BP&R May/June 2014

British Plastics

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bp&r may/june 2014

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Hot runners play out positive growth story

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

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

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t a Parliamentary reception held change behaviours. “Many unfairly target last week, the message from PAFA, products and brands and say they cause the BPF and the Plastics 2020 the litter,” said Turner, adding that a Challenge was educate, educate, “zero tolerance approach” was needed. educate when it comes to The Marine Conservation consumer knowledge of Society has this month “with some councils in launched registration for the benefits of plastics the UK excelling with packaging and recycling. the ‘Great British Beach the systems they have Clean’, a mass The associations praised in place, the gap is campaigns such as participation event to ‘Fresher for Longer’, but widening between local clean up the UK’s said there was still work authorities, making it coastlines. It has been to be done to stop “snide all the more apparent well documented within shots” being taken at industry the collaboration that there needs to packaging due to a between a number of be joined up thinking failure to understand associations, as well as about the importance businesses, to turn the what it is there to do. of recycling,” Speaking at the event, plastics found on Britain’s Barry Turner of PAFA said shores into sports kits, that it was “a sin” that some councils in retail goods and more. But we simply the UK still do not offer any sort of must get the message over to the collection or recycling of plastics waste. It consumer that the industry is not seems with some councils in the UK responsible for the litter being there in excelling with the systems they have in the first place, and reinforce the place, the gap is widening between local message that the plastics they might authorities, making it all the more come across is a precious resource that apparent that there needs to be joined should not be irresponsibly dumped. up thinking about the importance of However, as previously mentioned, the recycling and, as such, a clear message fact that some councils do not see being sent to the consumer to challenge plastics as a precious enough resource the ‘throwaway’ image with which to collect for recycling, makes it an even plastics packaging is often attributed. harder challenge to convince the Speaking of ‘throwaway’, also consumer of its worth. mentioned at the event was the problem Leanne Taylor, Editor of littering and the steps being taken to

PUBLISHER Mark Blezard T: +44(0)1244 680222 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Unit 2, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (01244) 671074 © 2014 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

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1964-2014: Piovan looks back on 50 years in plastics Piovan’s early factory floor

1934: Piovan before Piovan Costante Piovan & Figli (then Centro Meccanica), a specialist in precision mechanics, is established in Padua. It makes quality, reliability, and partnership its strengths.

an with a Constante Piov r in 1934 ee gin design en

THE BIG STORY

Piovan: A look back in time

1950s: The industrial evolution These years saw consolidation and reorganisation in an industrial context. The company lays the foundations for a widespread commercial expansion in Europe.

Machinery and equipment group, Piovan, is celebrating 50 years in the supply of auxilliaries for the plastics sector. Here, BP&R looks back at the group’s major milestones, as well as finding out its plans for the future.

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eflecting on the past fifty years, the Piovan group, which has more than 50,000 customers worldwide, cites its “entrepreneurial ideas whose roots may lie far back in time, but which remain deep and active” as one of the key mechanisms for its longevity.

In 1934 Constante Piovan founded ‘Costante Piovan & Figli’ as a metalworking shop equipped with machine tools, such as lathes and a few milling machines. Although Piovan was making moulds for prestigious companies, including Magrini Galileo (a major brand in Italy’s energy sector) he decided to focus the company on expanding ector Piovan conv feeder

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into other markets, an approach which he derived from a customer-orientated philosophy.

The company has remained in the family through three generations of management.

In 1964, Piovan launched its first piece of plastics processing equipment to the Italian market — a granulator and a material loader. Piovan has seen many expansions through the years, and now has production facilities in Italy, Germany, Brazil, China and the United States. The firm also has 21 subsidiaries, agents in more than 70 countries and 900 employees, of which 140 are customer assistance engineers.

The portfolio includes equipment for feeding, blending, drying and recycling systems, as well as industrial chillers and temperature controllers. Piovan equipment is integrated with proprietary production monitoring and control software.

The company says it looks to share knowledge with customers, acting not just as a supplier, but also “as a partner working alongside customers and sharing their challenges.”

