL UK manufacturer, Itac, is partnering a Scandinavian firm in the production of a new adhesive that could make the painful removal of plasters a thing of the past. The patented adhesive is applied to a polyurethane film, to create medical plasters, which behave like ordinary sticking plasters in respect to adhesion, water resistance and ageing. Crucially, however, due to its special formulation and a light-catalysed crosslinking process, the new adhesive transforms from sticky to non-sticky when the dressing is exposed to UV-A light. Itac says this unique feature makes this adhesive film particularly suitable for anyone with sensitive or damaged skin, and potentially the first choice for others who simply prefer pain-free plaster removal. The brief required a manufacturing partner with the flexibility to make low volume quantities of the material within tightly controlled conditions, which were protected from light. Itac was able to provide the right environment, plant and facilities plus a team with a high understanding of industrial coating processes, to ensure the finished formulation could be successfully applied in standard coating conditions. Manchester-based Itac undertook the project, creating the required product, with the coated film now ready for stability and full dermal and medical testing. Paul Armitt, Itac’s Managing Director, said: “We pride ourselves on our ability to create advanced adhesives, requiring critical manufacturing techniques. Our size and adaptability make Itac an ideal choice for high quality, bespoke, initial batches and subsequent production runs.” WWW.ITACADHESIVES.COM The new adhesive could provide a cure for pain-free plaster removal

Blog

This month, polymer expert and technical blog author, Dr Charlie Geddes, looks at one of the hardest working thermoplastics in the industry

Polypropylene: the Workhorse of the Plastics Industry Little did Karl Zeigler or Giulio Natta realise, over 60 years ago, when they were developing a catalyst system to produce a useful thermoplastic from the inexpensive monomer, propylene, that their work would have such far reaching consequences. The early propylene homopolymer had similar properties to polyethylene but with higher stiffness and a higher temperature working range. Soon it was discovered that particulate mineral fillers (e.g. talc) gave even higher stiffness, better elevated temperature performance, reduced mould shrinkage and better dimensional stability. Coupling agents ensured that glass fibre filled grades not only had high stiffness but also good strength properties. The unique ability to form a ‘living hinge’ fascinated designers… and frustrated moulders. Nucleating agents were added to provide higher transparency, while biaxial orientation during processing gave thin film with high strength and high clarity, quickly displacing packaging film based on cellulosic thermoplastics. Uniaxial orientation led to polypropylene tape and fibre, replacing jute and other fibres in sacking, carpets and sports surfaces. Incorporating ethylene as a comonomer yielded copolymers, both block and random, which greatly improved low temperature impact resistance, the Achilles heel of the polypropylene homopolymer. Higher ethylene content in the copolymers led to a range of thermoplastic elastomers with better chemical resistance than the styrene based TPEs. Homopolymer grades are favoured by the film and fibre sectors while copolymer grades are used more in injection moulding. Today, thermoplastics based on propylene can be considered the workhorses of the plastics industry but one wonders why propylene copolymers with higher olefins and more polar monomers have not been more developed.

Got a view on the above?

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

Comment: PVC and the path to sustainability: Past, present and future Fifteen years of experience and achievements

Fifteen years ago, the European PVC industry launched Vinyl 2010, its innovative voluntary commitment. Vinyl 2010 was a 10-year programme to move the industry closer to sustainability. The achievements of Vinyl 2010 were particularly notable when it comes to waste collection and recycling, and to substitution of hazardous additives. In 1999, there was no infrastructure for recycling PVC in Europe, and PVC was considered by many as an ‘unrecyclable’ material. In 2010 more than 200,000 tonnes of PVC were recycled, bringing the total recycled since 2001 to almost one million tonnes. In addition, problematic additives, such as cadmium stabilisers, were phased out. By 2010, the substitution of lead stabilisers was well on track to be completed by 2015.

Dr. Brigitte Dero, General Manager at The European Council of Vinyl Manufacturers/ VinylPlus in Brussels, writes exclusively for BP&R on how the PVC industry has moved closer towards its sustainability goals since the implementation of Vinyl 2010 in 2000 and the outlook towards the targets imposed for 2020.

From Vinyl 2010 to VinylPlus

Achieving the goals set in 2000 gave the PVC industry the necessary confidence to launch a new, and even more ambitious, programme in 2011. This new ten-year Voluntary Commitment was signed under the name of VinylPlus. It presents a much more comprehensive approach to sustainable development. Thanks to its partnership with The Natural Step (TNS, an international sustainability NGO), the European PVC industry pioneered an open preparation process of stakeholder dialogue based on this NGO’s ‘System Conditions for a Sustainable Society’, resulting in the identification of five key challenges for PVC manufacturing and use – emissions; energy and raw material consumption; recycling; and sustainable use of additives. When it comes to waste management, the industry aims to recycle 800,000 tonnes per year of PVC by 2020, including 100,000 tonnes of difficult-to-recycle waste. In addition, raising sustainability awareness is a key component of the programme, recognising that progress will be equally dependent upon widening understanding throughout industry, as well as in society generally. Because sustainability issues tend to become similar in all regions of the world, and because many products consumed in Europe are manufactured overseas, it was also decided to extend awareness-raising globally.

Achievements so far

A lot of progress has been made since 2011. Recycling in 2013 reached 444 kt, despite continued adverse economic conditions. The precise amount for 2014 is not known yet, but is expected to be close to 500 kt. A series of projects were launched to assess the possibility of increasing recycling volumes in PVC waste streams left aside so far, such as automotive trim, household packaging and uncontaminated medical waste. Investigations of solutions to recycle challenging waste streams (because of contamination by other materials, or because of composite products) have narrowed down to a few industrial solutions whilst extending contacts with academic institutions to develop innovative solutions for the longer term. In 2014, use of lead-based stabilisers in the EU-28 decreased by 86 percent compared to 2007, progressing towards complete substitution by the end of 2015. European plasticiser producers continue to adapt their products to legislation and to the evolving demands of the market, with a marked shift away from hazard classified low molecular weight phthalates even before the impact of the REACH regulation was actually felt. In a more holistic approach, VinylPlus developed a new methodology to evaluate the sustainability of additives use in PVC products, which integrates the current standard Environmental Product Declarations (EPDs) with TNS criteria for sustainability. This new ‘EPDplus’ approach was discussed and reviewed with external stakeholders at a meeting hosted by VinylPlus in Austria in autumn 2014. Assessment of the energy consumption for 2012-2013 of the PVC resin producers, partnering VinylPlus, showed a significant decrease in the energy used to produce a tonne of PVC, compared to the 2007-2008 baseline, well in line with the 20 percent reduction target by 2020. The analysis of alternative, renewable resources for the production of PVC, including potential scenarios for the future, has been completed and will be summarised in a detailed report, to be finalised in 2015. Dr Brigitte Dero

The preparations for the effective launch of the VinylPlus sustainability label were completed at the end of 2014. This product label scheme was developed in close cooperation with BRE Global (UK-based institute, one of the worldwide leaders in sustainability rating of buildings with deep expertise on responsible sourcing) and TNS. The stringent criteria combine traceability requirements with conditions directly derived from the VinylPlus commitments. Several companies producing PVC construction products have officially applied and are now preparing for their audits. VinylPlus deployed substantial resources to raise sustainability awareness. The voluntary approach of VinylPlus and its scope, encompassing the entire value chain, constitute an interesting and motivating example of what a committed and united industry can achieve. Its relevance extends well beyond the boundaries of the European PVC industry. Presentations in Australia, Colombia, India, Philippines, South Africa, and the USA have spread the knowledge all over the world, and fostered similar schemes in several of these countries. Another channel to spread the word is by using international organisations. In June 2012, VinylPlus participated in Rio+20, the United Nations Conference on Sustainable Development. The VinylPlus Voluntary Commitment has been included in the Rio+20 Registry of Commitments and the recycling target of 800,000 tonnes/ year of PVC was quoted by the UN Secretary General in the UN Summary of Voluntary Commitments. In November 2013, VinylPlus became a member of the Green Industry Platform, a joint initiative of the United Nations Industrial Development Organisation (UNIDO) and the United Nations Environment Programme (UNEP). The official Green Industry Platform ‘Statement of Support’ was signed by VinylPlus at the Green Industry Conference, jointly organised by UNIDO and the Ministry of Industry and Information Technology of the People’s Republic of China.

