British Plastics
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bp&r marCH 2017
Insight into engineering polymers market volatility EEF 2017: “MANUFACTURERS MUST NOT STAND STILL”
CARBON BLACK TAKES THE SPOTLIGHT IN NEW MATERIALS GROUP
MOULDERS CLOSE THE GAP ON PHARMA COUNTERFEITING
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bp&r BRITISH PLASTICS &RUBBER
www.britishplastics.co.uk EDITORIAL
group Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com
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duncan wood T: +44(0)1244 680222 E: duncan@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 rate: UK, Europe and rest of the world £249 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 (0) 1244 671074 © 2017 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 PLASTICS ON THE POLITICAL AGENDA
A
t the EEF’s National Manufacturing Conference recently it was no surprise that the focus very much centered on the upcoming negotiations for Britain’s exit from the European Union. Representatives from across industry spoke with passion about the need to put the needs and wants of UK industry high on the agenda when it comes to securing a future manufacturing base that is successful, competitive and a desirable place for investment. Not a day too soon, then, for the recent visits by MPs to plastics businesses across the country in a scheme organised by the BPF to put the spotlight on the industry and enlighten politicians about its importance as an enabler for many important sectors, including food and drink, automotive, aerospace and construction. Feedback from the companies involved has been positive, and represents another successful step towards reflecting the importance of the sector to the EU as a whole. Another pertinent EU-wide topic, sustainability, also features heavily throughout this issue, with coverage of a new sustainable materials group in the UK. On page 25 Martyn Bennett, Chief Scientist at independent rubber consultants, ARTIS, reflects on the launch of the
Not a day too soon, then, for the recent visits by MPs to plastics businesses across the country in a scheme organised by the BPF to put the spotlight on the industry and enlighten politicians about its importance as an enabler for many important sectors
group, which is calling for the wider use of sustainable materials, as well as a need to create the momentum and community needed for their uptake. One industry that has been working consistently on its sustainability credentials is PVC and, if you’re picking up this magazine onsite at the PVC conference in Brighton, turn to page 45 to read about the three keynote speakers taking to the stage to highlight the challenges and opportunities the industry faces in the coming years. As headline media partner to the event we’ll be attending and look forward to seeing many of you there. Enjoy the issue.
Leanne Taylor, Group Editor
bp&r
THE BIG STORY Engineering Polymers Market:
PRICE RISES AND MATERIAL SHORTAGES “As we move into the second quarter of 2017 the situation remains very unclear, however what is certain is that the market faces continued price rises and longer lead-times.”
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he fundamental reasons for recent events started with large cost rises for benzene in the Far East, which PLASTICS RAW quickly spread MATERIALS DISTRIBUTOR, to other key derivatives such PLASTRIBUTION, REPORTS as butadiene, THAT THE START TO 2017 adipic acid, HAS BEEN A TUMULTUOUS caprolactam, AND UNPREDICTABLE hexamethylene ONE FOR ENGINEERING diamine, bis-phenol A, POLYMERS; NOT SINCE THE acrylonitrile and 1990’S HAS THE MARKET more recently BEEN SO VOLATILE, WITH methanol and SO MANY PRICE INCREASES, ammonia. As LONGER LEAD-TIMES AND the situation SUPPLY SHORTFALLS. IN has developed, this has caused THE FOLLOWING ARTICLE, major shortages BP&R LOOKS AT SOME OF in most of THE REASONS WHY. these key raw materials and as a result lead-times for some materials such as polyamide, PC, ABS and PMMA have increased dramatically. Whilst typically the price of these engineering polymers is driven by the global supply/demand balance, within 4
which China is a significant component, the initiator of the current situation appears to be feedstock price inflation although this in turn this is escalating demand. For the UK, the situation for these materials started to change postBrexit in June 2016, when the relative costs for buying material outside of the UK and importing into the local market became 15-20 percent more expensive as the value of the GBP fell against major currencies. As the second half of the year progressed, it became apparent that the supply/demand balance was shifting in favour of the major producers with many choosing to supply Far East markets at pricing levels higher than could be realised in Europe and the UK. As demand in the Far East (mainly China) continued to grow, this began to impact on lead-times more generally and key derivatives such as Benzene started to rise in cost. The rate of increase accelerated at the back end of 2016; 2017 has continued in the same vein. Benzene is now trading at a level some 56 percent higher than December last year and this dramatic rise has been WWW.BRITISHPLASTICS.CO.UK
mirrored among many of the previously mentioned key engineering polymers raw materials. Plastribution’s Pete Tillin explained: “As we move into the second quarter of 2017 the situation remains very unclear, however what is certain is that the market faces continued price rises and longer lead-times. “The situation with some raw materials such as butadiene may improve quite quickly whilst others are thought to remain both on a longer lead time and continue to be traded at a higher cost. This will inevitably mean the unpredictable and volatile situation could continue for at least the remainder of this year.” Despite ongoing market uncertainty, Plastribution says that it is well placed to provide convertors with a reliable supply of stock. “This, combined with excellent lead times, technical support and great customer service, whilst remaining commercially supportive on price, should put our customers minds at ease whilst we’re in this period of uncertainty,” Tillin concluded. WWW.PLASTRIBUTION.CO.UK
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contents
PLASTICS &RUBBER
march 2017
on the cover Engineering Polymers Market: price rises and material shortages Plastribution reports that the start to 2017 has been a tumultuous and unpredictable one for engineering polymers; not since the 1990s has the market been so volatile, with so many price increases, longer lead-times and supply shortfalls. BP&R looks at some of the reasons why. SEE PAGE 4
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EDITOR’S LETTER Putting plastics on the political agenda
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Feature EEF 2017: “Manufacturers must not stand still” During a day of stimulating discussion and debate, the EEF’s National Manufacturing Conference last month signalled a call to action for the UK to capitalise on the opportunities being presented in a postreferendum era. Leanne Taylor reflects on the key points from the day.
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Feature Pushing the boundaries of the rotomoulding process Aldo Quaratino, Global Technical Director at Matrix Polymers, believes introducing more materials choice to the rotomoulding process is imperative to ensure competitiveness and growth. 6
21 REGULARS
Feature More than sustainable: PVC proves its environmental credentials through use of recycled material Dr. Jeff Ryan, Technical Director at Dugdale Ltd explains why the PVC sector is more than pulling its weight environmentally.
INDUSTRY NEWS 09 interplas 11 Reclamation and Recycling 18 machinery 40 materials 45 BUYERS’ GUIDE 47 SOFTWARE 49 NEWS FROM THE FRONTLINE 50
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Feature Recovered Carbon Black takes the spotlight at new Sustainable Materials Group launch
45
Martyn Bennett, Chief Scientist at independent rubber consultants, ARTIS, reflects on the launch of a new group that is calling for the wider use of sustainable materials, with an initial focus on overcoming the challenges of Recovered Carbon Black (rCB).
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Feature Closing the gap on pharmaceutical counterfeiting Kevin Heap, packaging expert at Sumitomo (SHI) Demag UK, explains how specialist medical and pharmaceutical closure moulders are using the latest injection moulding precision techniques to keep one step ahead of counterfeiters to protect trademarked brand integrity.
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INDUSTRY | NEWS MCLAREN AUTOMOTIVE ANNOUNCES £50M CARBON FIBRE CHASSIS PLANT IN SHEFFIELD McLaren Automotive has announced plans to open a new carbon fibre chassis factory in Sheffield, a £50 million deal that will create 200 new jobs. The luxury sports car producer has announced the development of the manufacturing facility next to the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) in a deal expected to boost the British economy by £100 million. Developed with the support of Sheffield City Council, McLaren’s new Composites Technology Centre will develop and build advanced carbon fibre chassis for McLaren Auto’s supercars, with a focus on developing its ‘Monocell’ and ‘Monocage’ carbon fibre monocoque designs, as well as the building the chassis. Full production will begin at the site by 2020. The Sheffield plant will make chassis that are currently built by a supplier in Austria. McLaren Automotive is expanding its consumer supercars production in the UK, focusing on British manufacturing to build the cars. Mike Flewett, CEO at McLaren Automotive, said: “We chose Sheffield because of the local expertise and experience of working with new materials and advanced composites, plus the development facilities offered by the University of Sheffield and its AMRC facility.”
Motan Colortronic Limited has been awarded accreditation from SafeContractor
Visual of the planned McLaren Composites Technology Centre in Sheffield
McLaren Automotive’s sister company, McLaren Formula One, is currently investing millions to pioneer carbon fibre lightweighting and polymer technologies for the automotive industry, hoping to develop a British rival to Ferrari. Engineers at the Composites Technology Centre will develop the next generation of McLaren’s supercar models, which include the MP4-12C and the P1, which costs more than £1 million. At the launch event on February 9th, Sir Nigel Knowles, Chair of Sheffield City Region Local Enterprise Partnership, said: “This is a truly important day for McLaren, the University of Sheffield and the Sheffield City Region.” The Government hailed McLaren’s announcement of its move to the AMRC, in Catcliffe, between Sheffield and Rotherham, as a major draw of investment into its ‘Northern
Powerhouse’. Liam Fox, Trade Secretary, said: “McLaren is a prime example of the UK’s continued world-leading role in technology, design and innovation. Establishing its new Composites Technology Centre in Sheffield shows McLaren’s confidence in the UK as a world-leader in research that will support local business and high-skilled jobs, while drawing international investment into the Northern Powerhouse.” The supercar firm only started building its consumer models six years ago, at its site in Woking, Surrey. With global demand for luxury cars booming it is aiming to double its output to over 3,000 vehicles this year. Some 92 percent of its cars are exported.
MOTAN COLORTRONIC ACHIEVES SAFECONTRACTOR ACCREDITATION
its commitment to the importance of good practice when it comes to health and safety. Commenting, Karl Miller, Managing Director of Motan Colortronic Limited, said: “We are delighted to receive such accreditation in recognition of the high standards we adopt with regards to health and safety and this demonstrates our ongoing commitment to our customers in the UK and Ireland.”
Chesterfield-based Motan Colortronic Limited has been awarded accreditation from SafeContractor for its commitment to achieving excellence in health and safety. The company, which supplies material handling solutions, chillers, temperature controllers, granulators and recycling equipment says participation in the scheme shows
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RESHORING OF MANUFACTURING TO THE UK LOOKS SET TO CONTINUE, SAYS PENTAGON Pentagon Plastics says last year’s spike in companies choosing to reshore their manufacturing practices to the UK shows no sign of waning for 2017. Over the past year the Surreybased contract moulder and toolmaker has welcomed an increase in enquiries from customers that have previously faced challenges when using suppliers overseas. “For example, [companies] were often faced with the issue of having inserts that don’t fit UK bolster sets and problems with not owning the complete tool. Such complexity with overseas tooling is putting UK manufacturing back on the map and it’s seen as a merit to ‘keep it local’,” explained Paul Edwards, Managing Director at Pentagon. Whilst Pentagon Plastics is enjoying the benefits of ongoing reshoring, it, like others, warns that the ongoing skills shortage could hamper the UK’s ability to benefit from the trend, particularly considering Brexit negotiations potentially ending free movement of labour within the EU. “The UK needs to maintain access to international skills in the future, whilst looking inward at developing home grown staff. This can be achieved through awareness in schools of the opportunities in manufacturing and investment in training existing staff,” Edwards continued. However, Edwards believes if the UK uses Brexit to help develop businesses and invest to support the
“LONG, REWARDING CAREERS” AHEAD OF AWARD-WINNING POLYMER APPRENTICES Three apprentices have been recognised with awards for their contribution to the plastics industry. Reece Connolly of BASF, Bradford, won the title of ‘Apprentice of the Year’, with runner-up announced as Robert Cummings of UCP Zeller, Norwich. Judges also separately noted Kane Bentley of Amaray for a
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Over the last year the Surrey-based contract moulder and toolmaker has welcomed an increase in enquiries from customers that have previously faced challenges when using suppliers overseas
plastics industry through grants and match funding initiatives, it will allow UK manufacturers to become more competitive on price and lead time, facilitating reshoring opportunities. “The Far East and China in particular are going through change and we’re in the position to capitalise. To do this we need to sell our services to those placing new work and most importantly, deliver on our promises,” he added. These promises, he explained, include service and support, as well as continued investment in facilities and good working practices.
“Although price obviously plays a part in being competitive, service is just as important, giving customers confidence in your ability to supply, be responsive and visible in all key elements. Our facilities need to be clean and the work flow fluid through the manufacturing process. Transparency and honesty are key as well as the investment in skills and equipment,” he concluded.
‘highly commended’ award. The British Plastics Federation (BPF) jointly runs the award with the Worshipful Company of Horners. Philip Law, Director-General of the BPF, said: “It brings me great pleasure to see exceptional contributors to our industry given the recognition they deserve — and I am certain both apprentices will enjoy long, rewarding careers in the plastics industry if they continue
along this path.” The apprentices were presented their ‘Master Certificate Awards’ at the Merchant Taylors Hall, in the City of London by the Lord Mayor of London, Andrew Parmley, and Master Horner, Alison Gill. Connolly won £500 and a ceremonial drinking horn.
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PRE-SHOW NEWS
INTERPLAS FEATURE: “Award for plastics innovation to be announced at the show for plastics innovation”
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he long-running award, organised in conjunction with the British Plastics Federation (BPF), rewards excellence in plastics design, manufacture or processing and celebrates AS THE ORGANISERS OF a variety of achievements, THE HORNERS’ AWARD including those that ANNOUNCE A CALL FOR demonstrate an environmental ENTRIES FOR THE 2017 advantage. Uniquely, the Horners Award PRIZE, IT HAS BEEN encourages excellence in UK REVEALED THE WINNER expertise and, as such, entries WILL BE UNVEILED AT must demonstrate that the A CEREMONY DURING product, machine, or process INTERPLAS IN SEPTEMBER. entered has significant UK content in design, materials or manufacture. As a further encouragement to UK entrepreneurship, entries must demonstrate their commercial potential or success. “With a theme so central to both innovation and UK manufacturing, it is a natural step for the award for plastics innovation to be announced at the show for plastics innovation,” commented Duncan Wood, Chief Operating Officer at Rapid News Communications Group, organisers of Interplas. The winner will be unveiled during a special ceremony on the opening day of the show, September 26th, within the purpose-built theatre in Hall 4 of Birmingham’s National Exhibiton Centre (NEC), where they will be presented with their prize by the Master Horner, Alison Gill. Stephen Hunt, BPF Membership Services Director, said: “We are extremely proud to work alongside the Worshipful Company of Horners to promote the importance of innovation in plastic design by our involvement with this longrunning and highly prestigious award. The winners of this award demonstrate the range of talent across the UK producing fantastic innovations in a variety of plastics applications.” Last year’s winner, the world’s first plastic trumpet, was designed by musicians in England and produced by
Previous Horners’ winners have included (clockwise from left) the EGLU Chicken coop; the Cycloc bicycle storage device and Airbus A350 XWB Composite Rear Spar.