Piovan says the best way to celebrate its 50 years in the world of plastic is to continue to do so with “passion and an awareness of its key role,” which will enable its future success. further information: www.piovan.com

1960s: The era of plastics begins Luigi, Costante’s son, guides Piovan to gain a leading role on the market of auxiliary machinery for the plastics industry. In 1964, it produces its first granulator, soon followed by the Convair dryer and Convector feeder.

1970s: From product to system, from machine to plant Piovan produces a complete range of auxiliary equipment for plastic processing. The first refrigeration line, in 1972, and the first central feeding, blending and drying system characterise Piovan’s production in the decade. A joint venture with Star, a Japanese robot manufacturer, gives life to Star Automation, a key brand in industrial automation. In 1974 Piovan Germany opens in Garching, near Munich.

1980s: Leader in niche markets Technological innovation, engineering, specialisation in PET, introduction of electronics, partnerships with key OEMs, further growth on foreign markets: these define the decade marked also by the largest drying system installed in Europe and, on a logistics level, inauguration of the new facility in Santa Maria di Sala (near Venice), Piovan’s current headquarters. In 1986, Piovan France opens in Brion.

1990s: A global company In the production sphere, Piovan increases its market share not only in the PET sector but also in other strategic fields like automotive, electronics and textile, while the international organisation expands by opening new branches in Canada, Brazil and Asia. A software company is purchased in order to develop remote plant monitoring and control systems.

2000s: Closer to the customer Two factories are started in Brazil and China, and new branches are opened in Mexico, UK, Austria, Hungary and the Czech Republic, India, Turkey, Thailand, Indonesia and Vietnam.

In 2008, Piovan purchases the US company Universal Dynamics, (UNA-DYN) and in 2010 it acquires the majority stake in FDM, a German company specialising in extrusion technology.

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on the cover

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40

bp&r BRITISH PLASTICS &RUBBER

contents may/june 2014

on the cover 1964-2014: Piovan looks back on 50 years in plastics Reflecting on the past fifty years, the Piovan group, which has more than 50,000 customers worldwide, cites its “entrepreneurial ideas whose roots may lie far back in time, but which remain deep and active,” as one of the key mechanisms for its longevity.

See page 4

24-26 FEATURE

REGULARS INDUSTRY NEWS

08

materials handling

Materials

38

Demands of ‘just-in-time’ manufacturing see record sales of dryer

Reclamation and Recycling

40

EVENTS

43

SOFTWARE

43

BUYERS’ GUIDE

44

27 FEATURE mo’s corner How do “loss-in-weight” dosing systems work?

3 EDITOR’S LETTER Education, education, education

12 FEATURE

28-31 FEATURE colour management Colour and Colour Management in Masterbatch

chinaplas review Chinaplas the “go-to” show as numbers hit record high

14-17 FEATURE

32-34 FEATURE hot runners Hot runners play out a positive growth story in UK

film and sheet BOPP film market dances to a different tune

36 FEATURE

19-22 ]FEATURE

BPF on India: A From the Front Line Special

packaging machinery Process reliability and high quality decoration hold the key to success for thermoformed packaging

8

India offers significant opportunities for British exporters.

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Industry News

news UK ranked alongside China as a sales growth country for global manufacturers, survey suggests Global manufacturing executives rank the UK as one of the top destinations for future sales growth, ahead of established manufacturing economies such as Germany, according to the Global Manufacturing Outlook published recently.

The UK has risen to second place – ranked equally with China – as a country where global companies expect to derive the majority of their sales growth over the next two years. Only the US (45 percent) beats the UK (17 percent), which is ranked in joint second place with China (17 percent).

Global Manufacturing Outlook, which surveyed 460 executives globally, also reveals that in terms of a country where

global companies expect profit growth in the next two years, the UK is ranked third (16 percent), only marginally behind China (18 percent), and marginally ahead of Germany (15 percent).

“This is encouraging news for manufacturers in the UK and reflects the increasing confidence in the sector we have seen in recent months. The UK economy overall is showing positive economic signs, while comparatively, some of our overseas competitors are on more shaky ground,” commented Stephen Cooper, KPMG’s UK Head of Industrial Manufacturing.