2015 – Time to review

The commitment document of 2011 stated that “The targets responding to the five VinylPlus challenges are based upon our current knowledge. As the industry progresses on its sustainable development journey, achievement against these specific targets will be constantly reviewed and reported within the annual VinylPlus Progress Reports. Each stakeholder event will be used to gain feedback, inviting new ideas. A formal interim review of all targets is foreseen in 2015.”

The business and regulatory environment has changed significantly since 2011. The economic crisis in Europe has gone on for longer than anticipated. Increasing emphasis on resource efficiency and circular economy policies is reshaping the environmental debate. At the same time, the REACH chemical regulation is affecting more and more substances and the criteria defining hazardous waste are being tightened. These regulatory developments will have a profound adverse effect on recycling post-consumer PVC waste, and potentially jeopardise 15 years of efforts to develop PVC recycling, with a significant negative impact on energy consumption and CO2 emissions as much more waste might have to end up in incinerators. The review will have to take this modified environment into consideration when carefully reviewing the VinylPlus targets and the means to achieve them.

“VinylPlus is working hard to demonstrate that sustainability is fully compatible with, and even becomes more a more a pre-requisite for, a sound business.”

Towards 2020

VinylPlus will continue to improve the way PVC products are manufactured, and dealt with when reaching the end of their useful life. VinylPlus is working hard to demonstrate that sustainability is fully compatible with, and even becomes more a more a pre-requisite for, a sound business. It will also pursue its policy of engaging stakeholders in constructive and mutually enriching dialogues. Last, but not least, unity and collaboration within the value-chain will remain the basis of its success. WWW.VINYLPLUS.EU WWW.BRE.CO.UK WWW.BRITISHPLASTICS.CO.UK

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ROTOMOULDING | NEWS The Envirobin is providing a recycling solution in healthcare environments

ROTOMOULDED LUGGAGE DESIGNED FOR HARSHEST OUTDOOR PURSUITS A Lancashire-based rotational moulding firm has helped design and create a robust luggage item designed for use in the harshest conditions. Excelsior Roto Moulding Ltd., based in Bury, worked alongside outdoor pursuits company, Adventure Orb Limited, to design and manufacture the main body of the ‘Tough Box’ (TBX), a waterproof, corrosion resistant and shatterproof luggage storage box. Unique in its combination of features, one of the TBX’s greatest assets is the single piece composition of its rotomoulded polyethylene main body, which, in the absence of joins, is waterproof and able to float. Excelsior was awarded the contract for the TBX due to its in-house CAD design facility as well as its manufacturing capabilities. It was able to work with Adventure Orb to develop the initial concept into a valid design, and then translate the design into a 3D model. “This was a tremendously engaging project for Excelsior, where we relish a challenge,” commented Managing Director, Giles Fielding. “It was particularly gratifying to be able to handle the job in-house, from concept to production, and of course this meant that we were able to do the work efficiently and cost-effectively.” WWW.EXCELSIOR-LTD.CO.UK

The Tough Box is designed for the harshest outdoor conditions

ROTOMOULDING OFFERS A CLEAN SOLUTION TO HEALTHCARE RECYCLING Leafield Environmental has designed and custom-built a new rotationally moulded recycling unit, said to be the very first self-sanitizing plastic recycling bin. The new pedal-operated ‘Envirobin’ is made with a built-in anti-microbial additive barrier to ensure it complies with the strict cleanliness and infection control regulations of the health industry for which it was designed. “The health industry has struggled to get recycling programmes off the ground in the past because of the lack of suitable products available,” said Leafield’s Managing Director, Phil Maddox. “We are constantly evolving our product portfolio to meet the changing needs of our customers.” The ease of emptying and cleaning the bin was given special attention by Leafield’s design experts. The central lid is operated by a foot pedal which means users never need to touch the bin with their hands when depositing waste: wheels make it easy to transfer to central collection points for emptying. The tilting mechanism at the back of the unit pulls down to simplify the removal and replacement of bags and is easily dismantled for deep cleaning. The antimicrobial Envirobin is currently being rolled out across the NHS Grampian and the NHS Lothian estates. It is also attracting attention as a popular recycling choice for other sectors concerned about maintaining high levels of cleanliness, such as food production and catering industries. WWW.LEAFIELDRECYCLE.COM

WHEN ROTOMOULDING MET DESIGN Italian furniture manufacturer, Serralunga, specialises in the production of items produced using rotational moulding. In its plant in Biella, Italy, it processes over 1,200 tonnes of plastic and produces around 200,000 items a year. The ‘new wave’ vase series (pictured) created by British designer, Ross Lovegrove, features a low-density linear polyethylene structure, achieved using rotational moulding, and a lacquered surface finish. WWW.SERRALUNGA.COM

ROTOMOULDED ‘FROG’ MAKES OFFSHORE TRANSFERS A HOP A Cornwall-based manufacturer of crew transfer technology for the offshore industry has recently upgraded its tooling for the production of a rotomoulded capsule. Reflex Marine Ltd is using tooling from UK-based Midas Pattern Company to create the first in a new generation of safe, rugged and aesthetically pleasing marine crew transfer capsules, the FROG XT4. “Building on the success of our FROG transfer capsule, which we’ve been making for 15 years, we decided to develop an upgraded version, including new, additional features that would benefit our clients,” explained Ken Poole, Supply Chain Manager at Reflex Marine. Midas, who specialise in complicated, multi-part rotational tools that include complex thread forms, loose pieces and sliding actions,

provided the tooling for the new FROG. “Midas made tools to produce three different polyethylene parts: the onepiece external buoyancy unit, a very big moulding weighing around 35 kg; the seat back; and the seat base,” said Poole. “There’s four of each part in every XT4 crew transfer capsule.” The external buoyancy units sit externally to the base frame of the capsule and are designed to offer the user more protection from potential impact. The units have to be capable of safely absorbing deck impact at up to 4.5 metres per second. The seats are also of a semi-saddle design to minimise any whiplash effects. “The external buoyancy units are extremely customer visible so aesthetics are vital. We relied on Midas’ knowledge of the rotational moulding process,” Poole concluded. WWW.MIDAS-PATTERN.CO.UK WWW.REFLEXMARINE.COM Buoyancy Aid from Reﬂex Marine

ROTATIONAL MOULDING TROUBLESHOOTING SEMINAR ATTRACTS RECORD NUMBERS An annual conference dedicated to rotational moulding has attracted a record number of delegates, according to organisers. The third annual rotational moulding seminar held by the British Plastics Federation (BPF) on February 24 brought together key industry experts, included a series of presentations and addressed audience questions. “The event attracted over 110 attendees from 50 firms. As there are only around 60 rotational moulders in the UK, the turnout for this event was exceptional and really demonstrates the hunger amongst UK firms to continually improve upon the excellent work they already achieve,” explained Sara Cammarano, Rotational Moulding Group Executive at the BPF. “It is no surprise that the UK’s rotational moulders are held in the highest regard and seen as some of the best in the world.” The BPF’s Rotational Moulding Group is one of the most active and fastest growing groups in the Federation and is currently occupied with a number of different industry initiatives. These include a code of practice for rotational moulding machines, which the Group is working on in collaboration with the Health and Safety Executive (HSE), as well as the harmonisation of technical datasheets. “This event proved to be the biggest gathering of Rotational Moulders in the UK since the Group organised ARMO 2008 in Belfast,” commented Karen Drinkwater, Chair of the BPF’s Rotational Moulding Group. “The attendance of this event bodes very well for the success of ARMO 2015, which is expected to attract in excess of 500 delegates and will provide an excellent opportunity to showcase the best of innovation and design the UK has to offer in September this year.” WWW.BPF.CO.UK 31

NEW PRODUCT FOCUS:

Rotomoulding machine is the crystal ball for production engineers

esigned specifically to be the starting point for new and innovative products within a rotomoulding plant, the new ‘K-KREATOR’ is said to provide the moulder with SUPPLIER OF PROCESS complete CONTROL SOLUTIONS FOR control, making it THE ROTATIONAL MOULDING a powerful INDUSTRY, 493K LIMITED, investigative HAS EXPANDED ITS tool in the PRODUCT RANGE WITH THE hands of a RELEASE OF AN INNOVATIVE production engineer.