“The winners of this award demonstrate the range of talent across the UK producing fantastic innovations in a variety of plastics applications,” - Hunt
Warwick Music Group, to make a trumpet more affordable for school children, as well as demonstrating a unique polymer lead pipe technology in its manufacture. The Horners’ say winning the Award can bring a number of commercial benefits, not least thanks to the publicity and exposure as a result of winning, but also through access to a range of industry experts and consultants in both its own and BPF networks. Testament to this, Andrew Lang, Director of Andrew Lang Product Design Ltd., the company behind 2011’s winning ‘Cycloc’ bicycle storage product, said the award had helped the company bring more distributors on board. “Word is spreading and awareness is growing, it is good to have the production capacity that allows us to promote the product both within the cycling industry and to the public and winning the Horners Award will help,” he told BP&R shortly after winning. Entries for this year’s award are open until the deadline of 31st July, with forms available from the website below.
WWW.BRITISHPLASTICS.CO.UK
WWW.HORNERSAWARD. CO.UK
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EEF 2017: “Manufacturers must not stand still”
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ome twelve months on from his passionate call for the UK to vote to remain as part of the European Union, Terry Scuoler, CEO of EEF, said the events which have transpired in the wake of the referendum DURING A DAY OF in June last year have “the STIMULATING DISCUSSION potential to be cataclysmic.” Opening the conference this AND DEBATE, THE EEF’S year, Scuoler said that despite NATIONAL MANUFACTURING the manufacturing sector CONFERENCE LAST showing signs of resilience MONTH SIGNALLED A CALL in the aftermath of the vote, TO ACTION FOR THE UK uncertainty and risk remain. “The process of exiting TO CAPITALISE ON THE OPPORTUNITIES BEING the EU is yet to commence and the negotiation process PRESENTED IN A POST- will be brutal. Brutal, not just REFERENDUM ERA. LEANNE behind the scenes during the TAYLOR REFLECTS ON THE process, but also very much KEY POINTS FROM THE DAY. in the public eye,” Scuoler told delegates. During these negotiations, he emphasised the importance of reaching a deal that works for both the UK and the EU, with key pillars of talks including ongoing access to the single market and a demand-led mechanism to allow businesses to continue to attract and retain employees from the EU, vital for the future success of the industry. However, Scuoler said that, as with any challenges arising from a change to the status quo – be it Brexit, the move to digitalisation through the fourth industrial revolution (4IR), solving the issues around productivity or exporting – there would also be opportunities. He urged manufacturers not to “stand still”, but to capitalise on these opportunities, including the chance to contribute to the Government’s Industrial Strategy consultation. “It is a strategy that calls for partnerships and collaboration, industry working hand in hand with Government and other stakeholders to make this work for Britain. This is an opportunity and one that all of us must work hard to shape and implement,” he added.
Clear challenges
Following Scuoler’s address, Ian Issac, Managing Managing Director of Lombard, told delegates that “it was clear where the challenges lie” for UK manufacturing, and these are clearly defined in the 10 pillars of the Industrial Strategy green paper. “Skills, education infrastructure, research and innovation are all areas where we need to concentrate our efforts,” Issac explained. “For me, the notable message from both the years of research, as well the green paper, is the productivity puzzle that needs to be solved.” Issac said that the apparent inertia of businesses to invest in new machinery and technology is where the key issues surrounding ongoing productivity issues lie, highlighting a recent survey that suggests although 50 percent of manufacturers questioned plan to invest in 2017, the other 50 percent do not.
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John McDonnell MP, said Brexit was “a call for change”, stating that the next two years would involve a long process of detailed negotiations.
“It’s easy for manufacturers to focus on what needs doing today and it is a challenge to find time to think about the future. However, if that time isn’t set aside then the future has a habit of catching up on us,” he continued. This, he added, was an incentive for businesses to “tool up for 4IR,” adding that this would help “multiply our strengths and find the last bit of the productivity puzzle.”
A call for change
In his address, Shadow Chancellor, John McDonnell MP, said Brexit was “a call for change”, stating that the next two years would involve a long process of detailed negotiations. He said that manufacturing must be a crucial consideration in these negotiations, adding “if Britain is going to prosper after Brexit then manufacturing must have a central place.” Part of this, he added, is ensuring the industry is not concentrated in “a central hotspot”, but throughout the UK. McDonnell highlighted the importance of seriously addressing reshoring, skilled workers, business rates and access to broadband for a manufacturing industry that is successful and central in the future.
Being competitive to survive
In the panel discussions sandwiched between keynote addresses, Martin Wolf CBE, Chief Economics Commentator, Financial Times, said that UK businesses “face an immense amount of uncertainty” in the future, with regards to the outcome of Brexit, with those that are pragmatic with decisions and competitive in the marketplace most likely to ride out the storm. “If businesses do nothing in the next ten years whilst this is all sorted out – they’re dead” Wolfe cautioned. “You must be competitive, this is how businesses will survive.” Alison Rose, CEO, Commercial and Private Banking,
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Natwest, said that despite a slowdown in the months preceding the referendum vote, manufacturers have not slowed in their demand for finance since. This, she added, is largely as nothing has - as yet - changed. However, she echoed Wolfe’s call to action for investment and for manufacturers to make this a priority in order to be successful in overcoming known future challenges.
Why manufacture in the UK
The final discussions of the day focussed on the strategic importance of Britain as a manufacturing hub from the perspective of some of the UK’s biggest companies. Jurgen Maier, CEO at Siemens, said that the knowledge and technical skills of workers in the UK was key. “Why is the UK a good place to manufacture? Well, I’d say skills. There are highly qualified peopled that we can access to work in our factories, combined with good R&D and innovation from our Universities. Also, there’s a pretty good policy framework and a tax system that supports us, despite all of our criticisms of skills and business,” he explained. “But, and there is a but, and that is that we don’t keep the levels of productivity that we ought. It’s down to not enough investment in technology, digitalisation and automation. We lack behind considerably in these areas, particularly automation. Certain studies have shown that if we invest on a par with Germany and China then we can compete on a very high level.” Maier said that there was an opportunity for Britain to “leapfrog” its competitors if it took the uptake of new, digital technologies seriously at all levels, and if there was a consistent message around 4IR.
“The process of exiting the EU is yet to commence and the negotiation process will be brutal. Brutal, not just behind the scenes during the process, but also very much in the public eye,” - Scuoler
WWW.EEF.ORG.UK
Big Ben provided the back drop to the day of discussions at EEF 2017
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ROTOMOULDING | NEWS
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SAFETY FIRST: WORKING TOGETHER TO BETTER ROTOMOULDING PRACTICE The QUBE is suited to demanding testing within the healthcare industry and pushes the boundaries of rotomoulding design
PHARMACEUTICAL WORKSTATION PUSHES THE BOUNDARIES OF ROTOMOULDING DESIGN A UK-based company specialising in decontamination and infection control solutions has developed a new workstation said to push the limits when it comes to rotomoulding design. As part of its ongoing product developments, Bioquell UK Ltd, based in Hampshire, designed and created the ‘QUBE’, a modular, flexible aseptic workstation with fully integrated hydrogen peroxide vapour (HPV) technology. The QUBE allows a variety of configurations that tailor the workspace to the needs of the specific process. The combination of unidirectional airflow and an ISO 5/Grade A working environment with rapid HPV biodecontamination means the workstation is suitable for applications such as cytotoxic preparation, gene therapies, cell therapies, sterility testing and others. Produced using rotomoulding powders from A. Schulman, the QUBE module demands a high level of quality in the production process, owing to the extreme high tolerances due to multiple parts, with higher scratch resistance and no warpage. “A. Schulman thrives on working closely with moulders on new projects, the closer we work with our moulding customers, the more opportunities of building partnerships that achieve high quality mouldings such as the QUBE,” explained Les Druyf, A. Schulman’s Roto Product Line Manager. “Bioquell UK Ltd. is a very good technical moulder that we have worked well with over many years to meet the high demands of the end user. I can honestly say the Qube is one of the best rotomoulded products I have seen in 36 years in the industry.” WWW.ASCHULMAN.COM
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ollowing on from the ‘Safety Notice’ relevant to owners, designers and manufacturers of rotational moulding DR SARA CAMMARANO, machines GROUP EXECUTIVE issued by OF THE ROTATIONAL the Health MOULDING GROUP AT and Safety THE BRITISH PLASTICS Executive (HSE) on 24th July FEDERATION (BPF), 2014, the BPF UPDATES READERS ON Rotational PROGRESS RELATING Moulding TO HEALTH AND Group decided SAFETY GUIDELINES to collaborate THAT WILL SOON BE with the HSE to re-write its AVAILABLE TO THE draft code of WHOLE INDUSTRY, practice in AS WELL AS WHY order to bring it ‘INNOVATION’ IS THE up to date. During 2016, BUZZWORD FOR 2017. the group continued focusing on health and safety and produced its ‘Health and Safety Guidance’ in collaboration with the HSE. The document tackles health and safety issues in the rotational moulding industry with the aim of providing a list of what-to-assess and what-to-look-for when a rotational moulder is carrying out a risk assessment. This guidance is aimed at employers, supervisors and managers responsible for the safe operation of rotational moulding machines. The guidance gives advice on the safeguarding requirements for foreseeable hazards associated with rotational moulding machines, including whole body entrapment following a fatality in a plastics rotational moulding oven. The document, in its draft form, is already available to BPF members for comments and it will be available to the wider industry free of charge once it gets the approval of the HSE. The BPF believes good Health and Safety practice should be available to everybody not just to its members; we
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believe that working together is the way forward to fortify our industry. As part of the BPF Rotational Moulding Group’s efforts to strengthen the sector, the group is pleased to announce that it will be running its annual seminar on 9th May 2017 in Worcester. The theme of the seminar will be ‘innovation’, in every form, whether it is design, tooling, machines, material or additives. As well as the presentations, there will be table top opportunities for suppliers to exhibit their latest achievements and to engage in productive discussions with the attendees.The full programme for the event will be available by the beginning of March. Following the success of the previous BPF rotational moulding events, we expect this seminar to be very popular and to attract an audience of over 100 attendees. The group strongly believes that knowledge sharing will strengthen the whole industry, thus, it has a dedicated case studies section on its very own webpage within the BPF website, showing examples of rotational moulding technology and innovation. Finally, as part of The Affiliation of Rotational Moulding Organisations (ARMO), the group is developing a marketing campaign to engage with designers by illustrating the achievements of the sector. WWW.BPF.CO.UK
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Material instinct: Pushing the boundaries of the rotomoulding process
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he big step-changes in the growth of rotomoulding will only happen if we develop new and better rotomoulding materials. Put simply, more choice in materials means that more ALDO QUARATINO, GLOBAL products can be produced TECHNICAL DIRECTOR AT using the rotomoulding process. MATRIX POLYMERS, BELIEVES At Matrix, when we INTRODUCING MORE develop new materials, MATERIALS CHOICE TO THE rather than spending a ROTOMOULDING PROCESS lot of time and money IS IMPERATIVE TO ENSURE creating things that no one wants, we prefer to look at COMPETITIVENESS AND specific problems that our GROWTH. IN THE FOLLOWING customers have. It could ARTICLE, HE HIGHLIGHTS AN be an existing product that EXAMPLE OF HOW THE USE OF isn’t performing well or a A NEW, SPECIALLY DEVELOPED totally new application. We recently worked PP GRADE TRANSFORMED with Venplast, an Italian THE PRODUCTION OF A company that specialises in CHALLENGING PART. manufacturing a wide range of industrial ventilators and extractor fans. Some of these ventilators are used in the petrochemical industry, in chemistry laboratories and in metal treatment processes. They are used to extract dangerous and corrosive fumes and gases.
A tough material for a harsh environment
The challenge we had was that Venplast wanted to produce the blower part for its ventilator system by rotomoulding and were having difficulties. The operating environment for these products can be extremely harsh and they needed a material that was tough and stiff and that could also operate at high temperatures – higher temperatures than polyethylene (PE) could cope with. In addition, the material had to handle varying pressures and there was the serious problem that some of the gases extracted can be explosive and so the material had to be electrically conductive as well, so no spark could be generated by a build-up of static electricity. To meet all these demands we developed – as part of our ‘Designed for Roto’ programme – a new material called ‘R Tuff PP60’. As I’ve said, one of the issues we had was that the product needed to withstand high temperatures and this made polyethylene unsuitable. We therefore decided to look at developing a polypropylene (PP), but it needed to be tougher and easier to rotomould than most other polypropylenes.
chamber at a temperature of 110 °C. After this time, an impact test was conducted to assess the performance of the material. An Izod was performed on notched samples in accordance to the ASTM D256. For the material to pass its value had to be greater than the 50 percent of the initial value of the impact. You can see that the material after 1,000 hours retained 63 percent of its original impact strength and easily passed the test.