“It is also interesting that the global companies expect a higher profit growth in the UK than Germany. Germany traditionally has a reputation of being efficient in manufacturing processes, so one would expect them to rate perhaps higher than the UK as a naturally more profitable country for investors. The wider Euro crisis and European debt issues may still have a lag impact on Germany.” further informatioN: www.kpmg.com

ggests rvey su The su of the is one the UK s for tination top des rowth, sales g future lished b f esta ahead o ing r u t c manufa ies m o n o ec

Bayer considers sale of plastics business Bayer AG is considering the sale of its plastics business in order to focus on the life-sciences industry, according to a report from news agency, Bloomberg.

The MaterialScience business has reportedly received interest from chemicals giant, Evonik, however, Bloomberg reports that those with knowledge of the discussions between the companies say the “talks are private” and thus far “no decision has been made.”

Earlier this month, Evonik’s Chief Financial Officer told a German newspaper that the company is ready to make acquisitions, including larger companies, “if they fit”.

According to industry analysts at Kepler Cheuvreux, the sale of Bayer’s MaterialScience unit could potentially fetch up to €7.8 billion.

There has been reported speculation in the industry for some time that Martin Dekkers, CEO of Bayer AG, might sell the plastics business in order to expand in healthcare and broaden its drug and lifescience offerings.

Representatives from both Bayer and Evonik have so far declined to comment. further informatioN; www.materialscience.bayer.com

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Plastics industry has a “vital strategic and economic role in the recovery of the UK economy” Trade organisation, PlasticsEurope, presented its most recent economic data for the global and UK plastics industry at a briefing in London this month, which suggests heightened confidence for the recovery of the UK’s plastics industry.

Six years after the economic crisis, the 2013 data shows that the UK plastics industry had a challenging year, but confidence is high that that early signs of a recovery at the end of 2013 will continue.

“The plastics industry has a vital strategic and economic role in the recovery of the UK and policy makers should continue to develop a genuine long term strategy for the reindustrialisation of the UK that includes a vibrant petrochemical industry,” commented Peter Davis, DirectorGeneral of the BPF. In 2013 the UK GDP grew to 1.7 percent compared to an EU average of 0.1 percent. Demand for plastics in 2013 stood at 3.47 million tonnes, a decrease of 3.7 percent in comparison with 2012. This is, at least in part, a reflection of continued light weighting and minimisation, increased recycling and a migration into higher technology, more added-value products, said the organisation.

However, the growing signs are encouraging for a strengthening of the UK rubber and plastics production, with seasonally adjusted figures for UK rubber and plastics product manufacturing showing a slight improvement in Q4 2013.

“Concretely, the plastics industry is under significant worldwide competition, for instance, the USA’s exploitation of shale gas has significantly reduced its energy prices and improved its competitiveness against Europe,” explained Kim Christiansen, Regional Director North, PlasticsEurope. “In order to guarantee the sustainable growth of the plastics industry, UK policy makers need to ensure access to competitive energy and raw materials, support for innovation and training to provide skilled workforces for the future, among other measures, to ensure a strong plastics industry,” he concluded. further information: www.plasticseurope.org

The PlasticsEurope data suggests heightened confidence for the recovery of the UK’s plastics industry

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Industry News

news Local MP opens Plastribution’s new premises Leicestershire-based Plastribution has moved into a larger office space officially opened recently by local MP, Andrew Bridgen.

The move has been made to facilitate the company’s “ambitious plans for future growth,” which include a combination of organic business development and acquisition.

“Our plans going forward are ambitious and we aim to continue our story of success,” said Plastribution’s Managing Director, Mike Boswell. “Today we employ a fantastic team of 65 people across three sites, with a turnover of £75m, generating a profit after tax in excess of £2m.”

The company says it carefully considered the design, style and layout of the new offices, which are three times the size of the company’s previous premises

and have been realised after an investment of £40,000.

“When some 10 years ago we moved into CEVA House across the road from here, we realised the importance of the environment on business performance; hence we are incredibly excited by the The newly redesigned offices have been carefully considered, says the company

opportunity that these new and larger offices create,” Boswell continued.