BENCH TOP LABORATORY ROTOMOULDING MACHINE. HERE, BP&R TAKES A CLOSER LOOK AT THE NEW MACHINE AND IT’S UNIQUE FEATURES.

The K-KREATOR has been designed by 493K Limited, a company established in August 2003 as an independent commercial enterprise exploiting engineering research and development work formerly undertaken at the Rotational Moulding Research Centre at the Queen’s University in Belfast, UK. Currently, 493K exports from Northern Ireland to a worldwide market, including Australia, North and South America and China. “We designed this machine for the moulder who wasn’t happy with just turning and burning; this benchtop machine will give moulders the development and control power to move their business forward into new and innovative product areas,” said 493K’s Managing Director, Dr Gareth McDowell. During much of the 1990s research was carried out at the Queen’s University of Belfast highlighting that significant savings and cycle time reductions could be had through the application of various process enhancing features, e.g. internal pressurisation, internal cooling, powder preheating, etc. Many of these used simple and basic techniques to improve the process dramatically, but were hindered in their uptake within the industry due to the difficulty with which they could be implemented on conventional rotomachines.

McDowell explained that 493K’s new concept machine provides a path to the mould for full access of ambient condition services and, therefore, there is no need to transfer gases, polymer powder, water, power or signals though a hot arm. “This will make new possibilities available to the moulder for new and advanced products,” he explained. The K-KREATOR comes with a hexagonal mould 300mm high x 270mm across the points. It moulds samples for mechanical testing using shot weights of less than 1kg for a 3mm wall thickness and heavier samples can be moulded as desired. “This is convenient for small shot weight testing to make sure the polymer is within specification and of the correct properties before going into production,” McDowell explained. The K-KREATOR’s control of rotation is said to provide an entirely new angle on rotomoulding. With accuracies of 0.1 of an angular degree on both the major and minor axes and rotational speeds of up to 150 RPM on the major axis, McDowell says moulders can decide precisely when and where they want the powder pool to be. Programmable wall thickness variation provides the moulder with opportunities to thicken areas containing inserts, strengthen parts of the moulding and even help to get powder to areas which are normally difficult to reach. The K-KREATOR heats the mould with electrically heated hot air and, because the oven is mounted on the inside of the major axis of rotation and all the mould support metal work is on the outside of the oven, there is less energy required to heat the system. This means less energy needed to bring the mould up to temperature and less heat lost to the structure of the machine. The designers intend the K-KREATOR to be used for educational purposes as WWW.BRITISHPLASTICS.CO.UK

well. “It was important that what we designed was easy to install and use; we wanted to make K-KREATOR as accessible as possible to all new investors into the industry, ranging from higher education establishments right the way through to material suppliers and moulders, without the need to invest heavily in new plant or training,” said Project Leader, Andrew Owens. In summary, 493K says the new product presents a more efficient and controllable rotomachine that “WE DESIGNED THIS MACHINE will be available FOR THE MOULDER WHO on a benchtop WASN’T HAPPY WITH JUST configuration for TURNING AND BURNING; the purposes of THIS BENCHTOP MACHINE testing of both regular and WILL GIVE MOULDERS novel materials THE DEVELOPMENT AND within the plant, CONTROL POWER TO MOVE as well as for the setting up of THEIR BUSINESS FORWARD new products. INTO NEW AND INNOVATIVE The machine will PRODUCT AREAS,” offer moulders the facility to test these materials without the need to interrupt production. WWW.493K.COM The K-KREATOR

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SOFTWARE FEATURE:

Welcome to Industry 4.0

ritain is on the cusp of a global, technologydriven 4th industrial revolution, according to research by the EEF. However, despite eight in ten manufacturers saying it will become a business reality by 2025, there is concerns that the UK’s ability to play a leading role in the revolution – dubbed Industry 4.0 – will depend on it keeping up with advances in technology. “The fourth industrial A RECENT REPORT FROM revolution will change the global face of manufacturing EEF, THE MANUFACTURERS’ beyond recognition. The UK ORGANISATION, SAYS BRITAIN must take a leading role if we IS HEADING FOR A “FOURTH are to realise our ambitions INDUSTRIAL REVOLUTION for a healthy, balanced and DRIVEN BY TECHNOLOGY”, growing economy,” explained SOMETHING IT IS CALLING Terry Scuoler, Chief Executive Officer of the EEF. But what INDUSTRY 4.0. BUT WHAT exactly is ‘Industry 4.0’ and EXACTLY IS IT AND WHY IS IT what are the significant EXPECTED TO HAVE SUCH A benefits to manufacturers? GAME-CHANGING IMPACT ON Brian Halliday, Managing INDUSTRY? LEANNE TAYLOR Director at Siemens Digital LOOKS AT THE BENEFITS AND Factory, says the opportunities it presents are vast. WHAT COULD HOLD THE UK BACK “The idea came from FROM CAPITALISING ON THE Germany but is absolutely OPPORTUNITIES IT PRESENTS. applicable to us in the UK and our journey too,” Halliday explained. “It works on the basis that mechanisation in the 1780s was the perhaps the start point for the industrial revolution, that electrification and division of labour as made famous by Henry Ford is the second stage, before automation in the early 1960s again moved manufacturing forward. Industry 4.0 argues that fully autonomous manufacturing is the future.” The idea of Industry 4.0 was discussed at length at the EEF’s National Manufacturing Conference recently, alongside the publication of a specially-commissioned report – ‘Manufacturing Britain’s Future’ – which sets out how the fourth industrial revolution is at hand, and how, in the global battle for dominance, innovative firms can take the lead and help position Britain as the manufacturing and technology hub of Europe. Echoing this, Pam Murphy, Chief Operating Officer of Infor, one of the largest global providers of software technologies specifically for manufacturers, says that capitalising on these new, digitally driven practises will give the UK competitive advantage over other countries. “Here in the UK we don’t have the largest market and we will never be the lowest cost producer,” she explained. “British success depends on overcoming its naturally higher cost base and tapping into growth markets beyond Europe. Where we see the biggest opportunity for UK manufacturers in in the use of technology to provide a competitive advantage and help level the playing field against a naturally higher cost base. “The Internet of things and Industry 4.0 is simply the next evolution of IT that comes about from connecting people, systems and devices to achieve levels of speed, innovation ad decision making simply never possible before. This in turn will allow UK manufacturers to consolidate their position as innovators, leaders and ambassadors of world class production.” In real-world terms, examples of how Industry 4.0 can be exploited on the factory floor include smart devices and machines that talk to each other, to people and to the parts being produced, yielding new levels of automation and productivity. It also includes