Electrical conductivity
Next was the issue of making the polymer electrically conductive. The surface of any rotational moulded product made from polypropylene is charged with electrons, which creates the potential for a static spark. This can trigger an explosion when certain vapours or gases are present. The way to prevent this happening is to make the material electrically conductive. Making polypropylene conductive presented a few challenges. Although conductivity is well established in rotational moulded polyethylene, it is less common in polypropylene resins. After extensive testing and experimentation carried out at the Matrix Technical Centre in the UK, Revolve R-Tuff PP 60 was developed with a surface resistivity of 2.5 * 10^5 Ω/sq, - which is enough to prevent any static sparks. This illustration shows the level of surface resistivity required for an inert polymer such as polyethylene and polypropylene to be conductive in comparison with a metal (e.g. steel).
Standing up to the heat
Venplast specified that the material must comply with the Underwriters Laboratory Standard ‘UL 746 B’ for ‘Relative Thermal Index’. The Relative Thermal Index (RTI) is a relative measure of a polymer’s ability to retain its physical properties over a period of time at an elevated temperature. Revolve R-Tuff PP60 was exposed for more than 1000 hours (greater than 40 days) in a climatic
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Mouldability and toughness
So how well does it mould and what about pin-holes? Well you can see from the image that the new grade moulds out very easily and there is no pin-holing. The most popular scientific test carried out on rotational moulded products is the impact test based on a falling dart method, which was developed by ARM in America. We used this to compare this grade with other materials.
applications for it in rotomoulding. We all know how dominant polyethylene is in our industry because of a number of characteristics like low viscosity (which makes this polymer ideal for a process with no pressure), impact resistance, chemical resistance and durability. It is well known that polyethylene cannot be the solution to every technical problem due to inherent limitations such as a lack of high temperature resistance and lack of stiffness. Expanding the horizon of rotomoulding by learning how to use materials such as polypropylene (PP), polyamide (PA), fluoropolymer (PVDF) and polycarbonate (PC) can add value to rotomoulded products and expand the product range rotomoulders can offer which can help rotomoulders to penetrate new and potentially lucrative markets. We believe this industry needs more advanced and higher performance polymers so that it can continue to compete with other processes and can continue to grow. WWW.MATRIXPOLYMERS.COM
Standard rotational moulded test mouldings were made with a 5mm wall thickness and were produced at the optimum moulding condition on our Ferry carousel RS1.90 rotomoulding machine. The oven temperature was fixed at 250 째C. The rotational moulded products were then cut and standard plaques were prepared. The plaques (125 x 125 mm) were then conditioned at -15 째C and + 23째C for 24 hours before being impact tested. The graph you can see shows the results. The impact performance of R-Tuff PP60 compared with a conventional rotational moulding polypropylene is very significant and the material has 50 percent better performance than an impact modified polypropylene. What is also unusual is that the material has some impact strength at minus 15째C, whereas traditionally rotomoulded polypropylene grades have been glass-brittle at temperatures below freezing.
The processing window
One of the popular misconceptions regarding polypropylene we repeatedly hear is its alleged poor mouldability and poor impact strength. Rotomoulding PP has inherited an image of a difficult material to be processed with a very narrow operating window. This can be true in some cases, but it is also true that there are several PP chemistries which could surprise even experienced moulders. Injected moulded products for automotive applications are dominated by PP as much as rotational moulded products are dominated by PE. So there are many PP grades which could be developed to suit our rotational moulded process.
The rotomoulding process needs more materials to stay competitive, says Quaratino
Conclusion
So, by listening to Venplast and by working with them in close co-operation on a specific product, we have developed a new material that is now in commercial use and we have a happy customer. We see that there are many opportunities for this new powder and, as polypropylene is very widely used in many other plastics processes, we see an immense number of
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RECLAMATION & RECYCLING | NEWS BRITISH-MADE 100 PERCENT RECYCLED ABS GRADES CAN REDUCE COSTS AND CARBON FOOTPRINT, SAYS AXION Axion Polymers has launched a new range of strong and durable 100 percent recycled ABS grades suitable for a range of injection moulding applications. It says the Axpoly r-ABS resins, which are recovered from the nonmetallic waste fraction from end-oflife vehicles, are particularly suited to applications in the construction and automotive sectors where they offer both cost and carbon savings. The resins deliver a carbon footprint saving of two-thirds when compared with virgin ABS made from petrochemical feedstocks. A full LCA study of Axion’s mechanical recycling process shows a saving of 2.1 tonne CO2 eq. for every tonne of ABS they produce. As the Axpoly grades are produced from material sourced from a UKbased closed loop supply chain, they bring the additional advantage of
stable and competitive pricing, as the input raw material costs are not linked to the volatile oil market. This, says Keith Freegard, Director at Axion Polymers, is important for processors faced with post-Brexit exchange rate fluctuations when importing material from overseas. “Anyone purchasing polymer from central Europe will be facing around a 15 percent price increase. Manufactured from feedstocks collected in Britain, our polymers are not affected by exchange rate changes. What better time than now to buy British?” he said. Examples of applications that have been produced using the Axpoly r-ABS include load plates for reinforced steel beams as well as strengtheners in the corners of windows. Axion Polymers’ Chemical Engineer, Dr Pasika Chongcharoentaweesuk, said that the grades have undergone rigorous testing to ensure the recycled material is equal to virgin in terms of properties and performance.
EREMA FRESHENS UP POSTCONSUMER RECYCLATES WITH ODOUR ELIMINATION SYSTEM
n of ReFresher The combinatio TVEplus and the proven ss offers odourle w no technology e tim st fir e th recyclates for of severely even in the case aging waste ck pa contaminated
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Following on from the launch of its ReFresher system for the production of odourless recyclates from contaminated packaging waste, EREMA has made a mobile version available. The company introduced the ReFresher, which works downstream of the extrusion process, at last year’s K Show in Germany. Based on EREMA’s TVEplus technology, the ReFresher works in conjunction with the system to offer filtrated, degassed and odourless recyclates for the first time in post-consumer recycling – even in the case of severely contaminated packaging waste. The technology keeps the recyclates at a temperature at which volatile materials can be discharged, meaning odours and impurities are eliminated from the end product.
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Axion Polymers’ Chemical Engineer, Dr Pasika Chongcharoentaweesuk
The properties of the standard recycled ABS grade, Axpoly r-ABS52 1009, can be modified to suit individual applications, using the compounding capability and materials testing laboratory at Axion’s factory site in Salford. WWW.AXIONPOLYMERS.COM
This, says EREMA, opens up a number of new sales markets for recyclers and producers, including consumer markets like homeware and cars. Commenting, Manfred Hackl, EREMA CEO, said: “We recognised the potential of continuously increasing packaging waste early on and worked intensively on finding a technical solution for the odour issue. With the ReFresher we offer recyclers and producers the edge in terms of quality to establish themselves in the marketplace with odourless recyclates from household waste.” The ReFresher is available in various expansion stages depending on the end application. The new, mobile unit is now being supplied as an additional service for on-site trials directly at the customer’s location to adapt the solution precisely to the requirements of the end product. WWW.EREMA.AT
UK’S LARGEST PVC WINDOW RECYCLER CELEBRATES 10 YEARS VEKA Recycling, the UK’s largest PVC window recycler, is celebrating its 10th anniversary in business. The Kent-based company, which has established a reliable and sustainable recycling service for PVC window waste over the last decade, will mark the occasion by attending this year’s annual PVC conference in Brighton. “We have taken the opportunity to be a sponsor at the world’s leading forum on vinyl at PVC 2017 as a chance to celebrate both our anniversary and the many positives of using recyclate in new products,” explained Simon Scholes, VEKA Recycling’s Commercial Director. He added that the company aims to continue to raise awareness of the many benefits of PVC-u as a
BRITISH PILOT TOUCHES DOWN AFTER BARNSTORMING FLIGHT ON POST-CONSUMER PLASTIC FUEL An aviator has proved a world first by using plastic fuel to fly the 500 miles from Sydney to Melbourne in a project known as ‘On Wings of Waste’. Jeremy Rowsell, a pilot and environmental campaigner originally from Kent, developed a unique fuel blend made up from 10 percent postconsumer plastic from the ocean and landfill sites, to fly his Vans RV9A twoseater plane in a pioneering journey endorsed by Sir David Attenborough. Rowsell took off from Illawarra Airport, near Wollongong in New South Wales on January 12, to fly 15 hours straight to Melbourne
VEKA Recycling has established a reliable collection service for PVC waste in the UK
sustainable material, including long lifespan and low maintenance, as well as create new markets for its use. “We are looking forward to meeting with the delegates at the Brighton Hilton Metropole in April and discussing the bright future of new products with recycled content,” he concluded. WWW.VEKARECYCLING.COM
on his custom fuel mix, which was reprocessed by London-based Plastic Energy. Rowsell said: “After years of preparation and many ups and downs, we’ve finally shown that the eight million tonnes of plastic dumped into the oceans each year can be put to good use - we blended 10 percent of fuel manufactured by Plastic Energy with conventional fuel and the flight was a dream.” Rowsell and his ‘On Wings of Waste’ team are now looking for support from investors to build a recycling plant in Australia, to showcase the refining technology and apply it to the aviation industry. WWW.ONWINGSOFWASTE.ORG WWW.PLASTICENERGY.NET
OPRL REVIEW LEADS TO MORE MATERIALS ‘WIDELY RECYCLED’ The On Pack Recycling Label (OPRL) has undergone a review for 2017 in order to inspire consumer action and increase recycling rates. The new guidelines have designated more packaging materials as ‘Widely Recycled’, following a detailed review of local authority collections. This means more packaging can be put in kerbside recycling collections by householders, without needing to check council advice. Certain clear and non-black opaque plastic pots, tubs and trays are amongst the materials now labelled ‘Widely Recycled’, as well as aluminium foils. Labelling for films has been simplified, so that PE films carry the specialist label ‘Recycle with Bags at Larger Stores: Check Locally for Kerbside’, while all other films are designated ‘Not Yet Recycled’. As the OPRL information is based on council collections data, black plastic trays, including ready meal trays, remain in the ‘Check Locally’ category. The scheme has taken a first step to separate materials that are collected for recycling and materials for energy recovery or other disposal, which are included on a ‘Less recyclable materials’ list in the guidelines, together with expanded and other plastics, mixed materials and biodegradables. Non-black PP, clear uncoloured aPET/ rPET and non-black HDPE are listed as ‘Recommended materials’, based on analysis of their likelihood of being recycled. This move is aimed at supporting WRAP’s ‘Consistency of Packaging’ work to shift materials used in packaging to those more readily recyclable, both technically and commercially. Emily Martin, Wastes Prevention and Education Manager at Essex County Council, said: “Residents want to understand what to do with packaging so clear instructions like Widely Recycled or Not Yet Recycled are much more likely to inspire action. That’s why reflecting current local authority collections and moving many pots, tubs and trays into Widely Recycled will help us capture this valuable material for re-sale and avoid unnecessary Landfill tax costs. That’s vital as council budgets come under increasing pressure.” WWW.OPRL.ORG.UK
Jeremy Roswell with his Vans RV9A two-seater plane
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viewed The recently-re are es lin ide OPRL gu rease designed to inc cling consumer recy
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MORE THAN SUSTAINABLE: PVC PROVES ITS ENVIRONMENTAL CREDENTIALS THROUGH USE OF RECYCLED MATERIAL By Dr. Jeff Ryan, Technical Director at Dugdale Ltd
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nyone visiting the world’s triennial plastics fair, K 2016, in Düsseldorf last year can have been left in no doubt that the PVC sector is more than pulling its weight environmentally. Clearly identifiable and clearly labelled, PVC-based products enjoy one of the highest rate of recyclability among plastics. The building and construction trades have led the way; the packaging sector continues to make progress and niche markets such as medical are also making great strides in collecting, recycling and finding second life uses for the material. Organisations such VinylPlus, Recovinyl and the Vinyls Group of our own British Plastics Federation have also done much to establish a robust and sustainable circular economy for the future. As an independent PVC compounder we are wholly committed to these developments. Dugdale sees clearly that PVC recycling and reprocessing both make good business sense.
Opportunity in waste
There is no argument against second-life production taking wastage out of industry and society – both for post consumer (PCW) and post industrial (PIW). The environmental and business cases for both are as one. There is, moreover, plenty of opportunity in both types of waste: typical PCW volumes consist of old windows, cable, flooring and other building products and PIW volumes consist of manufactured scrap or secondary operation scrap such as fabrication. Each kind of waste presents different recycling issues, commercial and technical: PCW, for example, can be heavily contaminated and contain not only brick dust, plaster, glass, silicon sealant, metal, nylon spacers and hardware (such as handles, hinges etc) but also non-PVC based gasket materials such as EPDM or
Typical PCW volumes consist of old windows, cable, flooring and other building products and PIW volumes consist of manufactured scrap or secondary operation scrap such as fabrication.
TPEs which are not compatible with PVC. In addition, some older PCW products contain ‘legacy’ additives, such as cadmium or lead (Pb), which, under current REACH legislation, are problematic. Normally the purchase price of PCW is lower due to the potential contamination. Second life applications, therefore, need to be carefully chosen as fit for purpose, such as unseen surfaces, products that are not surface critical, or those which use a capstock, either co-extruded or foiled. In the window industry, PIW can be carefully managed and is invariably much cleaner and normally free from most contaminants, although some PIW sources can still contain quantities of non-PVC based gasket materials. However, PIW is typically free from ‘legacy’ additives. As PIW is normally a clean, more controlled waste stream, building system companies normally re-use it in their own manufacturing processes where possible. PIW’s relatively clean status and often single shade commands a price, of course, and recyclers, keen to get hold of a clean source, tend to bid it up. Obviously, there are further streams of PVC-based materials that can be combinations of recycled material that have a varied and sometimes unknown source. It can contain various ‘contaminants’ i.e. metal, non-PVC WWW.BRITISHPLASTICS.CO.UK
polymer, paper or fabric, depending on the manufacturing process, application and end product. It may also contain further contaminants such as floor sweepings and general waste, depending on how well the waste stream has been managed. It may also include a variety of colours and contain combinations of different PVC formulations which can be rigid and/or flexible in nature. For these materials, individual assessment is required and only worth considering if there is a regular supply source and a specific application can be found which can cope with the level of variability and contamination.