During the official cutting of the ribbon to formally open the offices for business, Andrew Bridgen MP said Plastribution was an “excellent example” of local business doing well. The company was ranked No.46 in ‘Leicestershire’s Top 200 Companies 2013’, due to a 59 percent increase in turnover over a 15-month period. further information: www.plastribution.co.uk

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10 bp&r

Plastic population celebrates 40 years of playtime Playmobil's 40th birthday celebrations saw a lineup of life-sized plastic figures at London’s Camden Lock recently. Since Hans Beck debuted the first toy in 1974, 2.7 billion figures have been produced, with the miniature population reportedly growing by 3.2 every second. www.playmobil.co.uk

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chinaplas review

Review: Chinaplas the “go-to” show as numbers hit record high Words | Leanne Taylor

A

double-digit growth in visitor numbers at the recently-held Chinaplas 2014 trade show in Shanghai has made it the “go-to” event in Asia, says the Director General Designate of the British Plastics Federation.

Reflecting on the new records set by the most recent edition of the show, which saw 130,370 visitors over the four-day period, representing a 14.26 percent increase on the previous year, Philip Law said the heavy number of visitors from outside China made it an attractive place to do business.

“The British Group reported brisk business throughout the show,” Law commented. “Around 50 percent of the visitors to the BPF stand were from outside China and it is clear that Chinaplas is now seen by many as the show to go to. Specifically we saw a large numbers of visitors coming from Africa, Middle East, India and Australia.”

According to the show’s organisers, the total number of overseas visitors to Chinaplas increased by 19.73 percent to 36,841, accounting for 28.26 percent of total visitors and coming from 143 countries and regions. The number of domestic visitors maintained a strong

12 bp&r

Chinaplas 2015 will be held in Guangzhou

The British Group reported a successful Chinaplas 2014

figure of 93,529 with an increment of 12.24 percent.

“We are happy with the results of the show and have received very positive feedback from both our exhibitors and visitors. The continuous rise of overseas visitors reflects our show is gaining recognition from around the world, as an effective platform for industrial sourcing and for getting the latest information on market trends and technology,” commented Ada Leung, Assistant General Manager at Adsale Exhibition Services Ltd., the organisers of Chinaplas.

Chinaplas 2014 also marked a new record in terms of exhibition scale and number of exhibitors, with over 3,000 exhibitors from 39 countries and regions participating in the show.

The show was attended by 130,370 visitors over four-days

In addition to occupying all 17 exhibition halls in Shanghai New International Expo Center (SNIEC), 13 additional outdoor halls and six exhibition suites were also set up the central square of SNIEC to cope with the ever increasing number of exhibitors, resulting in a total exhibition area over 220,000 sq.m. for this year.

The British Group was made up of 10 companies, which was limited only due to the lack of available space in the show halls. Leading BPF member exporters — Meech, Zotefoams, Boston Matthews, Aerogen, and MSA — exhibited alongside Ceramicx and Rapidflame.

Commenting, Stephen Hunt of the British Plastics Federation stated: “When I first attended this show in Shanghai 10 years ago it comprised of just four halls.

This time there was 30. We could have taken five or six more companies but we simply could not get enough space to meet our demand as the show was massively over subscribed. This was a situation shared by all the major European trade associations whose demand for space at the show halls could not be accommodated. I would strongly advise companies thinking of coming to the show next year to sign up early.”

The 29th edition of Chinaplas will be held on 20-23 May, 2015, at China Import and Export Fair Complex, Guangzhou, PR China. further information: www.chinaplasonline.com

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film & sheet

Engineering Passion Labtech’s new coextrusion film blowing lines with up to nine layers

news New co-extrusion film blowing lines with up to nine layers launched Labtech has launched a new co-extrusion film blowing line available with up to nine layers and in sizes from 20mm to 120mm die lip diameters. Each die tier is custom made for a specific resin as per the customer’s request.

The film towers are made to suit the specific co-ex film blowing line in respect of die size, number of layers and extruders as well as required output. The nip-roll width of the towers varies from 250mm to 600mm and all towers have motorised height adjustments. The maximum height is made in accordance with requirements, but as an example the largest 600mm tower has a standard height range adjustable from 3.2m to 4.2m.