revolutionising warehouse management processes via robotics and unattended warehouses, or it’s about using powerful analytics and data science to enable spare parts inventory optimisation. But what exactly does it take to get there? Murphy advises business leaders to incorporate technology strategy into all business programmes and goals. “Technology is intrinsic to every business decision you make, whether its managing a global supply chain, opening a new plant in China or whether its about introducing a new service to your customers, systems, information and IT are the enabling forces,” she said. “I can personally speak to Infor customers today who are pioneering these concepts in a production capacity and gaining a significant competitive advantage in the process as they have recognise that they need to do something different to compete on the world stage. “ So, if the UK could get such a competitive advantage, as well as secure an efficient and successful manufacturing future, why are some manufacturers still cautious about it? Some cited the levels of investment required, impact on skills and keeping on top of technological advances as the main challenges holding the UK back in respect of Industry 4.0. Terry Scuoler believes it is a political question. “Our sector’s ability to remain on top of the fourth industrial wave hinges on the decisions made now and over the next decade by consecutive Governments,” he explained. “We must continue to establish the foundations to support our manufacturing renaissance, particularly alleviating the pressure that Industry 4.0 will place on investment and skills. It is vital that the Government steps up to “IN THE FUTURE, this challenge and works handMANUFACTURERS’ USE OF in-hand with manufacturers and TECHNOLOGY MAY BECOME academia to ensure that the UK THE COMPETITIVE ADVANTAGE, is not left behind,” he added. Despite this, the EEF’s AND THOSE THAT SEIZE THE research indicates half of OPPORTUNITY NOW WILL BE WELL manufacturers believe that the PLACED TO TAKE A LEADING ROLE rapid advance in technology ON THE WORLD STAGE.” will enable more reshoring of production back to the UK, with increased demand for highly skilled workers. “There are so many technologies available today – manufacturers are limited only by their own imaginations,” explained Murphy. “In the future, manufacturers’ use of technology may become THE competitive advantage, and those that seize the opportunity now will be well placed to take a leading role on the world stage.” WWW.EEF.ORG.UK

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Industry 4.0 in the plastics industry –

The shape of the future?

OFFICIAL UK DISTRIBUTOR FOR AVIAN GRANULATOR.

he plastics industry is not immune to the trend towards smart manufacturing and the use of technology to make processes more efficient, supply chains more transparent and management of people, inventories and logistics more streamlined. The last few years have seen a number of the industry’s biggest names leading the way with the technology they believe will both change and revolutionise how production and processes are both carried out and monitored. Commenting, Barry Hill, Managing Director of Wittmann Battenfeld UK, says that despite sounding somewhat futuristic, the vision of the ‘Smart Factory’ could be a reality sooner rather than later. “The concept of Industry 4.0 and Smart Factories all sounds rather futuristic – but the reality is that the future is arriving sooner than we think,” Hill explained. “Industry 4.0 stands for the synthesis and

networking of all relevant technologies in an Internet of objects, services and data. This means integrating, shaping and improving manufacturing in order to be able to offer quick, flexible responses to customer demands — including cost-efficient production of small batches.” With an increasing number of plastics machinery manufacturers leaning towards a ‘one stop shop’ approach in equipment for production, including machines, automation, ancillary equipment and software and process monitoring equipment – to an extent the industry is perfectly positioned to embrace the ideology of smart manufacturing. “We are placed like no other to design and integrate many aspects of the Industry 4.0 agenda,” Hill commented. “It is in many ways but a short and logical step for us to take and it also gives us a definite and decisive competitive advantage. This is the beginning of a long road but, as said, solutions will arrive sooner than we think.”` Testament to this, the company is dedicating a technical seminar at an upcoming event at its manufacturing facility in Kottingbrunn, Austria. Continued overleaf

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Professor Friedrich Bleicher, Head of the Institute for Production Technology at TU Vienna, will give the opening presentation in Kottingbrunn on ‘Industry 4.0 for the Plastics Industry’. Delegates will also get to see some of Wittmann Battenfeld’s own solutions, centred on the Wittmann Battenfeld moulding machines and the Unilog B6P control panel – with other pieces of equipment in a ‘star-shaped array’ as connected to the machine control. This will include its very recently launched ‘WiBa QuickLook’ app, a simple way of checking the status of injection moulding machines and robots via Smartphone. Wittmann Battenfeld is certainly not alone in its forward-thinking approach. At its technology days in Lossburg in 2014, Arburg demonstrated its own vision of Industry 4.0 with its systems and equipment. The company used production of a toy buggy to illustrate in practical terms the benefits that can be achieved with Industry 4.0, as it incorporated the data integration of machines, order information and process data. Visitors received a personalised chip card, which was read by the control system of a production cell. An injection-moulding machine then produced a toy buggy, before part removal via a robotic system to a laser printing station to apply an individually printed QR code. Once built, all data surrounding the toy was logged so that it could be called upon later. The key element in the process was the host computer system, which acted as a network between various independent stations, recording all the parameters and

transmitting them to a web server. All the work steps were documented, ensuring transparent and traceable production. “We used the Technology Days as an opportunity to demonstrate that Arburg has already started the journey towards the smart factory. We can individualise every component and trace it at every point in it production. This ensures transparency,” explained Michael Vieth, Group Manager for Technical Coordination at Arburg. Since the technology days, Arburg has used its appearances at major trade shows, including Fakuma and the upcoming NPE, to demonstrate similar processes for visitors. Despite the evident endorsement of the concept of Industry 4.0 illustrated by these examples, Europe’s largest “IT IS IN MANY WAYS BUT A application-based research SHORT AND LOGICAL STEP organisation, the Fraunhofer Institute, has identified issues of FOR US TO TAKE AND IT protocol and communication as ALSO GIVES US A DEFINITE one of the greatest challenges AND DECISIVE COMPETITIVE in connection with Industry 4.0, including guaranteed safety ADVANTAGE. THIS IS THE of data and access. It says BEGINNING OF A LONG ROAD establishing a common platform BUT, AS SAID, SOLUTIONS for a MES (Manufacturing WILL ARRIVE SOONER THAN Execution System) “will immediately run into the issue of WE THINK.” a lack of agreed communication protocols” and calls for standardisation. It would seem that with regards to the themes of efficiency, productivity and sustainability that have been so prevalent in the plastics industry over the last few years, the uptake of industry 4.0 is the next logical step. All that remains to be seen is how quickly. WWW.WITTMANN-GROUP.COM WWW.ARBURG.COM WWW.FRAUNHOFER.DE

WWW.BRITISHPLASTICS.CO.UK

Are You Testing Melt Flow to ISO 1133 or ASTM D1238? Instron®’s versatile Melt Flow Tester range is the ideal solution for measuring melt mass-flow rate (MFR) and melt volume-flow rate (MVR) according to the latest standards.

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FPT-H1 Horizontal Dedicated Friction Peel Tear Tester Mecmesin’s FPT-H1 is a dedicated horizontal test system designed specifically for the packaging industry and for manufacturers, converters and users of sheet and film materials.

Key Features Versatile, perform coefficient of friction, peel or tear tests using one machine Pre-programmed for instant selection of industry standard test methods e.g. BS EN ISO 8295 & ASTM D1894 Comprehensive range of friction, peel and tear fixtures Interchangeable loadcells Stainless steel horizontal plane

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TESTING & INSPECTION | NEWS NEW WEBSITE DESIGNED FOR ENHANCED USER EXPERIENCE

Instron’s new AVE 2 video extensometer

Instron, a provider of testing equipment designed to evaluate mechanical properties of materials and components, has launched what it describes as the “fastest, most accurate non-contacting strain measurement device commercially available.” The new AVE 2 second generation, advanced video extensometer is said to conform to the most rigorous testing standards, such as ISO 527, ASTM D3039, and ASTM D638. The fully integrated device easily adapts to the normal fluctuations of environmental conditions in a lab and is easily adapted to any testing

machine on the market that uses a ±10v analog input (performance depends on the system). Designed to dramatically reduce errors from thermal and lighting variations that are common in most labs, the company says the AVE 2 is the only device on the market to utilise the real-time 490 Hz data rate while also achieving a one-micron accuracy. Its versatility allows for testing under multiple environmental conditions and can be used for advanced strain measurement with Digital Image Correlation (DIC). The AVE 2 measures both modulus and strain to failure of almost any material including plastics, metals, composites, textiles, films, biomaterials, and many more.