Quality control is key
Strict quality control over all incoming recycled materials, to ensure that the quality of the feedstock has a controlled level of contamination that is considered acceptable to the process and its intended use, is imperative. For Dugdale, this involves working in partnership with the recyclers but does restrict our supply sources. We also take our customer manufacturing waste and re-process this back into a consistent re-usable form – a service that is increasingly in demand due to the cost and environmental impact of disposal. Our work with various kinds of PVC recyclate is, in truth, part and parcel of the 50 plus new compounds/colour variations we are developing across the board every month and have been enabled through our £3 million plus investment in capital plant and laboratory equipment since 2014. The PVC industry’s continuing embrace of recycling and secondlife production continues to be inspired and driven by economics and good business sense as much as environmentalism. At Dugdale we are more than happy to play our part in facilitating these important changes. WWW.DUGDALEPVC.COM WWW.PVC2017.ORG 21
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RUBBER | NEWS NEW LEXUS IS A SAFE BET THANKS TO NEWLY DEVELOPED RUBBER The latest model of Lexus’ LS Sedan vehicle is utilising a newly developed, sidewall-reinforced rubber from Bridgestone, contributing to a safer and more comfortable drive. The newly developed rubber featured in the new ‘Turanza T005 RFT’ tyres features a molecular structure that makes the crosslinking of polymer chains more resilient to high temperatures. This structure enables run-flat tyres to be made with thinner sidewall, which offers a quieter ride and more comfortable driving experience. The tyres maintain their shape and support vehicles at zero air pressure, effectively allowing for driving on flat tyres.
CASE STUDY: UK-MADE CUSTOM RUBBER MOULDING STANDS UP TO HARSH ENVIRONMENTS Poole-based manufacturer of custom rubber, seals, gaskets and mouldings, DP Seals, has completed the development of a new, intricate seal for Ridgemount Technologies, a company that specialises in the design and manufacture of specialised fibre optic connector interfaces. The seal, which has a unique cross sectional profile, is for a new connector which will be used in military, industrial and hazardous environments, in particular, immersion and exposure to weather extremes. In all cases, the product has to maintain optical continuity for communication, data or sensing, meaning product failure is not an option. The project required challenging production aspects, including the overmoulding of rubber onto a tubular anodised aluminium substrate ensuring compliance to stringent military standard (MIL) specifications,
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Additionally, the RFT tyres can help reduce the total weight of a vehicle because they eliminate the need for a spare tyre. Their use can also contribute to a more sustainable vehicle, as a spare tyre is often disposed of without being used.
Bridgestone says through the widespread use of its RFT tyres in vehicles it aims to contribute to a safe and stable mobile society while reducing overall environmental impact. WWW.BRIDGESTONE.CO.UK
The new Lexus LS vehicle with Turanza T005 RFT tyres. Credit: The Bridgestone Group/Lexus
Collection of ldings rubber mou r fo ed produc ector finished conn ction se sos cr and ing ow sh diagram face the intricate location seal and its tic op e in the fibr r to ec nn co
as well as the face seal. This seal is a vital component as it not only locates and seals the precision optical insert within the shell of the host connector, but also performs a critical dynamic function at the optical mating face. To do this, it displaces into a predetermined diametric cavity so as not to impair the functionality and optical performance of the mating optical inserts, whilst also maintaining the sealing of the host connector. Mark Limbert, Technical Director at Ridgemount, commented: “Through the product development process DP Seals has played a vital role in
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delivering technical excellence and a first class product in a timely manner. Such service levels and confidence makes managing new product introduction relatively stress free.” DP Seals’ Managing Director, Andrew Piper, added: “This product is another example of DP Seals responding quickly to the challenging problems and high specification requirements of customers who need custom rubber mouldings for harsh environments.” WWW.DPSEALS.COM
European Master Distributor for Dow Corning/Xiameter Silicone Elastomers
MPG ANNOUNCES LINE-UP FOR UPCOMING RUBBER SEMINAR Manchester Polymer Group (MPG) has announced the programme for its upcoming sustainability-themed rubber seminar on May 15th 2017. Seminar discussions will cover fillers, with a keynote paper from Artis entitled ‘Sustainable Fillers for Future Elastomers’, leading the programme. Following this, recycling papers will cover developments in recycling and re-use of waste rubber from Smithers RAPRA, with Polymer Recyclers asking the question as to whether recycling tyres back to tyres is an opportunity or a pipe dream. The seminar will also look materials and additives, with Versalis, Dupont Performance Elastomers and BASF to focus on how EPDM, ethylene acrylic elastomers and stabilisers can face
LANXESS UNVEILS NEW SOLUTIONS FOR CLEANER AND MORE EFFICIENT TYRE PRODUCTION The rubber additives division of Lanxess, Rhein Chemie, has launched new solutions for cleaner and more efficient production of tyres. At the recent Tyre Technology Expo it unveiled a new range of unfilled, single-release inside lubes, including Rhenodiv BP-337 and Rhenodiv BP-3091. These products enable tyre producers to apply very low quantities of inside lube onto the green tyre. Rhein Chemie says when used in combination with robotic spraying equipment, a precise coating procedure is guaranteed, without contamination of the tyre area next to the inner liner. An additional benefit, it added, is that Rhenodiv BP-337 is based on hydrogen-free crosslinking chemistry. The company has also added new products to its portfolio that respond to the increasing demand for the elimination of migrating silicones in the tyre moulding process, with new Rhenodiv BP-166, low-filled, siliconefree and Rhenodiv BP-9500, unfilled, silicone-free products. In addition to its new unfilled inside lubes, Rhein Chemie also unveiled at the Expo its recent work into increasing its capacity for
up to sustainability challenges. The seminar will end with a ‘Processing and Testing’ session, during which Elastocon will cover ‘Stress Relaxation and Lifetime Estimation of Rubber Materials’ and RAPRA will discuss ‘Exploiting Innovation to meet the challenges of Sustainable Manufacturing’. Finally, Sherkin Technologies will also review equipment to support R&D and manufacture of materials and products. The Rubber in Engineering Group will also join Manchester Polymer Group at the seminar at the Lancashire County Cricket Club, Manchester, where the event will be held. WWW.IOM3.ORG/MANCHESTER-POLYMER-GROUP
permanently coated bladders. The company’s Rhenoshape tyre curing bladders, equipped with Rhenodiv permanent coatings, now enable tyre manufacturers to produce tyres without using an additional release agent. This is of special importance for the production of high-value tyres, says Rhein Chemie, such as run-on-flat, sealant and noise-reduced tyres – wherever the absence of migrating silicone from traditional release agents is mandatory. Additionally, it means the spraying operation for green tyres, including the collateral contamination of critical tyre areas and working areas, becomes obsolete. Finally, the company also displayed its Rhenogran aramid fibre masterbatches, its mechanical reinforcement options for tyres. WWW.RHEINCHEMIE.COM The rubber additives division of Lanxess, Rhein Chemie, has launched new solutions for cleaner and more efficient production of tyres.
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Manchester Polymer Group has announced the programme for its upcoming sustainability-themed rubber seminar in May
EVONIK’S NEW TYRE ADDITIVES HAVE POTENTIAL TO “SIGNIFICANTLY REDUCE” ROLLING RESISTANCE Evonik has added ‘Polyvest ST’ additives to its silica/silane system, a development which it says will reduce rolling resistance in tyres. Evonik’s chemical engineers have tested the additives on natural rubber-based rubber compounds, which they say will “significantly reduce” the fuel consumption of vehicles. Evonik has already reduced rolling resistance by 30 percent on standard carbon black filled tyres, using precipitated silicas and rubber silanes. Dr. Kai-Steffen Krannig, Evonik’s Innovation Manager, said: “By combining the existing technology with Polyevest ST, tyre manufacturers [can] further optimise their products. “This is the latest chapter in our long history of successfully developing rubber additives for the tyre industry.” Krannig explained the special feature of the new development is that unlike previous improvements to the core properties of a tyre – namely rolling resistance, wet grip and abrasion resistance – where the improvement of one comes at the expense of another, the new development improves compatibility in all areas. WWW.EVONIK.DE/EN 23
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Recovered Carbon Black takes the spotlight at new Sustainable Materials Group launch
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n Wednesday 18th January ARTIS’ launched its ‘Sustainable Materials Group’ at The Institute for Materials, Minerals and Mining (IOM3) in London, to an audience of over 50 MARTYN BENNETT, delegates from companies and CHIEF SCIENTIST AT academia. Launching the Group, ARTIS’ INDEPENDENT RUBBER Dr Chris Norris gave a keynote CONSULTANTS, ARTIS, presentation during which REFLECTS ON THE he called for, amongst other LAUNCH OF A NEW GROUP things, that all those involved THAT IS CALLING FOR in sustainable rubber materials THE WIDER USE OF to work together to promote SUSTAINABLE MATERIALS, their wider use. He explained WITH AN INITIAL FOCUS how ARTIS will facilitate this interaction through the ON OVERCOMING Sustainable Materials Group THE CHALLENGES OF and be the centre of technical RECOVERED CARBON expertise for its members to BLACK (RCB). help solve the key issues faced by the field. Dr Norris explained that, initially, the Group will be focussed on Recovered Carbon Black (rCB) and detailed ARTIS’ specific solutions to counter rCB’s challenges. In a further presentation, he focused on the unique nature of rCB. In this, he emphasised that rCB is not equivalent to a regular Carbon Black and that, for its success, it is necessary that attitudes shift towards it being regarded as a new material rather than a conventional Carbon Black product. He argued that rCB has a different, not worse, in-rubber performance than regular Carbon Blacks and that, subsequently, the right application must be found for it. He pointed out the need for definitions of specifications around this material in order to ensure more uniformity in the quality of rCB output to be able to better predict its in-rubber performance. This was highlighted in the 2016 benchmarking programme which demonstrated the range in quality of current rCB offerings. The presentation and subsequent panel discussion provoked much debate around sustainable materials and why these materials prove hard to sell. Much of this was centred around rCB and a key and reoccurring issue was the name chosen for the material. Explaining, Dr Norris pointed out that by its very name, rCB indicates it is a Carbon Black when, actually, it is a unique new material and should be treated as such. Some audience members argued that the name should be changed, whereas others believed this would confuse people and that the current name, although misleading, should stay the same. Audience members also stated that they felt there was not enough data on rCB available and that this is needed in order to prove rCB is a viable replacement of Carbon Black.
Dr Chris Norris presenting on the challenges relating to Recovered Carbon Black (rCB)
Sustainable materials as a whole
On the issues surrounding sustainable materials as a whole, the problems with getting the whole lifecycle integrated from the waste manager, to the recycler, to the end user of the product were discussed. It was agreed that this is proving to be a major barrier in the uptake of recycled or sustainable materials. Centrally, the problems with selling sustainability were raised. The major barrier to uptake is that many times the most sustainable solution is not the most cost-effective. The appeal of the product being sustainable is not enough for customers to pay the higher price. It was suggested that there needs to be a shift in the global mentality for the more expensive, sustainable product to be selected. A key point that also arose from the discussion was that, by exploring synergies in the recycling process between different sectors, recycling could be better promoted. For example, from the production of rCB, energy can be generated from gas and pyrolysis oil. The extra financial incentives of selling energy back to the grid or using it for the plant needs to be considered in the overall economics.
Sustainability at all levels
During the event, other issues, such as the need to understand the incorporation of sustainability into all levels of a product, from the materials that make up the formulation to the manufacture and performance of the product itself, were discussed, as well as issues highlighting value optimisation, the circular economy and cost efficiency. In all, the debate and conversation justified the need for a group of this kind to create the momentum and community needed for the uptake and promotion of sustainable materials. Networking during the course of the event saw relationships being built between partners and interest growing steadily in membership. WWW.ARTIS.UK.COM
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TESTING & INSPECTION | NEWS LUCIDEON PUBLISHES PAPER ON FAILURE ANALYSIS OF PLASTIC PRODUCTS Lucideon has published a new white paper, looking at failure analysis in plastic products. The paper, written by Dr Xi Peng, Polymer Scientist at Lucideon, discusses some of the principles and methods of testing and analysis which are applied to plastic products to perform effective failure analysis. “Plastics are revolutionary materials but their application can also lead to some common failures due to their unique characteristics. Often we see failures because they are either being used in applications they are not fit for, or they are used in environmental conditions that affect their chemical or physical makeup, making them unfit for purpose,” Dr. Peng said. “This paper details some of the limitations of plastic materials along with their common failure modes, and the techniques that can be applied to analyse failures. Often, where we see plastics being used,
any limitations are outweighed by the benefits of using the material. With failure analysis those limitations can be understood to help develop a better product and increase the safety of the product in use.” WWW.LUCIDEON.COM
LEX MACHINERY ADDS ROMMELAG LEAK DETECTOR TO PORTFOLIO
The detector finds leaks by running the discharge current to flow through a pinhole into a container - the detection of this current will automatically cause the container to be rejected.