The towers are equipped with adjustable A-frames which are provided with almost friction-free carbon fibre

rollers, including adjustable cross rollers inside the frame. The film bubble is stabilised with a cage made from a number of Teflon rollers, which are all simultaneously adjustable with one turning wheel. High power single, as well as multi-channel air rings, are available for optimum cooling efficiency.

The co-ex film blowing attachment can be connected to a range of Labtech single screw extruders, ranging from the smallest 12.5mm size to the largest 45mm version.

All the extruders are 30D long and come with a large variety of screw designs to handle the complete range of co-extrusion film blowing polymers. The smaller extruders are also available with convenient large range height adjustments so that they can be easily moved from one layer to another.

Millmerran Research and Manufacturing Ltd is the exclusive UK agent for the Labtech range of laboratory processing equipment. furthr information: www.millmerran.co.uk

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Davis-Standard launches latest film line to Asian market Davis-Standard launched its latest cast-film line to the Asian market at Chinaplas 2014 last month.

First launched at K 2013, the dsX inline pre-stretch line is specifically aimed at the fast-growing stretch film market.

“At Chinaplas we are excited to launch our latest cast-film line.

It’s a high-speed line capable of producing 750m per minute of eight micron film,” explained Jim Murphy, Vice President of Global Sales and Marketing at Davis-Standard. “In addition to the high speed and ability to run very thin films, we have a unique winder on the dsX line, which has the capability to do coreless winding, as well as re-stretch.”

The company says the line would benefit film producers looking to increase efficiency and output versus older lines, as well as distributors looking to vertically integrate and drive down cost.

Murphy added that in the six months since its European launch at K 2013, the dsX line has been demonstrated to a number of customers in its Düsseldorf factory and has been “very well received.”

In addition, Davis-Standard says it is continuing to invest in its Chinese manufacturing facility with the addition of a spare parts and service centre.

Chinaplas 2014 marks two years since the company opened its first manufacturing facility in China, which the company said it considers an “important” market. further information: www.davis-standard.com

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SABIC launches “industry-first” clear and lightweight sheets for aircrafts SABIC has launched two new sheet solutions for aircraft interiors that it claims provide long awaited solutions to airlines’ quest for differentiated cabin interior designs while also helping to take out significant weight, resulting in a more fuel efficient aircraft.

The new Lexan sheet solutions, clear Lexan XHR2000 and Lexan Light F6L300, are said to be lightweight, durable materials that will benefit design engineers by reducing system costs, offering ease of fabrication and compliance with the industry’s strict regulatory standards.

“SABIC understands the need for its aircraft interior customers to not only stay ahead of design trends, but also to meet the demand for lighter weight aircraft interior components that can help improve overall fuel efficiency,” — explained Kim Choate, Director of Mass Transportation for SABIC’s Innovative Plastics business.

The new 80 percent light transmission Lexan XHR2000 sheet has the current highest level of light transmission available in an OSU-compliant sheet material, according to SABIC, as well as offering robust vertical burn performance with the use of a post-secondary process, such as a functional coating or laminated film. This, says SABIC, adds further design, chemical resistance and scratch resistance properties in applications such as design of large components such as security partitions and oversized windows.

SABIC says Lexan Light F6L300 sheet is the lightest thermoplastic sheet option available today, regardless of base material, that complies with flame, smoke and OEM toxicity. With a specific gravity of 0.85 g/cm3, it is said to offer up to 40 percent weight savings when replacing traditional polyvinyl chloride and acrylic blend (PVC/PMMA) -based sheet products for potential applications such as seating parts, cockpit dashboard enclosures, partitions, luggage compartments and passenger service units.

The potential weight savings are due to Lexan Light sheet’s closed cell structure, which SABIC says can be thermoformed into complex 3D shaped parts with very thin walls, down to 0.6 mm, offering substantial potential for overall weight reduction and fuel efficiency across an airline fleet. further information: www.sabic-ip.com

SABIC has announced two new Lexan sheet solutions for weight reduction and highly transparent aircraft interiors

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film & sheet

Engineering Passion

news Sheet manufacturer reports strongest start since 2008 Plastic sheet manufacturer, Polycasa, says the UK shop-fitting market and European leisure transport markets have been key drivers of business in the first three months of the year.