MALVERN LAUNCHES “GROUNDBREAKING” NEW PLATFORM FOR POLYMER ANALYSIS UK-based Malvern instruments has launched a completely new permeation/size exclusion chromatography (GPC/SEC) platform that it says “breaks new ground” in delivering the high performance, ease of use and productivity demanded in today’s analytical laboratories. The new ‘Omnisec’ platform integrates highly efficient sample separation and high sensitivity analysis and has applications for wherever there is a need for detailed analysis and understanding of natural or synthetic polymers, proteins and macromolecules. GPC/SEC is a two-step analytical process that involves separating a sample on the basis of its size and then analysing the resulting fractions. The technique delivers molecular weight, molecular size and structural information, all of which define the performance of many industrially important materials.

WWW.INSTRON.COM Instron has launched a new website dedicated to user ease of use

Malvern says by coupling efficient sample separation with fully optimised, multi-detector, information-rich analysis, it has produced a market-leading solution for researchers and formulators developing novel natural and synthetic polymers, pharmaceutical and biopharmaceutical products. WWW.MALVERN.COM

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The new OMNISEC GPC/SEC system from Malvern Instruments

INSTRON LAUNCHES “FASTEST AND MOST ACCURATE” STRAIN MEASUREMENT DEVICE

In addition, Instron has launched a new global website dedicated to making it easier for users to find the testing equipment and technical information required. By simplifying the navigation of the site’s pages, improving the literature library and adding services tailored to the users geographical location, the site is now more intuitive and more responsive than the previous version. Toby Kemp, Global Marketing Communications and Web Manager for Instron, commented: “This has been such a great opportunity for us to enhance the experience for our users. Many of the changes we incorporated into the new site resulted from customer feedback and our investment in making their site journey positive and rewarding. We are still working towards the completion of our site, including the release of our content in 11 additional languages for our global customers.”

NEW TESTER FOR FOAMS LAUNCHED Producer of test equipment for polymers and elastomers, Hildebrand Gmbh, has launched a new machine designed for foam-based materials. The new ‘Digital Ball Rebound Tester’ is designed for the determination of the resilience elasticity of foam materials in accordance with DIN EN ISO 8307 and ASTM D 3574. Hildebrand says the structure of the tester allows for easy and safe measurement of ball rebound whilst intelligent firmware controls the measuring cycle and eliminates operator error, as no manual calibration is needed. The measuring cycles are short and precise, according to the required standard. WWW.HILDEBRAND-GMBH.DE The new Digital Ball Rebound Tester

LUCIDEON MOVES TO CAMBRIDGE FOR DEVELOPMENT AND TESTING OF POLYMERS International materials development and testing company, Lucideon, is opening new offices in Cambridge where it will develop novel polymer systems as a result of continued growth. Operating as Lucideon Cambridge Polymer Limited, the new site on Cambridge Science Park will be the hub of development for high-value applications for use in industry, particularly in the healthcare sector.

MANUFACTURER SEALS THE DEAL WITH NEW ZWICK TESTING MACHINES A producer of highly specialised rubber and elastomeric seals and sealing systems has invested in two new Zwick testing machines to ensure accuracy and quality. Toyoda Gosei Meteor GmbH’s products are used in automotive applications, rail vehicles and aircraft, in buildings and in electrical and domestic appliances. The strict regulations of these industries means the company has to ensure its products meet high standards of quality and endurance. Meteor is now using a new, single-column zwickiLine testing machine (Fmax 2.5 kN) primarily for compression tests on seals. Involved here are door seals, edge-guards, seals for convertible tops, headlight seals and seals for wholesale distribution. The zwickiLine is equipped with test fixtures that reproduce the operating conditions of seals. To enable optimum sealing and optimum seal closing, closing forces are determined

“As our strategy for the future is based on innovation and developing cutting-edge technologies it seemed a natural move for us to be part of the thriving and energetic science, engineering and business communities that exist in the greater Cambridge area,” said Tony Kinsella, Chief Executive at Lucideon. Lucideon develops and tests cutting-edge materials technologies for sectors including medical devices, ceramics and nuclear. Current work includes the development of field-enhanced processing

WWW.BRITISHPLASTICS.CO.UK

proportionately to seal height. The test results are transmitted directly to the SAP system via Zwick’s testXpert II testing software. The second testing system, an AllroundLine with a maximum force of 5 kN, is mainly used for tensile, tear growth, adhesion and peel tests on elastomers. The new technology (new electronics, new force-measurement technology, lightXtens extensometer) has allowed improvements to be achieved, says Meteor, particularly in test-result accuracy and reproducibility. The information gained is channelled directly into product development; this testing machine also has the advantage that data-transmission errors, which can occur with manual input, are prevented, thanks to the direct SAP connection. WWW.ZWICK.CO.UK Toyoda Gosei Meteor GmbH produces highly specialised sealing products for industries such as automotive

technology to reduce the energy used to produce ceramics, inorganic controlled release technologies for the healthcare industries and a new technology, MIDAR, which can be used to encapsulate nuclear industry waste. The decision to have a base in Europe’s longest-serving and largest centre for commercial research and development forms part of Lucideon’s expansion plans, which include opening offices in North Carolina, Turkey, Japan and Australia. WWW.LUCIDEON.COM

MECMESIN LAUNCHES NEW FRICTION, PEEL AND TEAR TESTER UK-based testing instruments manufacturer, Mecmesin, has introduced its latest model it says is designed for ease of use and maintenance for friction, peel and tear testing of plastic films and other materials. The new ‘FPT-H1’ model is said to be ideally suited to the packaging industry, and for manufacturers, converters and users of sheet materials. “Mecmesin understands industry’s need for dedicated yet versatile testers. With the FPT-H1 we have put ease of use and clean design at the forefront,” said Mecmesin Managing Director, John Page. “This is a market-leading machine suitable for continuous daily use, but also for finer and more detailed laboratory friction testing.” In the dynamic environment of sheet and web-fed machinery, quick and accurate measurement of the coefficients of friction is vital. Machine speeds can only be only optimised for productivity if tearing, jamming and misfeeds are prevented, so the FPT-H1 is designed for reliable and rapid testing. With an integral touch screen to access test routines, and guidance through each run, Mecmesin says testing requires minimal training with maximum repeatability. For quality testing of seals, closures and perforations, and the tear strength of sheet materials, the FPT-H1 is said to prevent

convenience and high throughput. It features Mecmesin’s ‘Emperor’ software for control, data acquisition and analysis, which the company says makes the FPT-H1 ideally suited to detailed laboratory testing and extension into other tensile testing. When fitting plastic film samples it is vital not to compromise the surface being tested, so to minimise handling, the FPT-H1 employs quick-attachment grips, and coefficient of friction (COF) sample sleds with magnetic grips. Sample sleds are available to comply

with the weights and dimensions requirements of all the main test COF standards, with linkages as defined for static and dynamic coefficients of friction and avoidance of stickslip behaviour. The FPT-H1 can be employed equally for tear and peel testing in packaging situations, says Mecmesin, including fixturing for 90 and 180 degree and T-peel standard methods, and trouser tear or perforation line testing. WWW.MECMESIN.COM

For ALL your plastics testing needs

> Universal Testing Machines > Fatigue Testing Machines > Pendulum Impact Testers > Extrusion Plastometers > HDT/Vicat Testers > Hardness Testers

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Kongskilde your conveying specialist

Kongskilde offers complete systems for conveying and handling large volumes of plastics materials generated from today’s production lines. These systems ensure a high efficiency, significant savings and an improved working environment.

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

Tel: +44 (0) 1793 827666 Email: sales@transxl.co.uk Website: www.transxl.co.uk

QUALITY USED MACHINERY

1300mm wide Kuhne sheet extrusion line with K701E - 30D vented extruder, melt pump, 1200mm die head, 1300mm x 300mm chrome rolls, pump group, winder.