Lucideon has published a new white paper, looking at failure analysis in plastic products
Lex Machinery, based in Flint, North Wales, is selling a system designed for fully automatic in-line leak testing of plastic ampoule blocks. The Rommelag HVLD high voltage leak detector, made by Swiss machinists Rommelag, finds leaks by running the discharge current to flow through a pinhole into a container - the detection of this current will automatically cause the container to be rejected. The high voltage leak detector represents a testing method without risk of contamination of product and does not require human intervention. Operation pressure is six bar and depending on ampoule width, the machine can test up to 6,000 ampoules per hour, based on a block width of 65mm or less. WWW.BRITISHPLASTICS.CO.UK
Jim Angel, Managing Director, said: “EU GMP guidelines stipulate that all plastic ampoules should be subject to 100 percent integrity testing. Current FDA guidelines require validation for container closure integrity tests. We are pleased to offer a high specification machine at low cost that meets FDA requirements”. The machines have ampoule feeding systems to the leak detector; transport systems with product holders; switches for ampoule separation; inspection electrodes; ampoule discharge systems; machine guards; ozone exhaust systems; electrical panel with all inspection devices and PLC and colour monitors. WWW.LEXMACHINERY.CO.UK
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ATLAS COMBINES UK AND GERMAN SITES TO FORM LARGEST WORLDWIDE TESTING LAB
Atlas says its new lab will streamline its testing operations
SABIC AND PDI RELEASE RESULTS OF STRESS CRACKING STUDY FOR PLASTIC MEDICAL DEVICES The results of a joint study on the environmental stress cracking resistance (ESCR) of SABIC’s thermoplastic materials used for medical device enclosures have been published, and will reportedly provide manufacturers with “new options” when it comes to materials choices. Conducted in conjunction with PDI, a producer of infection prevention products and solutions for the healthcare industry, the study evaluated how well SABIC’s thermoplastics withstand repeated exposure to PDI’s Super Sani Cloth wipes, a widely-used surface disinfectant product to help prevent healthcare-associated infections (HAIs). The companies collaborated to establish a testing procedure following ASTM D543 guidelines, and applied more stringent compatibility criteria compared to other benchmarks often used in the industry. The study revealed that several of SABIC’s product technologies – including Lexan EXL polycarbonate (PC) resin, Xylex (PC/polyester blend) resin and Valox polybutylene terephthalate (PBT) resin – deliver improved compatibility with PDI’s 28
Atlas Material Testing Technology is opening a new accelerated laboratory at its German headquarters in Linsengericht-Altenhaßlau near Frankfurt, the company’s largest worldwide. The laboratory, which will be used for weathering technology and testing services for a range of materials including rubber and plastics, combines the company’s existing sites in Leicester, UK, and Duisburg, Germany, in a move that Atlas says will streamline its operations. “This new testing lab was built to serve not only all of Europe, but our clients from Asia as well,” explained Richard Slomko, Director
hospital-grade disinfectant. SABIC has published the study findings in its brochure, Resistance + Durability: Chemical Resistance Performance Testing for Healthcare Materials. Also featured in the brochure is a new section, “Designing for ESCR,” which describes why following best practices in injection moulding processing and design can be instrumental in reducing mouldedin stress, a key contributor to ESCR performance. “Combatting HAIs is greatly important for hospitals, but if materials are not appropriately selected for the healthcare environment, the frequent application of cleaning chemicals can cause device enclosures to crack prematurely, which can lead to increased maintenance costs for healthcare providers,” said Cathleen Hess, Healthcare Business Leader for SABIC. “SABIC and PDI are committed to supporting the healthcare industry with information about compatibility between medical enclosure materials and commonly-used disinfectants. Our joint study highlights the complex issue of environmental stress cracking, and provides valuable insights to help our customers make informed material selection decisions.” Cheryl Moran, Senior Director of
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of Atlas’ Weathering Services Group. “Combining our laboratory operations within Europe will allow us to further streamline the Atlas testing experience for our customers and provide them with increased laboratory offerings in the future.” The new laboratory is equipped with over 40 Atlas weathering instruments, including Ci5000, Ci4000, and Ci3000 WeatherOmeters, Suntest XXL+, XLS+ and CPS+, Xenotest Beta+ and Alpha+ instruments, UVTest and Solar Climatic 1000 and 340 instruments. The lab also has a fully operational evaluations department that offers instrumental colour, gloss and visual evaluations. WWW.ATLAS-MTS.COM
Portfolio Management, PDI Infection Prevention, added: “By guiding manufacturers towards plastics that are better suited for the specific disinfecting requirements of each medical device, our study benefits both medical device manufacturers and healthcare providers, ultimately benefiting the patient, who can be protected from potential adverse events resulting from damaged or improperly disinfected equipment. Continuing our collaboration with SABIC and medical equipment manufacturers will enable even further insights as additional technologies emerge.” WWW.SABIC-IP.COM SABIC and PDI evaluated how well SABIC’s thermoplastics withstand repeated exposure to a surface disinfectant product to help prevent healthcare-associated infections (HAIs).
NEW ZWICK ROELL TESTING SYSTEM TO BOLSTER MATERIALS RESEARCH AT COVENTRY UNIVERSITY The Centre for Manufacturing and Materials Engineering at the University of Coventry has recently enhanced its research capability with the installation of a Zwick Roell nanoindentation testing system. Professor Nigel Jennett and his colleagues within the Centre will use their new acquisition to research contact mechanical testing methods in the micro and nano ranges. “It is fascinating that a simple change in the size (length-scale) of a material, structure or measurement strongly affects the properties achieved and measured,” explained Jennett. “Recently, I have been developing and using validated nano-mechanical measurements to obtain a better
INSTRON LAUNCHES NEW SOFTWARE SYSTEM FOR MORE EFFICIENT TESTING Instron has released the latest version of its Bluehill software in a new, intuitive package it says brings enhanced functionality and improved workflows to its machines. Bluehill Universal has been designed for touch interaction and allows the user to view the test workspace on a large format monitor. Instron says features such as intuitive gestures and large touchpoints make the user experience “simpler and smarter”. New features unique to the Bluehill Universal version of the software include ‘QuickTest’, which enables simple tests to be carried out without having to build new methods. This, says Instron, is designed for new or infrequent users, as the function allows the user to start a test speed at the touch of a button. A pre-defined graph and results table populates the most common results, such as ‘Maximum Force’ and ‘Displacement at Break’. Additionally, the software also follows the trend of connected devices and the Internet of Things (IoT), by offering users technical support from Instron technicians via
fundamental understanding of plastic deformation as a function of length scale, temperature and time.” Jennett said his next goal is to develop the ability to distinguish measurement effects from genuine material performance and generate impact by providing design rules for material performance enhancement through length-scale engineering; higher resolution test methods for testing small volumes of material and for mapping surface properties; and analysis methods to derive macro property information from nanomechanical tests. This recently-commissioned facility at Coventry University will open up new research possibilities in multi-scale and multi-axis materials testing, and in materials design for improved friction, scratch and wear characteristics. It is predicted that research will benefit the
performance and sustainability of many engineering and advanced manufacturing sectors including; the transport sector, surface engineering and coatings, additive manufacturing, composites, polymers and energy generation/recovery, to name but a few. “We are delighted to have acquired such a technologically advanced testing product which is extremely robust and user-friendly whilst being at the cutting edge of measurement science in the field of nanomechanics,” Jennett concluded .
the touchscreen. When a message is sent from Instron Connect, it carries all of the important system information, such as frame model number, software version, etc., helping users get back to testing faster. Secure screen-sharing tools can speed up the support process even further and also allows users to keep track of their system calibrations and software versions. To increase productivity and efficiency of setting up and managing data, enhanced exporting tools give users the ability to customise results and raw data export files so that they can easily interface with Laboratory Information Management Systems (LIMS). Instron says that one of Bluehill Universal’s “most groundbreaking features” is its built-for-touch architecture. Testing systems can now be operated from an Operator Dashboard - a large-format touch monitor - which can be mounted on the side of the test frame for improved ergonomics and accessibility, which, says Instron “profoundly increases” testing throughput.
NEW DMA INSTRUMENT LAUNCHED FOR HIGHLY ACCURATE TESTING OF RUBBER AND POLYMERS
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Metravib, a manufacturer of analytical instruments for materials characterisation using dynamic mechanical analysis (DMA), has launched ‘Xpander’, a new system for accurate testing of rubbers and polymers. When used with a Metravib DMA instrument, Xpander is said to enable entirely automated DMA test campaigns on a large number of specimens. Xpander has been designed to significantly increase the number of tests performed by DMA instruments in various test modes, including compression, tension and shear. The unit can accommodate material specimens of various shapes and sizes. In addition to a high test throughput, Xpander also offers several other advantages, says Metravib, including reduced labour costs; improved accuracy and uniformity of results, elimination of human error; and improved operator safety. WWW.METRAVIB.COM
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MEDICAL | NEWS LYONDELLBASELL LAUNCHES NEW PP GRADE FOR IMPROVED PROPERTIES OF MEDICAL PLASTICS LyondellBasell has launched a new polypropylene (PP) random copolymer that it says can improve the properties of medical plastic products such as caps and closures, flexible and rigid packaging and pharmaceuticals. New Purell RP320M is a clear resin that maintains its homogeneity for applications in cast film extrusion conversion and injection moulding. Purell RP320M has a low gels content, boosting optical properties for gloss, transparency, surface smoothness, planarity and tear resistance in end products. Additionally, it is said to have excellent sealing properties in film structures and its rheology offers good processability for injection moulding. It does not contain slip or anti-blocking additives and it is manufactured using a non-phthalate based catalytic system. This new polypropylene grade is backed by LyondellBasell’s ‘Purell’ service concept for healthcare applications, which
ner tool Hot run recision P at GB
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New Purell RP320M is a clear resin that maintains its homogeneity for applications in cast film extrusion conversion and injection moulding.
offers consistency of formulation, continuity of supply, single sourcing and compliance to regulatory requirements. “The Purell Service Concept [is based on] the requirements of the healthcare industry, that demand continuous innovation, higher reliability and dedicated technical support,” explained Rodney Fox, Marketing Manager
of LyondellBasell’s Europe PP Healthcare. “Purell RP320M offers a physical, mechanical and optical balance of properties that strengthens LyondellBasell’s leading portfolio of resins used in pharmaceutical, healthcare, laboratory and diagnostics applications.”
GATED HOT RUNNER HELPS MEDICAL MOULDER IMPROVE PRODUCTIVITY
this case have resulted in a reduced cycle time and a narrower moulding window, due to the nature of the material being moulded,” explained Paul Turner, Director of GB Precision. Turner therefore recommended incorporating a gating system to not only optimise the tool design and provide better filling and cavity orientation, reducing the moulding cycle-time, but also substantially increasing the moulding window and reducing material wastage. “By providing our engineering expertise at the tool design stage we could provide our customer with long term benefits in the tool’s productivity. We were able to show that the initial additional cost of incorporating the more complex valve gated hot-runner system would be quickly outweighed by savings in accurate mould control, setting optimisation and waste reduction, which is particularly important in medical applications, where scrap often cannot be re-used,” Turner concluded. WWW.GBPRECISION.CO.UK
A UK-based precision engineering and tooling firm says switching to a gated hot runner system has helped one medical moulder increase the productivity and efficiency of its operations. GB Precision says its customer, a producer of medical packaging, is now delivering better quality products with shorter cycle times following the switch from a relatively simple hot runner to a custom-designed, gated system. The customer was looking for a new mould tool and hot runner system suitable for a rapid-cycling, multi-impression production. It also needed to capably handle the high performance engineering polymer used for the medical packaging being produced. “The original specification had assumed quite a simple system, which, although it would have been perfectly adequate for a less challenging application, would, in WWW.BRITISHPLASTICS.CO.UK
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VELOX TO DISTRIBUTE SPECIALISED MEDICAL POLYOLEFINS FROM REPSOL European materials distributor, Velox, has announced a new distribution agreement with Repsol that will see it supply the latter’s specialised medical portfolio. Repsol, one of the leading polyolefin producers in Europe, has recently launched a ‘Repsol Healthcare’ group of Polypropylene (PP), Polyethylene (PE) and Ethylene Vinyl Acetate (EVA) materials specifically targeted at producers of pharmaceutical packaging and medical devices. Velox will now distribute the portfolio to customers in the United Kingdom, as well as much of central, western and eastern Europe.
Through these medical polyolefins Velox says it “is in the position to offer its customers a more complete and holistic product range” for the production of their medical applications. The products meet European and US Pharmacopoeias (USP/EP) requirements and Velox says its medical sales team can provide customers with high-level technical and commercial advice to integrate these new products, combined with the existing medical portfolio, into their value chains.
Velox will supply Repsol’s newlylaunched medical portfolio
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Makrolon 2458 has improved safety and durability in oxygenators made by Wego
OR A DATE F Y! R YOUR DIA
COVESTRO POLYCARBONATE BREATHES LIFE INTO ARTIFICIAL LUNGS Wego New Life Medical Devices, a medical device manufacturer based in Shandong, China, has used Covestro polycarbonate to improve safety in its membrane oxygenators. Membrane oxygenators, also known as artificial lungs, are used to provide lung function during open heart surgery, by oxygenating patient’s blood outside the human body. This requires its material to have good blood compatibility and durability. Chengwu Liu, Production Director of Wego, said: “Thanks to its outstanding balance of properties, medical-grade Makrolon polycarbonate from Covestro makes oxygenators safe and durable.” The glass-like clarity of Makrolon 2458 polycarbonate makes an entirely transparent shell that enables clear observation of the proper functioning of the oxygenating process. The polycarbonate also exhibits high impact strength and reduces the risk of accidental damage during surgery. Its biocompatibility has been tested according to ISO10993-1, ensuring highest safety for the human body. Mo Liu, Director of China polycarbonates at Covestro, said: “Covestro polycarbonate is widely used in medical applications, and we have partnered with Wego in many medical devices including dialysers and oxygenators. “We want to bring Makrolon polycarbonate to more medical applications in China based on the proven successful cases in Europe and North America.” WWW.COVESTRO.COM
The Medical Technology Event Med-Tech Innovation Expo is the UK and Ireland’s leading showcase for medical technology and innovation – it is the only event that serves the whole of the £27bn UK and Irish medical technology sector. Med-Tech Innovation Expo brings together stakeholders from the medical and healthcare sectors to source products, explore new ideas, understand emerging technologies and talk to over 150 companies representing the supply chain from the ideation stage, through design and validation to manufacture. The centrepiece Med-Tech Innovation Conference, produced in association with Medilink, enhances the show floor experience with a world class programme.