Since rebranding in October 2013, the company, which operates from several countries across the continent, says its early figures show promising results.

“We are very satisfied with the start to 2014. Volume is up eight percent on last year and is strong in many products, across many markets. In fact, it’s our best start since 2008. This will hopefully give us good foundations for a strong recovery.

We’re very excited about this year and next,” said Peter Kelly, Special Projects Director.

Polycasa says there is promising signs within the European market as a whole, with UK shop fitting very healthy in the first three months, caravan and motor-

home manufacturing across the continent having grown (for which Polycasa provides the window sheet), and industrial companies showing confidence across all applications.

The company says demand has been evident across the board, most notably from two major names in the automotive and home electronics industries. These companies worked closely with Polycasa

Polycasa says it has enjoyed a strong start to the year with its plastic sheet business

to devise new mixes, sizes and finishes on special pan-European projects to ensure brand integrity was maintained. further information: www.polycasa.com

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BOPP film market dances to a different tune

BOPP film has been one of the global success stories in flexible plastics packaging and is now an industry which produces over seven million tonnes of substrates a year

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OPP film has been one of the global success stories in flexible plastics packaging and is now an industry which produces over seven million tonnes of substrates a year, worth more than USD 18 billion, A new report from plastics according to a new market research and report from AMI consultancy firm, AMI, suggests Consulting. there is a shifting balance of However, it is power in BOPP film markets. The increasingly an industry following article looks at who that is driven by the leading players are. markets and areas of the world that historically have been considered “developing nations”. This is not just a function of market volumes and growth rates, but also market leadership as the major players in the BOPP market today are now head quartered in what AMI is calling the CHIME nations — China, India and the Middle East.

The report suggests that over the past three years, the BOPP film industry has been through a period of major structural change with the emergence of two major power houses with sales in excess of USD one billion: Jindal Poly Films based in India and Tahgleef Industries headquartered in Dubai. Jindal Poly Films takeover of ExxonMobil Chemical Films, completed in 2013, creates a group with the largest nameplate capacity for BOPP at over 400,000 tonnes with assets based in Europe and the USA, as well as being the largest producer in India. Taghleef, which AMI estimates to be just behind Jindal in capacity terms, has similarly built a global position through the acquisition of various heritage businesses in Europe and North America. In 2012 it completed the takeover of AET Films in the USA and only recently has announced another acquisition in Europe with the takeover of Derprosa in Spain.

Despite these impressive moves, these two businesses still account for less than 10 percent of global production and the report suggests they are likely to be overtaken — on a volume basis at least — by Chinese producers over the next few years. The investment in capacity and growth in demand for BOPP films in China has been well documented, but the leading producers there are now looking to move to a whole different level. From the original business model of setting up

a large plant with three or four big lines, the leading players are now looking to build a network of plants within China with state of the art 8.7 metre and 10.4 metre, high speed (525 metres/minute and more) lines and to vertically integrate into polypropylene resin production. The rapid growth of businesses such as the Gettel Group and China Soft Packaging — backed by cash rich real estate businesses — is leading the Chinese industry to have its own structural shakeout. Many of the early movers there have sold off assets, moved out of the sector or are looking to develop more speciality, niche products unable to compete in the commodity packaging sector.

The growth in BOPP film manufacturing in the CHIME area is also expected to lead to growing levels of trade and increasing pressure on BOPP film producers in other parts of the world whose assets are not so up to date or cost effective.

The report analyses international trade in BOPP film, which shows that approximately 1.8 million tonnes of the seven million produced were exported during 2013, of which just over 800,000 tonnes were traded inter-regionally. While less than 10 percent of Chinese production is exported, with output of over three million tonnes, this still makes it the largest exporting nation and these volumes are increasingly disruptive, especially in Asian markets where most of this material ends up. Europe, which historically was always a significant exporter of films, now has the highest net import of BOPP films at nearly 100,000 tonnes. Increasingly, says AMI Consulting, these volumes are coming from the Middle East and North Africa, although this region also still imports significant volumes — notably from India. Despite the rapid growth in demand for BOPP films in India, the market is still relatively small and the Indian producers have been very successful at developing export sales.