2950mm wide Welex Davis Standard sheet extrusion line with 150mm DS extruder, 33D, Flex lip die, 2950mm x 500mm 3 roll stack, pump group, haul off, guillotine

SHEET LINES

1800mm wide Reifenhauser sheet extrusion line. 120mm Reifenhauser extruder, melt pump, 1800mm die, 3 roll stack, pump group, haul off, cross cut saw.

THERMOFORMERS

2950mm Sheet line for HDPE 2290mm Sheet line for ABS 2000mm Omipa/Union Sheet line. 1800mm Reifenhauser sheet extrusion line 1500mm Bandera stack 1350mm Welex/union sheet line 1300mm Kuhne Sheet line 1000mm Omv sheet line 1000mm Esde 3 rollstack

DIES

115mm Davis Standard Thermatic extruder model 45IN45T . 30:1 L/D with barrier PP/HDPE screw, 305kw motor, Fan cooled electrically heated 6 zone barrel 2008!!

2000mm wide Omipa/ Union coextrusion sheet line. 120mm and 90mm Omipa extruders, 2000mm wide Union 3 roll stack 500mm rolls, haul off guillotine. 2002

EXTRUDERS 50mm Welex extruder 90mm Egan extruder 90mm Kaufman extruder 100mm Union Extruder 100mm Omv extruder for P.P 115mm Davis standard extruder 120mm Omv Extruder 150mm Egan extruder 1000mm wide Bulldog model F-40HB skeletal waste granulator with dancer arm, sound prooﬁng, blower and cyclone. 2006 .

PROFILE LINES

MIXERS

TRANSXL INTERNATIONAL • THORNHILL • SOUTH MARSTON • SWINDON • WILTSHIRE • SN3 4TA • ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk

WWW.BRITISHPLASTICS.CO.UK

RECLAMATION & RECYCLING | NEWS The EREMA Group has announced it is to expand with the formation of a new sister company specialising in technology for the recycling of production waste.

EREMA LAUNCHES NEW COMPANY DEDICATED TO RECYCLING PRODUCTION WASTE The EREMA Group has announced it is to expand with the formation of a new sister company specialising in technology for the recycling of production waste. ‘Pure Loop’ will focus on developing combined shredder and extruder technology for repelletising of production waste including film, tapes, fibres, nonwovens, fabric, hollow bodies, solid plastic parts and more. The first plant systems offered by Pure Loop will be based on this technology and will be sold under the brand name “ISEC” (Integrated Shredder Extruder Combination). Manfred Dobersberger, who was the co-founder and

SHREDDERS TEAR APART HIGH MATERIAL RECOVERY COSTS A series of size reduction shredders, new to the UK market, are eliminating the need for expensive systems or third party recycling for cost-effective material recovery. The Crushmaster Q Series of shredders is designed to reduce a wide array of plastics, from wheelie bins to purgings, at 30 percent less than the price of a standard shredder and built to work in combination with a low-cost granulator for optimal consistent, low cost material recovery. “Some of our clients with bulky waste asked for a way to avoid investing in very large expensive granulation systems or having to

former co-owner of recycling machinery manufacturer, NGR GmbH, will head up the new company. “With ISEC we are able to adapt to the scrap logistics of our customers in an optimum way, always with the aim of returning the largest possible amount of recycled pellets to production,” explained Dobersberger. “The key lies in the handling of the material and, therefore, minimising the possibility of contamination as far as possible.” The official launch of Pure Loop and the global premiere, including live product demonstration of ISEC, is taking place at the NPE show in Orlando, Florida. WWW.EREMA.AT

outsource to a third party recycler,” explained Mike Jordan, Managing Director of Summit Systems, supplier of the shredders in the UK. “We identified the answer to be the Crushmaster as it provides a low cost way of breaking down scrap, prior to granulation. Clients are then able to granulate material using much smaller, lower cost equipment than they otherwise could.” The Q Series is suited to medium to light duty applications across several industries, covering blow moulding, large injection moulded parts, profile extrusion and thermoset mouldings. Built to withstand continuous processing, it can reduce up to 50 tonnes per week. By cutting out third party recycling, it is said to

WWW.BRITISHPLASTICS.CO.UK

reduce the cost of recycling by as much as 75 percent, paying for itself within 22 tonnes of processing. “The rapid action of the Q Series reduces a tonne of waste in a matter of hours, eradicating the need to store mountains of bulky waste to await collection. The end product takes up a fraction of the space of scrap, and is of a consistent quality for immediate granulation and then re-use,” Jordan added. Designed for simplicity the Q Series combines a variety of features to reduce downtime and maximise productivity. Cutters can be turned after a side is worn, and an easily removable screen allows for quick rotor access and screen changes. WWW.SUMMITSYSTEMS.CO.UK

IPEG SELLS RAPID GRANULATOR TO LIFCO

PLASTICS EUROPE REINFORCES ACTIONS TAKEN TO REDUCE MARINE LITTER In response to a new study on marine debris looking at ways to tackle the amount of plastic waste in the world’s oceans, PlasticsEurope has reaffirmed the industry’s commitment to proper waste management systems. The association of plastics manufacturers in Europe said it welcomes any study that helps to better understand the impact and global dimensions of marine litter. The industry continues in its efforts to highlight the importance of proper waste management systems as key to tackle plastics waste ending up in the (marine) environment. “We, as an industry, are not only seriously concerned about marine litter: we take action,” commented Karl-H. Foerster, Executive Director of PlasticsEurope. “In 2011, the European plastics industry launched the initiative Zero Plastics to Landfill, which aims at reducing the amount of post-consumer plastics waste sent to landfills to zero. Seven EU member states, plus Norway and Switzerland, introduced landfill bans or similar measures applicable to plastics waste. The experience of these nine countries shows that

phasing out landfilling together with a better implementation and enforcement of existing waste legislation is crucial to tackle this issue.” At global level, the European plastics industry together with their global peers and other stakeholders have put in place more than 185 projects to tackle marine litter through the ‘Declaration of the Global Plastics Associations for Solutions on Marine Litter,’ a public commitment by the global plastics industry to tackle plastic waste in the marine environment. Another example of the efforts that the industry is doing to share ‘best practices’ in plastics waste management is the “Identiplast” conference. This event, where international experts will share their knowledge to identify key drivers to reach a zero plastics waste society, will take place in Rome in April. “IdentiPlast is relevant to local authorities and municipalities, policy makers, waste management organisations, plastics recyclers, manufacturers, converters and compounders, but also to OEMs, academia and research institutes and NGOs to understand how we can solve this issue,” concluded Foerster. WWW.PLASTICSEUROPE.ORG

WWW.BRITISHPLASTICS.CO.UK

US-based manufacturer of machinery and equipment for plastics processing, IPEG, has announced the sale of the Rapid Granulator group of companies to Lifco AB of Sweden. Rapid Granulator manufactures and supplies size reduction solutions for plastic processors and recyclers. IPEG said the sale of the group would not impact the other companies in its portfolio, including Conair, Republic Machine and Thermal Care. IPEG CEO, Chris Keller, said the offer to buy Rapid was unsolicited and “very attractive in many respects.” He described the opportunity as “an excellent fit for the [Rapid] business and its employees. Lifco is a well-endowed Swedish company with a very credible business strategy and a record of strong growth over the last 10 years.” Dr. Toni Reftman, Managing Director of Eldan Recycling, a Lifco subsidiary based in Demark, will assume responsibility for the Rapid business, with all other Rapid employees expected to remain with the company, which will continue to operate under the Rapid brand name. Eldan Recycling, which is part of an environmental group in Lifco’s systems solution business area, is a global supplier of recycling equipment and systems for processing tyres, cables, WEEE, aluminum, refrigerators, municipal solid waste, magnesium and various other scrap materials. Eldan does not have its own granulator product line, so the acquisition of Rapid is thought to be highly complementary to its business. WWW.RAPIDGRANULATOR.COM

Dr. Toni Reftman will assume responsibility for Rapid Granulator as well as Eldan

Comment: Going full circle: how Retailers can create value by closing the loop

hanging patterns of behaviour within businesses and other organisations is no small task and is one that requires a conscious effort. But closing the loop in the supply chain is an important step in progressing towards more sustainable business, and is a way in which retailers can both RETAILERS CAN REDUCE manage their environmental obligations and add to the COSTS, IMPROVE MARGINS value of an important resource AND MOVE TOWARDS – waste.