Register now to see the entire spectrum of medical technology under one roof
www.med-techexpo.com WWW.BRITISHPLASTICS.CO.UK
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POLYONE’S RIGID VINYL CHOSEN FOR HOUSING OF INNOVATIVE WOUND THERAPY DEVICE A manufacturer of a new medical device has chosen a rigid vinyl formulation from PolyOne for its ability to resist stress cracking from exposure to disinfectants. The UltraMIST Ultrasound Healing Therapy system, an innovative device for wound therapy from Alliqua BioMedical Inc, features PolyOne’s Resilience HC formulation for the housing. The UltraMIST R&D team chose Resilience HC from PolyOne as a potential solution for their new device after extensive materials evaluation. It said in addition to its disinfectant resistance, the material contains the necessary flammability and UV resistance needed for the application of the new device, whilst also providing excellent mouldability and surface finish. “We gained speed working with PolyOne,” explained Doug Duchon, VP of R&D for Alliqua BioMedical
SOLVAY’S MEDICAL-GRADE PARA RESIN CHOSEN FOR METAL REPLACEMENT IN SURGICAL DEVICE A medical grade resin from Solvay has been utilised for the development of a new single-use surgical device, providing a viable alternative to metal and other polymers. Ixef GS-1022 polyarylamide (PARA) resin is being used for the ‘Elasso Tissue Removal Device’, an innovative new single-use electrocautery instrument for adenoid and tonsil surgeries manufactured by US-based Elasso Surgical Instruments. lxef PARA’s high flexural strength and high flow provides a viable alternative to metal, allowing Elasso Surgical Instruments to optimise the ergonomics, precision and surgical efficacy of its instrument without compromising the rigidity of key components. “We pursued a very ambitious design for our single-use Elasso instrument, which relies on very long, thin forcep-like arms fabricated from Solvay’s high-performance polymer rather than metal to ensure better leverage, reach and control,” said
Inc. “They gave us immediate access to material, engineering, and processing expertise, making our converter comfortable with moulding rigid vinyl. As a small company, we never expected that level of service and speed from a supplier, and the outcome is a well-received commercial product.”
Alliqua BioMedical Inc. is using PolyOne’s Resilience HC formulation for its new medical device. Credit: ©Alliqua BioMedical Inc.
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Olivier Lecerf, Chief Operating Officer, Elasso Surgical Instruments. “We tested several very high-end polymers, but only Ixef GS-1022 PARA resin delivered the necessary combination of high flow in the mould and outstanding strength and stiffness in the finished part to give the forceps the leverage that our design targeted.” Blue and grey-coloured grades of Ixef GS-1022 PARA, a 50 percent glass fibre-reinforced compound, form the device arms, which end in a metal loop that is heated by an electrical current to a temperature that precisely cuts and cauterises isolated tissue. “Like many of our speciality polymers, Solvay’s Ixef PARA introduces more effective alternatives to conventional plastics, and even offers a viable new substitute for many metals,” said Jeff Hrivnak, Global Business Development Manager for Healthcare at Solvay’s Speciality Polymers Global Business Unit. “Elasso Surgical Instruments is the latest innovator to demonstrate the WWW.BRITISHPLASTICS.CO.UK
breakthrough potential that Solvay’s polymers offer biomedical device OEMs today, and we are very proud to have played an important role in the development of their innovative new Elasso device.” WWW.SOLVAYSPECIALTYPOLYMERS.COM
edical-grade ide Solvay’s m am 22 polyaryl 0 -1 S G Ixef s rm fo in s (PARA) re s and forcep the handle ical rg u S o s of Elas so ts new Elas Instrumen e ic ev D l ova Tissue Rem
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Closing the gap on pharmaceutical counterfeiting KEVIN HEAP, PACKAGING EXPERT AT SUMITOMO (SHI) DEMAG UK, EXPLAINS HOW SPECIALIST MEDICAL AND PHARMACEUTICAL CLOSURE MOULDERS ARE USING THE LATEST INJECTION MOULDING PRECISION TECHNIQUES TO KEEP ONE STEP AHEAD OF COUNTERFEITERS TO PROTECT TRADEMARKED BRAND INTEGRITY.
Kevin Heap
P
harmaceutical safety demands traceability. Yet, even with stringent serialisation standards and covert technologies like barcodes, holograms, sealing tapes, and radio frequency identification devices to preserve the integrity of the pharmaceutical products, counterfeiting remains a multi-billion pound industry. However, thanks to new security measures, including anti-refill and tamper evidence caps, many of which are designed using complex injection moulding techniques in the UK, pharma companies are fighting back against these illicit networks.
The cost of fakes
Fake medicines cost the EU pharmaceutical sector €10.2 billion EU (approx. £8.85 billion GBP) each year. In July 2016, the European Union Intellectual Property Office (EUIPO) reported that €605 million EU (approx. £524 million GBP) or 3.3 percent of the UK pharmaceutical sector’s sales, is now lost annually as a result of counterfeiting, with 2,940 direct jobs lost**. And task forces are finding more fake drugs every year. Incorporating security solutions in product packaging is becoming an important anti-counterfeiting measure. One way to counteract fake medicines and product tampering is through the innovative design of packaging that cannot be easily copied. Until recently, this may have involved having a simple tab on the cap which is broken once opened, or developing blister or strip packs and breakable caps that cannot be resealed. However, pharma cap moulders are stepping up the anti and investing in dedicated cells to produce high quality closures made up of a number of complex parts.
Keeping it senior friendly
However, the challenge for cap moulders supplying this sector is balancing protection of consumers with usability. As well as child resistance (CR) closures, pharmaceutical companies need to provide for senior friendliness. Consequently, we are increasingly seeing moulders utilise
sophisticated valve technology within the cap, as these can control the dispensing of product, while also preventing containers being refilled. Along with dosage control, these remain some of the key influences for cap moulders, and many new CR packaging concepts utilise complex and sophisticated opening mechanisms, such as blister packs that requires pressure being applied to two points. Other recent examples involve developing a two-piece combination tamper evident closure for pharmaceutical syrups. Also popular are flip caps that can be locked or feature tear off bands. But, with just two years until the Falsified Medicines Directive (FMD) comes into force in the UK, some pharma cap moulders are being inspired by major breakthroughs in the alcohol and spirit cap market.
A spirited approach
One of the most innovative examples in the spirit sector is a cap that comprises 14 plastic parts, and features a non-refillable valve and a tamper evidence mechanism that provides an irreversible opening event to leave permanent evidence of initial opening. The cap is produced in high volumes and is modular by design, so that trade customers can adapt it to different brands and applications. This cap works by releasing a plastic part when each bottle is opened. It is impossible to reinsert this part back into the cap’s neck and when it drops down it reveals a highlighted ring to indicate that the bottle has been opened. With 14 plastic parts, assembly of this cap is highly complex. Because each plastic element is small and needs to fit together to form the overall tamper evident mechanism, part quality is paramount. The producer uses five Sumitomo (SHI) Demag all-electric IntElect Smart 220 tonne and 450 tonne injection moulding machines to make the plastic component, which is then assembled
into the cap’s aluminium sleeve by downstream automation lines.
Alternative deterrents
Other overt packaging methods to deter counterfeits include concealing unique identifiers, such as a QR code or holograms, on the inside of cap labels. While these can assist with track and tracing, they only really help to validate the origin of a bottle. To outsmart quick-witted counterfeiters, pharma manufacturers may need to deploy several tactics simultaneously to prevent brand value being diluted, including tamper evident caps with holographic labels. Use of infrared and ultraviolet (UV) light, microscopic tagging, molecular markers and biological tracers are also being deployed. These technologies can only be identified by customs agencies and authorised distributors using laboratory equipment. For trade moulders producing pharmaceutical caps and closures by the millions, cost effectiveness is vital. It therefore makes good economic sense to build a complete moulding system to take care of all the anticipated applications, rather than trying to adapt existing equipment. Due to the increased precision involved in moulding caps, many manufacturers today are prepared to invest. UK.SUMITOMO-SHI-DEMAG.EU
Pharmaceutical packaging involves many complex and sophisticated opening mechanisms
*https://euipo.europa.eu/tunnel-web/secure/webdav/guest/document_library/observatory/resources/research-and-studies/ip_infringement/study9/pharmaceutical_sector_en.pdf
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SOFTWARE AND SYSTEMS | NEWS PLASTICS MANUFACTURER ELIMINATES “NIGHTMARE OUTAGES” WITH NEW DATA PROTECTION SYSTEM A UK-based plastics manufacturer has eliminated “nightmare outages” following the implementation of a new data protection system that has allowed it to cut its backup time and reduce its storage requirement. PW Hall, a Glasgow-based producer of colour and additive masterbatch, has recently installed the ‘Unified Data Protection (UDP) Appliance’ from data protection and recovery software specialist, Arcserve, after its previous tape backup and recovery solution was proving to be unreliable. Using its existing system, the company’s backup window was reaching 13 hours, limiting PW Hall to one daily backup. If an outage did occur, a member of the team would have to travel six miles off-site to retrieve tape backups before the restore could begin to take place, impacting on manufacturing, sales and productivity. The company worked with Epaton, a UK-based reseller of Arcserve products, to select a backup and recovery solution that could handle its data volumes and cut down the time it took to backup and recover business-critical data. The UDP appliance chosen protects 850GB of PW Hall’s data that is core to manufacturing and sales processes - reduced from 3TB through deduplication. This includes flat files, SQL, ERP (enterprise resource planning) and Exchange mailbox data across 12 virtual and five physical servers. Instead of one time-consuming
PW Hall is protecting its data with the installation of a new backup system
overnight backup, the new system makes incremental backups throughout the day, reducing the backup window to approximately 90 minutes. Backups run every six hours for servers where the change in the data is low, and every four hours where the server data delta is high. These backups are then replicated offsite to Arcserve’s cloud-based server. “Outages were a nightmare – one of us would have to drive six miles to pick up our backed up tape before we could even start to restore missing data. And the backups themselves were time consuming and difficult,” explained Robert Jackson, PW Hall’s IT Manager. “But it all takes care of
itself now, and we have a much more efficient means of restoring data. We don’t need to be actively involved anymore so it frees us up to focus on other tasks such as testing recovery points and other business-focused tasks.” Arcserve UK and Ireland Territory Director, Richard Massey, added: “A 13-hour backup window is not something any company should have to contend with. Backup and recovery are essential, but they should also be simple. Something IT managers can set up and leave, so they can get on with their jobs.” WWW.PWHALL.CO.UK WWW.ARCSERVE.COM
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DENROY GROUP ‘BREAKS THE MOULD’ WITH ERP SOFTWARE INVESTMENT Precision plastics injection moulding and tooling manufacturer, Denroy Group, has invested in a cloud-based software package as it looks to enhance planning, service and quality control across its companies. The investment in ‘CloudSuite Industrial’ from software specialist, Infor, will reportedly help the mouldings specialist to capitalise on new opportunities and consolidate business growth across the Group. Denroy Group made the decision to invest in the system following significant growth, particularly in the aerospace market. Following a review of its existing operations, it concluded that the increased production volumes it was experiencing, alongside a more complex operating environment, required enhanced ERP capabilities. “Our aerospace business is complex, with projects spanning the entire lifecycle, from design to manufacture,” commented Kevin McNamee, Group Financial Director, Denroy Group. “In the wake of increased demand and rising complexity, we needed an ERP system which could support our current and future requirements, from planning and customer service, to quality control and compliance, an area which is scrutinised with increased rigour all the time.” Denroy Group says it selected CloudSuite Industrial based on a number of areas. The application’s CRM, Project Management, Quality Control and Data Capture capabilities were deemed hugely valuable in helping the Group to provide optimum service levels for its aerospace customers looking for full project management.
Denroy Group has invested in Infor cloud-based software and technology across its businesses (Image: Denroy Group)
In addition, the Group has also chosen to utilise a ‘Moulding Industry’ pack, which is designed to provide additional capabilities for advanced resource management spanning component design, tool manufacture, component manufacture, through to quality control in order to support traceability and accountability. To enhance this process further, Denroy also selected Infor ‘Factory Track’ to capture in-depth shop floor data and inform resource planning going forward, as well as a technology platform to connect, access and anaylse everything quickly. The project will be rolled out in three phases, starting with Denman International Limited, the Group’s plastic haircare sales and marketing
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division, followed by Denroy Plastics Limited, which concentrates on manufacture across a number of sectors, including aerospace. “Discrete manufacturing is inherently complex, and continual pressure from customer demands, market volatility and the regulatory landscape mean that this complexity is on the increase,” explained Phil Lewis, European VP of Solutions Consulting, Infor. “Manufacturers must leverage their systems to deliver agility and profitability, and through using Infor CloudSuite Industrial, they can have confidence in their ability to deliver against customer demands diligently and profitably.” WWW.INFOR.COM
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1200mm Cloeren Epoch 111 Auto flex Die
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TRANSXL INTERNATIONAL LIMITED . THORNHILL . SOUTH MARSTON . SWINDON . SN3 4TA . ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB WWW.TRANSXL.CO.UK
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GRANTA DESIGN RELEASES LATEST VERSION OF MATERIALS MANAGEMENT SOFTWARE Granta Design has released the latest version of its materials information management software for businesses to make better selection decisions. The Cambridge-based company says new ‘Granta MI Version 10’ delivers a new workflow system, plus new and updated apps and tools based on experience and feedback from implementations worldwide. The new software also brings users control over how they collect and apply materials knowledge and removes major barriers to digitalising materials-related processes, says Granta. Designed to bring the engineering materials community in line with the highly digitalised processes adopted by other industries over the last three decades, Version 10 of the Granta MI software aims to remove constraints such as manual and error-prone processes, the widely-varying needs of different groups in an enterprise, and the lack of a consistent approach across key engineering tools such as computer-aided design (CAD), computer-aided engineering (CAE), and product lifecycle management (PLM) systems.
SENSEYE LAUNCHES NEXT GENERATION OF PREDICTIVE MAINTENANCE SOFTWARE Senseye, a Southampton-based producer of software for enhanced uptime in manufacturing, has launched its next generation of predictive maintenance software, allowing for the ‘Remaining Useful Life’ of machines to be easily viewed
Schematic of a MI workflow
The software removes these barriers and ensures that materials information is captured digitally and linked intelligently, establishing a single, consistent, traceable ‘gold source’ of materials data for the organisation. Central to this, says Granta, is the new Granta ‘MI:Workflow’, which enables companies to manage the processes by which materials information is requested, collected, approved and released in a controlled, traceable manner. Its simple user interface of forms and task-based activities reportedly enables workflows such as to-do lists, email notifications, approval sequences, and moderation queues.