SUSTAINABLE BUSINESS MODELS BY INTEGRATING THEIR WASTE RECYCLING PRACTICES INTO THEIR SUPPLY CHAINS.

IMPROVED TECHNOLOGY, TOUGHER REGULATIONS, GROWING CONSUMER AWARENESS AND COMMODITY PRICE VOLATILITY ARE JUST SOME OF THE FACTORS THAT ARE DRIVING THE BUSINESS CASE FOR ABANDONING LINEAR MODELS AND GOING CIRCULAR WITH CLOSED-LOOP BUSINESS PROCESSES. HERE MIKE MAXWELL, OPERATIONS DIRECTOR AT UK RECYCLER, JAYPLAS, EXPLAINS THE VALUE OF FORMING NEW INDUSTRY PARTNERSHIPS AND REEVALUATING SUPPLY CHAINS IN ORDER TO CREATE VALUE THROUGH A CIRCULAR MODEL.

Going full circle

A circular economy is where the value of the ‘waste’ resources is recaptured and re-fed into the manufacturing process. This requires businesses to re-evaluate the way some of their processes work. It’s true that over the last 10 or so years there has been a significant improvement in the awareness shown by many retailers toward the environmental impact of their practices and a keen awareness of their own duty of care, but according to Defra calculations, a shift from linear thinking could be worth up to £23 billion per year to UK businesses.

Heavy footprints and volatility in the market

Achieving the financial, efficiency and environmental benefits of a more circular economy involves collaboration right across the business cycle with people working together towards the same ends. Chiefly, this requires less reliance on virgin material and extracting the value from vastly underutilised waste resources. In the plastics recycling business there is a heavy reliance on the export market where waste is collected, consolidated and transported abroad. This waste often ends up in China or other countries in Asia where there has historically been high demand. Although what we are seeing now is the effect of China’s rapidly developing domestic recycling infrastructure, as they are now looking to reduce their reliance on imported material year on year. While this business model has worked well in recent

years, the market is seeing some changes. Retailers are starting to look to solutions that address the weaknesses in this process and are keen to find new ways of working that address some of their top concerns, such as the large carbon footprint incurred from transporting bulk waste for processing in Asia, as well as too great a reliance on export markets, which are becoming increasingly more volatile, with tightening restrictions on what can and cannot be exported.

Reshoring the process provides transparency and reliability

What retailers are really asking us for is greater traceability, stability and value. What we at Jayplas have been doing over the last few years is investing heavily in our UK recycling infrastructure, allowing us to control the whole process, from collection to recycling into pellets, to processing into manufactured goods made from recycled feedstocks. This investment has allowed us to remain cost competitive while reducing the cycle’s carbon footprint. This means we can offer retailers and other organisations a transparent, traceable, closed-loop system in which their own plastic waste is transformed into new products or packaging. This change in approach to resource management takes collaboration. Collaboration in the form of new industry partnerships between retailers, reprocessors, manufacturers, packaging technologists and designers. But also more collaboration within organisations, with better communication between the various roles involved in waste management, packaging and supply chain management. There is an obvious environmental value in growing the UK’s ability to offer a circular process for recycling plastic waste. Sending plastic to landfill or incinerating plastic for energy capture poses significant environmental costs. Yes, recycling plastic material keeps it out of landfill, but a closed-loop recycling system also keeps the value in businesses.

WWW.BRITISHPLASTICS.CO.UK

Engineering Passion

www.kraussmaffei.com

MACHINERY | NEWS FANUC UK PARTNERS WITH POLYMER TRAINING AND INNOVATION CENTRE IN TELFORD Fanuc UK, a provider of all-electric injection moulding technology, has announced its partnership with the Polymer Training and Innovation Centre (PTIC) in Telford. Under the partnership, Fanuc is supplying a Roboshot S2000i 30B injection moulding machine to the centre in order to facilitate training and increased course capacity. “Our loan of the Fanuc injection moulding machines to the Polymer Training Innovation Centre will not only benefit the training needs of our own employees, but will enable us to service the training needs of our customers,” explained Chris Sumner, Managing Director of Fanuc UK. “In addition the centre will give us another level of access to the global plastics industry, allowing us to showcase the reliability and high precision of our injection moulding machines.” Georgina Parker, Director of Employment Skills and Commercial Delivery, Polymer Training and Innovation Centre, said: “The partnership enables us to train our global client base on the new high performance Roboshot. At the same time, FANUC UK will be able to have our plastics training expertise at their disposal, as well as access to the plastics industry for developing new business opportunities.” WWW.WOLVCOLL.AC.UK/POLYMER WWW.FANUCROBOMACHINE.EU The new Fanuc machine installed at the PTIC in Telford

NEW TECHNOLOGY ‘REFORMS’ PRODUCTION PROCESS FOR PACKAGING COMPANY Derby-based flexible polythene packaging specialist, Reform Plastics, says the installation of a new bag making machine has significantly enhanced its production process. Reform extrudes, prints and converts high, medium and low density polythene film and bags. The new BMTEK ETL 1.4 Automatic Bag Making Machine, which is supplied exclusively in the UK by Packaging and Converting machinery supplier, Optimation Ltd, is said to be making a marked difference to Reform’s output, floor space and flexibility. “This machine has increased our production process significantly. It is already performing at a higher output than our existing machines and we have not yet used it to its full capacity,” explained Reform’s Managing Director, Dave Waller. “With such an improved metres per minute conversion rate we are fulfilling orders more quickly and invoice sales have increased, thus reducing our work in progress which takes up shop floor and racking space. We are a BRC accredited company and the quality of bag produced is vitally important. With this machine we are confident we will not sacrifice quality with the increased WWW.BRITISHPLASTICS.CO.UK

L-R Moreno Roveri – General Manager -BMTEK Italy & Dave Gurney – Works Manager, Reform Plastics (Derby) Ltd.

outputs. Our reaction time to orders is now far faster and we have added flexibility.” The BMTEK machine features a motorised unwind to facilitate the movement of large and heavy film reels. Designed to align with the height of a pallet for ease of loading the reel onto the motorised rollers, the system allows two or more reels to be loaded easily with no need for a shaft inside the reels. This makes it possible to utilise reels with damaged cores. A tear line perforation system is installed between the rubber rollers and the distance between perforations is adjusted through a roller for length control. A password protected touch screen controller is also included. This has the ability to implement and control a wide range of operations including speed of cycle, bag length and repeat weld (sealing twice on the same bag) with the possibility to delay the film advance in order to make a stronger seal or to have two separate seals at the bottom of the bag. WWW.OPTIMATION.CO.UK

BUYER’S GUIDE vibration welding

MATERIALS

Branson Ultrasonics

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

MASTERBATCH

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

BUY/SELL

NEW Q Series Crushmaster Shredder 10% Introductory Offer to the end of May 2015 Quote ‘Crushmaster Spring Deal’ n Affordable Material Re-use n Reduces up to 50 tonnes per week n Cut out 3rd party recycling n Medium to light duty applications n Suits almost all plastics n Easy to use

E info@summitsystems.co.uk W www.summitsystems.co.uk T 01827 265 843

DEHUMIDIFIERS Motan Colortronic Ltd

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

EXTRUSION SYSTEMS new and used

Cooper Plastics Machinery

MOULD RELEASE

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

ASSEMBLY hot plate welding Branson Ultrasonics

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

Burgess Colours & Compounds, 1-10 Burgess Street, Middleport, Burslem, Stoke-on-Trent, ST6 3PD, T: 01782 819670 F: 01782 816133 Email: sales@burgesscolours.co.uk We are one of the UK’s leading supplier of black, white, colours and additive masterbatches

HEATING EQUIPMENT

pulse staking H.T.E Engineering 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

colour masterbatch

ultrasonic welding

CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd

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

DRYERS

Eclipse Buyers Guide_Layout 1 07

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.

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

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

MACHINERY & EQUIPMENT ANCILLARIES InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) New and used Granulators, Shredders, Pulverisers, Wash Plants Blades and Screens

The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

Blade Sharpening Ancillary Items Service – Repair - Spares UK & Ireland Agents for

Tel: 01827 838840 Email: info@granulators.org www.granulators.org

Telsonic UK Ltd

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

induction heating for platens and tools MF Induction Heating

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 F: 01543 574460 E: sales@mfinduction.com W: www.mfinduction.com BS EN ISO9001: 2000 registered. BS EN ISO9001:2008

HOT RUNNER SYSTEMS hot runner controllers

BUYER’S GUIDE

MACHINERY & EQUIPMENT LABORATORY MACHINES

Filter Testers

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

Engineers to the Plastics & Rubber industries, specialising in the following: Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd

STATIC CONTROL Arrowquint Ltd

Unit 2 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.

TESTING EQUIPMENT

SERVICES

Clayton Thermal_Layout 1 19/04/2

CONTRACT CLEANING

Injection Moulding Extrusion • • • • • •

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

E: info@millmerran.co.uk T: +44 (0)1626 83 63 73 www.millmerran.co.uk

MATERIALS HANDLING AND STORAGE

INJECTION MOULDING

gravimetric/volumetric 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

PRINTING MACHINES pad

SCREEN CHANGERS

hopper loaders

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

RECYCLING 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

MIXING, FEEDING & DOSING

EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H. Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at

CHOOSE THE NUMBER ONE.

SCREWS & BARRELS

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 Machinery UK

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

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 For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

MOULDFLOW ANALYSIS

inspection & measurement MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER

For DOSS visual solution of Italy – Inspection & sorting machines for O’rings, Seals, Gaskets. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

3D PRINTING

3D Printing in Plastic & Rubber

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

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

Tel: 01420 88645

www.projet3d.co.uk

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

BUYER’S GUIDE PRINTERS printers of plastic mouldings

TESTINg/CONSULTANCY

Total Print Ltd

manufacturing management directory

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

enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com

PRINTERS 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

PARTS & SERVICE

SOFTWARE DIRECTORY

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

TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222

BPR online ad_Layout 1 07/12/2012 11:41 Page 1

Keep up with the social side of BP&R The Word on the Tweet… @BritishPlastics, the official Twitter feed for British Plastics and Rubber magazine, keeps followers informed of breaking news, the latest event updates and industry insights that will keep social butterflies at the cutting edge of all things plastic and rubber. www.twitter.com

Let’s link up sometime Our ever-growing BP&R LinkedIn group provides a great forum for discussion if you are looking for a specific supplier, needing advice or looking for recommendations. It’s also a great way to provide feedback and share your experiences with colleagues or fellow readers. www.linkedin.com

www.britishplastics.co.uk

Epicor’s ERP (on-site, hosted & SAAS) manufacturing software for the polymer 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 Epicor Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

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

real time production monitoring, scheduling and process monitoring intouch T: 01604 646144 E: enquiries@ intouchmonitoring.com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/ Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages). PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/ SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts. Easy to use systems from a €600m company with over 30 years experience. SYSCON-PlantStar MTec Services Ltd T: 0114 2476267 F: 0114 2476267 E: mt@mtec-services.co.uk W: www.mtec-services.co.uk W: www.syscon-intl.com PlantStar systems provide customised, scalable applications that deliver real-time plant floor data from any machine, shift, and plant anywhere in your business. Affordable systems available for all size of processor. Browserbased software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include realtime 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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NEWS FROM THE FRONTLINE

bp&r BRITISH PLASTICS &RUBBER 50

But, if there was ever a sector that exudes confidence, it is rotational moulding. On February 24th in Redditch, the BPF’s Rotational Moulding Group organised its third annual seminar, this year focusing on the topic of troubleshooting. It attracted over 110 attendees from 50 firms. As there are only around 60 Rotational Moulders in the UK, the turnout for this event was exceptional. In the last days, the BPF has reacted strongly to an article featured in ‘The Times’ newspaper (March 2) investigating “the chemicals in supermarket packaging”. The piece was entitled ‘What Toxic Packaging Does to Your Healthy Food’. We said that the author of the article, Joanna Blythman, was misleading ‘Times’ readers in claiming that ‘packaging chemicals’ are not controlled. The fact is that plastics used in food packaging are subject to a whole battery of EU and national regulations, which are constantly being updated. Bisphenol A and phthalates are some of the most widely studied chemicals in the world and their continued safe use has been thoroughly risk-assessed by both EU and international authorities. Developments in plastics packaging have been responsible for vast improvements in food hygiene over the last 50 years — without such packaging, food hygiene would likely regress to pre-war levels when the incidence of food poisoning was much higher. It was not uncommon before the days of durable and sealable packaging for rotting food, improperly packed, to cause worrying levels of fatality. We made the point that not only is plastics packaging safe, public health benefits from it. WWW.BPF.CO.UK

ASSOCIATED ORGANISATIONS

’ve just returned from a short trip celebrating the Tet lunar New Year in Hanoi with my Vietnamese family. All oracles combine to suggest that the Year of the Goat will be very good for business in Vietnam, following several years of economic lassitude. But in the UK we are at a more advanced stage in the cycle. The BPF has just published its latest survey of Business Conditions, which has revealed a further PHILIP LAW, DIRECTOR- flattening of business confidence, first indicated in GENERAL OF THE BRITISH the mid 2014 survey. This PLASTICS FEDERATION, is affecting expectations of ANNOUNCES NEWS THIS ISSUE sales turnover, profitability OF ITS LATEST BUSINESS and investment intentions CONDITIONS SURVEY AND over the next 12 months. WHAT THE RESPONSES FROM The current survey was conducted in January MEMBER FIRMS INDICATE IN and February 2015 and TERMS OF THE INDUSTRY’S attracted responses from OVERALL HEALTH. HE 93 member firms. Whist overall ALSO LOOKS AT PLASTICS PACKAGING AND THE ONGOING performance remains robust, the world is currently BATTLE TO PROMOTE ITS a very uncertain place POSITIVE BENEFITS. and it’s hardly surprising that manufacturers are exercising cautious judgement and to some extent sitting on their hands. The international political situation is volatile, potentially impacting the supply of raw materials and energy sources and the outcome of the general election only adds to the haze. Whilst two thirds of the firms surveyed were predicting an increase in UK sales turnover, only 37 percent predicted an increase in profitability, which is significantly down from 46 percent only one year ago and is the lowest we have seen in over two years. The survey showed that the construction sector was performing extremely well, with all pipes and windows firms surveyed predicting an increase in sales turnover over the next 12 months. Polymer distributors were, however, more pessimistic, with only 40 percent predicting an increase. Despite conservative predictions of future profitability, the survey showed that 52 percent of firms were planning to increase staffing levels over the next 12 months; the highest ever recorded in our survey. The issue, however, is that firms simply cannot attract the right staff and once again nearly half of those surveyed stated they were having difficulty recruiting. This is something we are looking at tackling head on via our newly established ‘Skills and Education Committee’.

WWW.BRITISHPLASTICS.CO.UK

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Weight-saving potential in large series Hollow composite parts with FiberForm KraussMaffei has developed an innovative process which combines injection molding and thermoforming of organic sheets. FiberForm significantly strengthens components and allows a wide range of functions to be integrated. Other strengths: – Fully automatic manufacturing of continuous fiber-reinforced thermoplastic injection moldings – Short cycle times thanks to seamless integration into the injection molding process – Ideal for manufacturing lightweight structural components for mass-production applications

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