A key feature is the audit trail of who performed which step of the process, and when. “With this release we can transform the way that organisations integrate materials information around their business. MI:Workflow is the result of several years’ collaboration with key customers who understand the importance of controlled, auditable processes for critical materials data. We are thrilled to bring this technology to our worldwide community of user organisations,” commented Dan Williams, Product Manager for Granta MI.
by maintainers. Version 2.3 of its automatic condition monitoring and prognostics software empowers maintainers and their managers to quickly see for how long assets can be expected to keep performing as they should, and what they will need to do to avoid unplanned downtime. Senseye says its software program
is the only product in the world to offer automated condition monitoring combined with Remaining Useful Life analysis. Knowing the Remaining Useful Life of machinery helps industrial companies to implement costeffective predictive maintenance, typically allowing for a 10-40 percent reduction in maintenance costs and downtime reduction of 30-50 percent. Remaining Useful Life has been an academic focus until now, accessible only to those with extensive data engineering skills. Senseye says its patent-pending technology makes it accessible to all. Robert Russell, Senseye CTO, commented: “Being able to see the Remaining Useful Life of machinery – without requiring expert input – empowers the hero maintainers to get maximum value from their condition monitoring solutions.”
Senseye works on software for enhanced uptime in manufacturing
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Engineering Passion
MACHINERY | NEWS WITTMANN LAUNCHES PRIMUS 16 - A PICK AND PLACE ROBOT WITH POTENTIAL Wittman has launched a new series of robots, starting with the Primus 16, a ‘pick and place’ robot designed for industry developments in miniaturisation and part separation, without complex automation. The model has a payload of up to 5kg, with a Wittmann absolute encoder regulator included, preparing it for such applications. The encoder provides users with constant position feedback, without preceding referencing, which simplifies and quickens the run-up of the process. The mechanical layout and the geometry of the axes of the new Primus robot are similar to Wittmann’s existing, high-volume W818 model. However, in contrast to the W818, the Primus 16 is designed
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for single removals. The Primus also has a modular design, meaning serial production of the robots is easier and more efficient. This, says Wittmann, leads to lower costs for the user. The horizontal axis of the new robot has a stroke capability of 1500mm or 2000 mm, a vertical axis of either 800mm, 1000mm, or 1200mm and a demoulding axis of either 420mm or 620mm. Martin Stammhammer, Wittmann’s International Sales Manager for Robots, explained: “Our customers have to face changing requirements every year. For us, this means stimulation as well as a challenge. As the European market leader for linear robots, we have great advantage in getting specific and comprehensive feedback from our customers – something that helped us immeasurably in defining the Primus 16.
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“We bring both complex and simple applications under our one roof. We therefore expect excellent market opportunities for the new Primus 16 in many varied markets.” WWW.WITTMANN-GROUP.COM
new ot The us rob m i Pr
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UK SALES OF HAITIAN INJECTION MOULDING MACHINES “SMASH” TARGET WITH 320 PERCENT INCREASE Sales of Haitian injection moulding machinery in the UK grew by a record 320 percent in 2016, thanks to a combination of repeat orders and an expanding customer base. According to Aylesbury-based Premier Moulding Machinery (PMM), the UK sales and service partner for Haitian International, half of all sales came from the servo hydraulic Haitian ‘Mars II’ Series. PMM noted a “marked increase” in demand for all-electric technology, with the electric ‘Venus II’ series and electric ‘Zeres’ series accounting for over 40 percent of sales from customers in the medical and automotive sectors; both of which require high precision and control. Commenting on the results, PMM’s Sales Director, Richard Hird, said: “This outstanding result smashes what was an already ambitious target for Haitian International in the UK. We have basically quadrupled our turnover in the last 12 months, outperforming the market with record growth in 2016.”
Formula Plastics’ new Engel injection moulding machines
Sales of Haitian injection moulding machinery in the UK grew by a record 320 percent in 2016
Haitian International’s strategy – offering ‘technology to the point’ – focuses on delivering highly engineered, energy-efficient products for the right application. It is this approach, says Hird, that has been crucial to PMM’s performance in the last 12 months. “Providing targeted solutions for customer applications has underpinned our outstanding performance,” Hird continued. “Given the targeted machinery ranges on offer with ex-stock availability, combined with a proven reliable track record backed up with a three-year parts and labour warranty
as standard, we believe that this is exactly what our customers are looking for.” Reflecting on this success and its commitment to the UK plastics sector, PMM has doubled its stand size at the upcoming Interplas trade show, being held on 26th – 28th September at the NEC Birmingham. This decision, says Hird, is to “showcase how Haitian International innovation in partnership can make money for its customers.”
FORMULA PLASTICS INVESTS IN ENGEL FOLLOWING AUTOMOTIVE GROWTH
James Goodliffe, Managing Director, said: “I believe in cultivating close, long term relationships with both our customers and our suppliers. In doing this we have been able to not only retain existing business, but also to attract new customers. This approach has resulted in us gaining additional work from both inside and outside the automotive sector.” Formula Plastics’ order for Engel injection moulding machines was driven by the possibility of reducing energy consumption by half. Goodliffe said: “We’ve chosen Engel for their quality, reliability and environmental impact. We currently have 11 of their injection moulding machines in various tonnages from 50 tonnes up to our latest acquisition at 650 tonnes. This investment is part of the ongoing growth plan of Formula Plastics as we continue to win more business.”
Following four years of increased company growth, Formula Plastics is to further its investment with new, fully automated Engel injection moulding machines. The company, based in Newton Aycliffe, County Durham, has invested over half a million pounds since the start of 2016 in advanced technology equipment, for meeting increased demand. The investment package included a grant of £94,500 from the regional growth fund ‘Let’s Grow North East’. The automotive supplier moulds high tolerance precision components, with experience in single and twin shot moulding, and recently increased capability to mould larger components. Its highly efficient project management of new business and ability to provide ongoing support has enhanced the service to its clients. WWW.BRITISHPLASTICS.CO.UK
WWW.HAITIAN.CO.UK
WWW.ENGELGLOBAL.COM
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Engineering Passion
WARDEN PLASTICS INVESTS £240,000 FOLLOWING GROWING DEMAND Warden Plastics has invested £240,000 in new extrusion and cooling technology at its Luton factory following a surge in demand. The plastic extrusion and moulding manufacturer supplies into several industries, however, says its expanded Biomedia product range of random filter media for wastewater treatment is fueling the need for enhanced production capabilities. As a result the company has invested in two extruders from Davis Standard and five standalone, custom made chillers for
The new extruders at Warden Plastic
Storage – Indoor & outdoor modular silos
extrusion from F&R Products Ltd. Warden Plastics Managing Director, Mark Barrett, said: “We’ve invested heavily in our production capability with new technology to improve speed of output and performance. We’re gaining new customers monthly and they are demanding higher volumes. “We’re also building a formidable reputation in the wastewater treatment sector. Ongoing innovative product development will put us ahead in the marketplace to help the European waste water industry reduce its energy consumption to meet environmental targets and reduce costs.” Warden Plastics its Biomedia brand, which it launched in the 1980s, is being continually strengthened by an ongoing research partnership with Cranfield Water Sciences Institute (CWSI), an internationally recognised centre of excellence in wastewater treatment technologies for research, education, training and consultancy, as well as Warwick University. WWW.WARDENPLASTICS.CO.UK
UPM CONVEYORS DEVELOPS BESPOKE SYSTEM FOR BRITAIN’S LARGEST CAP PRODUCER Cleaning – de dusting & separation equipment
Conveying – Vacuum & pressure systems
Kongskilde – Your cleaning, conveying and storage specialist Kongskilde also offers complete project installations, service visits and customised control panels.
Kongskilde UK Tel. 01263 808580 kuk@kongskilde-industries.com www.kongskilde.com
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UPM Conveyors has developed a fourin-one mobile system for Britain’s largest producer of injection-moulded drinks closures. The new, stand alone system has been designed to transfer closures to a bulk feed hopper for cooling, singulation, orientation and counting before output into wadding or sealing machines, or other post-moulding application with small footprint criteria. The bulk feed hopper allows for a production rate of 130 caps per minute (60mm diameter x 25mm height) on five minute cycles to allow for a reel change on the downstream equipment. It includes cooling fans that incorporate finned coils with chilled water to eliminate heat distortion, prior to isolating and orientating each cap, with a photoelectric sensor for counting. The system is mobile so can be used at any production cell as a standalone system or integrated into moulding machines. UPM initially custom engineered the conveyor for this customer, but will now offer it as a standard unit for similar operations. WWW.UPMCONVEYORS.CO.UK
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Engineering Passion
www.kraussmaffei.com
HRSFlow, has developed three new solutions it says optimise the injection moulding process and simplify routine maintenance of hot runner systems.
HRSFLOW LAUNCHES NEW HOT RUNNER SOLUTIONS FOR SIMPLIFIED MOULDING Hot runner specialist, HRSFlow, has developed three new solutions it says optimise the injection moulding process and simplify routine maintenance of hot runner systems. The new components consist of a ‘Three Layer Tip’, ‘Pressure Block’ and a ‘Thread Safe Kit’, each designed to either produce enhanced quality in the finished part, improve the processing of materials in the mould or make routine maintenance simpler. The Three Layer Tip is a special coating-free tip made of three materials, one of which is a copper bushing internal to the flow channel to improve thermal conductivity. The new design provides increased temperature at the gate, improving processing of materials such as glass filled fibre. Thanks to the use of a special material and the removal of any coating, the new Three Layer Tip ensures wear reduction of the nozzle tip, elimination of black spots on the moulded parts and an optimal mechanical resistance. Although these improvements
The new lab system at the Institute for Lightweight Engineering and Polymer Technology. Photo: Dresden University of Technology/ ILK
KRAUSSMAFFEI TECHNOLOGY ENHANCES HYBRID FIBREREINFORCED PLASTICS FOR CAR MATERIALS Researchers at the Dresden University of Technology are using technology developed by KraussMaffei to pioneer hybrid fibrereinforced plastics for automotive lightweighting applications. KraussMaffei has provided a new laboratory test system as part of research project, ‘Leichtbau in
have been produced especially for the automotive lighting sector, all injection moulded parts with high cosmetic requirements can benefit from this new product. The Pressure Block is a new component made with special low heat conductible materials. It is positioned between the hot runner system and the mould, which increases the clamp plate stiffness under load, and at the same time provides an optimal thermal profile along the whole hot runner system. The main feature is the flexible positioning without negatively affecting the thermal profile of the hot runner system. Optimising the injection moulding process is fundamental
for production of a quality finished part but simplifying the routine maintenance is equally important, says HRSFlow, adding that the new Thread Safe Kit provides both requirements. A special bushing positioned between nozzle and manifold provides easy nozzle removal without thread damage when processing materials such as PMMA and PC. The new design eliminates thread seizing between the duct and manifold allowing for simple removal of the nozzle from the manifold for routine maintenance in any condition.
Karosseriebauteilen’ (LEIKA), or lightweight construction in auto body components, which aims to reduce structural mass in electric vehicles by using hybrid materials that could have large-scale series production. Martin Würtele, KraussMaffei Director of Injection Moulding Technology Development, said: “The new lab system at the Institute for Lightweight Engineering and Polymer Technology allows us to form and back-inject FRP-metal hybrid materials in one step. The resulting process and structure quality, together with the achieved cycle times of significantly less than two minutes, supports the potential of such hybridisation on both the material and production end.” Designing floor structures for electric vehicles, the researchers used hybrid plastic/ metals to make metallic outer layers of steel with a core of CFRP for a centre tunnel. Würtele said: “The first test results are excellent. The mass is reduced by 25 percent compared to an all-metal lightweight construction solution. Simultaneously, it was
possible to demonstrate comparable performance under the most important load conditions regarding stiffness and crash situations for components with significantly lower mass.” KraussMaffei has provided systems and aided project engineering from the start of the LEIKA project. The new lab system is suited both for the manufacturing of components by injection moulding and for the back injection of semi finished products. Additionally, plastics can be used for compression in the mould or for reinforcement for local areas in the component. This process sequence is applied through the integration of a flat sheet die as well as a conveyor belt with an insertion robot. Michael Krahl, LEIKA Project Manager, said: “The new test system lets us project a large number of incredibly varied processes on a single system. This lets us offer significant added value to our partners from the automotive industry.”
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WWW.HRSFLOW.COM
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NEC BIRMINGHAM, UK | 26-28 SEPTEMBER 2017
INJECTION MOULDING
EXTRUSION
ROTATIONAL MOULDING
BLOW MOULDING
RECYCLING
THERMOFORMING
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VACU UM FOR M I N G
DESIGN
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MATERIALS | NEWS PLASTRIBUTION REPORTS “OVERWHELMING FEEDBACK” FROM UK CONVERTORS TRIALLING ETHYDCO PRODUCTS UK plastics raw materials distributor, Plastribution, says feedback from its customers trialing newly-available products from Egyptbased materials producer, Ethydco, has been “overwhelmingly positive.” So far, Plastribution has supplied nearly 40 UK and Irish customers with Ethydco products since securing an exclusive distribution agreement in July 2016. The company says those that have purchased, or are trialling the products, have been “entirely positive” about their competitiveness and performance. Plastribution has UK stock of the majority of Ethydco’s grade range, following a delivery of materials from its new facility in Alexandria, Egypt, in the last quarter of 2016. The remaining materials in the range are scheduled to be fully available by the end of the first quarter of 2017. “We have been delighted with the progress we have made. The process has been made easier by the range and quality of the products from this
The new coffee pod in the Bebo B2nature material
Ethydco’s new facility in Alexandria, Egypt
brand new plant,” said Katherine White, Plastribution’s Commercial Director. “The flexible packaging market has always been strong for Plastribution, so the Ethydco C4 LLDPE and MDPE grades have been an excellent addition to our range.” Alongside products for the flexible packaging market, there is four new HDPE grades suitable for blow moulding: including grades suitable for small bottles aimed at the cosmetics and industrial markets and, at the other end of the scale, high ESCR grades for large blowmoulded parts. Plastribution says its distribution
RPC DEVELOPS NEW MATERIAL FOR DISPOSABLE COFFEE CAPS RPC Bebo has developed a material for single serve coffee capsules that can be industrially composted, while delivering longterm protection of the contents. WWW.BRITISHPLASTICS.CO.UK
agreement with Ethydco has also enabled the company to target other untapped markets, such as providing a UV-stabilised MDPE for rotational moulding, together with PE80 and PE100 grades for pipe manufacture. “The Ethydco relationship is proving to be a resounding success,” commented Plastribution’s Managing Director, Mike Boswell. “In addition to the quality and range of products available, we are also able to ensure security of stock and competitive pricing, providing convertors with some great supply options.” WWW.PLASTRIBUTION.CO.UK
The ‘Bebo B2nature’ material has a multilayer sheet with an oxygen barrier to deliver a long ambient shelf-life and maintain the quality of coffee in the capsule. RPC Bebo says within 12 weeks of industrial composting only a minor amount of capsule material is left thanks to efficient decomposition, assisted by the coffee itself, which gives nutrients to the compost and improves the nature of the soil. The container can be certified for industrial composting, based on EU and US regulations. Matthias Michaelis, RPC Bebo’s Business Unit Manager for Thermoformed Barrier Packaging, said: “B2nature means consumers can benefit from the convenience of small portion packs by providing a sustainable means of disposing of them. “The material also offers the high level of protection that means no compromise on the freshness, aroma and quality of the coffee.” WWW.RPC-GROUP.COM 45
Conference Preview:
PVC: Industry thought leaders put sustainability in the spotlight
S
aving energy, being abstemious, making production processes more efficient and less harmful – these current principles of sustainability do not sound particularly attractive to Professor Dr Michael Braungart; they lack AT THE UPCOMING real innovation, positivity and PVC CONFERENCE IN effectiveness. Braungart, founder of EPEA, BRIGHTON, THREE OF THE INDUSTRY’S MOST Environmental Protection Encouragement Agency, will take PROGRESSIVE SPEAKERS to the stage on the first day of ON THE SUBJECT the conference to explain why he OF SUSTAINABILITY believes the ‘Cradle-to-Cradle’ WILL TAKE TO THE approach to sustainability can STAGE TO CHALLENGE be an innovation driver for the AND INFLUENCE PVC industry. Braungart says unlike traditional principles of THE DIRECTION AND sustainability, Cradle-to-Cradle is OBJECTIVES FOR different, as it values products and FUTURE SUCCESS. HERE, production processes designed BP&R LOOKS AT THE through principles that are healthy MESSAGES EACH WILL and even beneficial to both humans and nature. It revolves around DELIVER TO DELEGATES products that function in material AT THE EVENT. flows so that there are only useful resources, or even better, nutrients. This approach, he will say, paves the way to a new economic system for which innovation, positivity, quality and creativity are key. Following Braungart, Dr Brigitte Dero of VinylPlus will emphasise how VinylPlus is about much more than PVC recycling - an industry that has been developed
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effectively and successfully over the last 15 years - but that its broader sustainability aims fit very well in the framework of the Circular Economy’s resource efficiency objective. She will say that by saving energy during production, ensuring sustainable use of additives and raising awareness about sustainability in and beyond Europe, VinylPlus may be considered as a model of what a united industry can achieve. The last of the three keynotes to be unveiled, Dr Martin Baitz, Director of Content at thinkstep AG, will discuss how leaders in sustainability achieve an increase in revenue, cut costs, enhance their brands and reduce risk. He will note that almost any major company, and certainly all industry sectors, cope with the topic of sustainability in more or less structured ways. Certain industries have sustainability programs to harvest synergies in the sector and certain companies have specific sustainability processes already installed. The programs and initiatives are sometimes called by different names (e.g. Foot printing, Environmental Labeling, Design-for-Environment, Sustainable design, Sustainable engineering, green procurement, Cradleto-“X”, Circular Economy, CSR, HS+E, etc.) but virtually all follow the “Life-Cycle-Thinking” Approach. He will argue that a solid normative foundation is important for implementation of sustainability in companies and for sustainable policy making. The PVC 2017 event is taking place from 25-27 April in Brighton, UK. WWW.PVC2017.ORG
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BUYER’S GUIDE
MATERIALS
MOULD RELEASE
ultrasonic welding
CONTROL SYSTEMS AND EQUIPMENT
HOT RUNNER SYSTEMS hot runner controllers
quality monitoring control
MASTERBATCH
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.
BLACK & WHITE MASTERBATCH Compounding
Recycling
Moulding
Film
Pipe
Conduit
DRYERS
Whitelands Mill, Whitelands Road Ashton-under-Lyne, OL6 6UG, UK Tel: +44 (0)161 308 2550 Fax: +44 (0)161 343 2026 E-mail: aml@abbeymb.com Web: www.abbeymb.com
Motan Colortronic Ltd
InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)
PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk
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
gravimetric/volumetric blending Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
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: telsonicuk.wordpress.com
Accurate colour systems for the PVC and additives industries t: +44(0)1942 254006 e: sales@astropol.uk.com www.astropol.uk.com Eclipse Buyers Guide_Layout 1 07
colour masterbatch
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.
MACHINERY & EQUIPMENT ASSEMBLY hot plate welding 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu
infrared welding
automation
DB-Automation specialises in designing and building bespoke high speed injection moulding automation • Reliable and robust machinery with installation worldwide • High performance de-mould automation for injection moulding • High speed axis for reduced cycle times • Dependable after sales support if required
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
hopper loaders
HEATING EQUIPMENT
induction heating for platens and tools
www.frimo.com
MF Induction Heating
Turn your redundant stock into cash
MATERIALS HANDLING AND STORAGE
01455 289842 enquiries@db-automation.co.uk www.db-automation.co.uk
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Welding machines Innovative tooling concepts Emitter systems Control technology
Alderley Polymers
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
Motan Colortronic Ltd
Infrared Welding
mmcrellin@hotmail.co.uk Tel: 07803 759680 or 01625 531 434
158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu
CHILLERS/TEMPERATURE CONTROLLERS
HIGH TECH AND HIGH PASSION.
Wanted: PP, HD, LD, HI, ABS & Polycarb in any form Immediate Payment
Suction Blowers pipework cyclones New and Used recycling Equipment Kongskilde Spares, Parts and Pipework Suppliers industrial BLOWERS FLAKE/REGRIND Friendly Expert advice Les 01568 611338 Hereford W: WWW.GRAINBLOWERS.CO.UK
Branson Ultrasonics
Branson Ultrasonics
wanted
AM&LT PUGH KONGSKILDE MAIN DEALER
vibration welding
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
MATERIALS HANDLING AND STORAGE
pulse staking
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
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
WWW.BRITISHPLASTICS.CO.UK
MIXING, FEEDING & DOSING 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 FOR SALE W: www.motan-colortronic.co.uk
METAL DETECTION & SEPARATION EQUIPMENT Motan Colortronic Ltd
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
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
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BUYER’S GUIDE
MACHINERY & EQUIPMENT METAL DETECTION & SEPARATION EQUIPMENT Magnetics Separators Metal Detectors Eddy Current Separators
Bunting Magnetics Europe Ltd European Design & Manufacturing Facility
Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co
RECYCLING SYSTEMS
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
TransXL International Ltd
Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk
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.
/magnetic_separation_and_metal_detection/
Contact: Carlton Hicks
Mould change
I’VE GOT A BUMPER LOAD OF RECYCLED PLASTIC IN ME, THANKS TO VANDEN
50mm high and 35mm We buy and sell high quality plastics
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
SECONDHAND AND RECONDITIONED
Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com
ANGLO PLASTICS LTD
Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com
www.quick-mould-change.com
NOZZLES & NOZZLE TIPS
Cooper Plastics Machinery
QUALITY PVC PELLETS FOR EXTRUSION
SCREEN CHANGERS Industrial Plastics Ltd
Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk
pad
SCREWS & BARRELS
8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 719850 E: Cooperplastics@gmail.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.
Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries.
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
TESTING EQUIPMENT hardness - IRHD and shore 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
Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.co.uk
3D Printing in Plastic & Rubber
inspection & measurement
DM Machinery Ltd
Tel: 01420 88645
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
www.projet3d.co.uk
SERVICES
- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com
MOULDFLOW ANALYSIS
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
Injection
Moulding
Trainingancy Consultow fl & Mold
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
WWW.BRITISHPLASTICS.CO.UK
c.co.uk www.rjgin
Contact us to find out how we can help you
3D PRINTING
211 )1733 232 P. +44 (0
• Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks
ulders injection mo
FOR SALE
DTL Machinery UK
www.magog.co.uk
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MAPRA Technik Co — BAREISS
COMPOUNDS
vekacompounds.com +44(0)1322 387 219
PRINTING MACHINES
TRAINING
c.co.uk www.rjgin
www.vandenrecycling.com supply@vandenrecycling.com
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
11 )1733 2322 P. +44 (0
028 9266 8009
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
thermocouples
BUYER’S GUIDE PRINTERS
SERVICES MOULDFLOW ANALYSIS
Gammadot Rheology Testing & Consultancy Services
printers of plastic mouldings Total Print Ltd
Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry
SOFTWARE
TESTINg/CONSULTANCY
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
Component PRINTERS TAMPO.SCREEN.FOIL
c.co.uk www.rjgin
211 )1733 232 P. +44 (0
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
TO ADVERTISE IN THis SPACE CONTACT kirsty wilcox 01244 680222
SOFTWARE DIRECTORY A listing in the Software Directory costs £160 per programme per year. Call Lisa on 01244 680222 for details. 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: info.uk@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). 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. 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). SYSCON – PlantStar Tel: +44 (0)7747 014545 E: ianh@syscon-intl.com W: www.mtec-services.co.uk W: www.plantstar.org
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, Materials traceability, barcoding. New QuickShot entry level system, provides real-time data collection & reporting, plus drag & drop scheduling and much more for less than £500 per machine!
enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Epicor ERP 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, warehousing and distribution. Available on-site, hosted & SaaS it seamlessly integrates with Epicor Mattec Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.
WWW.BRITISHPLASTICS.CO.UK
Process Optimisation Software RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E ingo@rjginc.co.uk Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.
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NEWS FROM THE FRONTLINE
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that a circular economy approach should be central to policy in Scotland. All Parliamentarians were very keen that we repeat this event in a year’s time. We owe a debt of thanks to Angus MacDonald MSP for hosting the event, which was also supported by local NGO, Fidra, which has developed a strong interest in assisting in the roll out of Operation Clean Sweep to non plastics industry parties, such as logistics companies. Our latest Business Condition Survey is showing a largely positive expectation about the development of the industry in the next 12 months. We have had approximately 100 responses and firms are expecting a significant increase in overall sales turnover, including export sales, and profitability. Inevitably, with this business growth, 44 percent of companies are looking to increase their staff, however, and there is some inevitability here, there is an even greater increase in the number of companies finding it difficult to recruit staff with the right skills. This survey showed that some 65 percent of firms are now experiencing difficulties., up from 46 percent just six months ago. Interestingly, there is a slight increase in companies proposing to ‘invest significantly’ in the coming year, perhaps muted by the weakness of sterling and the increased costs of imported equipment. Finally, the BPF and its members are succeeding in raising the profile of the industry with the political community at a time when Brexit is uppermost in our consciousness. Recent meetings with MPs have included Andrew Bridgen MP, at Plastribution, and Sir Julian Brazier at Hellyar Plastics. BPF staff were able to engage with Parliamentary Under Secretary of State at the Department for Environment, Food and Rural Affairs, Therese Coffey, at M&H Plastics. A leaked government document recently published in ‘The Times’ indicated that the plastics industry, alongside the chemicals sector, is seen as a priority industry sector for upcoming Brexit negotiations. I was pleased to see that all four requirements specified by the BPF on behalf of the industry as essential in these exchanges were mirrored in the leaked document. www.bpf.co.uk
ASSOCIATED ORGANISATIONS
his week saw the BPF team north of the border in Edingburgh and Glasgow. In conjunction with PlasticsEurope and the Scottish IN THIS MONTH’S EDITION Plastics and Rubber OF HIS EXCLUSIVE COLUMN, Association, PHILIP LAW, DIRECTOR- we staged a GENERAL OF THE BRITISH reception in PLASTICS FEDERATION, the Scottish DISCUSSES TAKING THE Parliament at Holyrood on PLASTICS ENVIRONMENTAL the subject of MESSAGE NORTH OF THE ‘Plastics - Challenges and BORDER, GIVES INSIGHT INTO Opportunities in a Circular THE LATEST FINDINGS FROM Economy’. There was a large ITS BUSINESS CONDITIONS audience for our message. SURVEY AND REVEALS HOW A We were complimented by Scottish Parliamentarians on LEAKED POLITICAL DOCUMENT the great turnout from the SUGGESTS THE INDUSTRY’S local industry. VOICE IS BEING HEARD. I made the point that the Scottish Plastics Industry is crucial to the overall UK sector. It has some 255 companies and a turnover of £1.5 billion which has grown 8.5 percent since 2012. It also employs nearly 9000 people. I said that as well as an impressive array of processors, Scotland has a centre of strategic importance internationally in Grangemouth, and indeed, Scotland produces around 30 percent of the polymer made in the UK. In a month of heightened negative press attention on our industry and its products, I was able to profile the positive role plastics plays in society and highlight the excellent work our members are doing to prevent pellet loss from their facilities. We now have over 170 BPF member sites signed up to the Operation Clean Sweep programme, which between them handle more than 40 percent of all the plastics raw material processed. I would urge all companies (members and non-members) to consider joining this momentum to demonstrate our environmental responsibilities. Companies can sign up at www.operationcleansweep.co.uk We were privileged to have present Scotland’s Minister for Business, Innovation and Energy, Paul Wheelhouse, who showed a keen interest in our activities and believes
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www.netstal.com
Outstanding quality High returns Are you looking for an injection molding system for certified production to the highest of standards? Do you need to supply your customers with superior quality health-care products? Then Netstal injection molding systems are a must have! Our team is made up of experts specialized exclusively in the manufacture of medical components. This guarantees maximum output at a consistently high level of quality.
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