While the balance of power may be shifting in the BOPP film industry, the prospects for it overall remain very positive according to AMI. Global growth is expected to continue to advance at between five to six percent over the next five years, which will add a further two million tonnes of demand by 2018. further information: www.amiplastics.com

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The plastic packaging sector… glad we can help.

At its plant in Kirkintilloch, Scotland, Guala Closures UK produces millions of precision mouldings each week, including tamperevident bottle caps, valves and internal devices to make counterfeiting increasingly difficult, as well as decorative closures for premium brands. Since adopting IntElect injection moulding technology from Sumitomo (SHI) Demag, the company says it has reduced energy consumption and boosted production output by over 12 percent.

The IntElect injection moulding technology at the Guala plant

In 2011, Guala, which has 26 plants in five continents, installed two all-electric presses from Sumitomo (SHI) Demag into its Kirkintilloch manufacturing centre. The rationale behind the purchase of the 100 and 160-tonne machines was to “speed up production and increase the manufacturing consistency of Guala’s precision components, whilst also reducing energy consumption,” explained the company’s Manufacturing Manager, Stevie Houston. As a result of the results achieved, Guala has since invested in a further six 100 and 160T IntElect machines.

Rising energy costs was just one factor behind Guala’s decision to invest in allelectric moulding technology. The eight

IntElect machines installed on site have reportedly contributed to speeding up production and meeting quality targets.

“Over the last four years, output of closures has increased by 12 percent and our overall equipment efficiency (OEE) rating has seen a five percent increase,” highlighted Houston. “This has consistently made us one of the group’s top performing plants since 2009.

“In addition, the technology we’ve adopted has made a real impact on our quality targets, with a 40 percent reduction in scrap.”

Dave Raine, Technical Sales Manager at Sumitomo (SHI) Demag UK, commented: “Manufacturers of massproduced precision parts are choosing IntElect machines to improve the quality and production speed of their products, from closures to medical devices, packaging, automotive and electrical components.”

packaging machinery

Case Study: Cap that! The future’s electric for precision mouldings at Guala Closures

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Guala Closures produces tamper-evident bottle caps, valves and internal devices as well as decorative closures

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packaging machinery

The plastic packaging sector… fastest growing, versatile, sophisticated, innovative, consumer driven. Glad we can help.

news New company offers turnkey systems and machinery for thermoformed packaging A new company, formed from the collaboration of the thermoforming division of Italy-based AMUT and the packaging company, Comi, is supplying machinery as well as complete turnkey systems and solutions to manufacturers of thermoformed plastic packaging.

Called AMUT COMI, the company says that by merging the technological knowhow and strengths of the two component companies they have created a facility capable of providing systems that benefit from “sturdy structure, high running speed and low energy consumption.”

With a large R&D department and bespoke systems for unusual applications, AMUT COMI says it “works on constant improvements of its machines to always meet the needs of the market.”

The new company says technical knowledge of the extrusion process

Cost reduction for plastics packaging a four-part process, says Netstal State-of-the-art drive technology, supreme reliability and maximum availability and performance can sustainably reduce unit costs in the production of plastics packaging, according to Netstal.

Exhibiting with a range of injection moulding machinery at Interpack 2014 in

Machines from the AMUT F Series of thermoformers

enables it to supply complete in-line plants and ‘turnkey projects’ with the appropriate auxiliary equipment, including rimming machines for PP or HIPS, pre-heaters for PP foil; multi-axis stackers; stacking manipulators, automatic units and end line automated systems.

AMUT COMI says design plays an important part for machine optimisation, with its F and V series units including pressure or vacuum forming and steel rule die cutting technology suitable for the production of applications including trays, plates, lids, containers, plant pots from “every thermoplastic material.”

Its AMP, FTV and PA1000 series are said to be suitable for processing materials with barrier layers and general purpose thermoplastic (PP, GPPS, HIPS, PET, PLA, PVC), with simultaneous forming and punching technology.

AMUT COMI says the range also includes special machines for peculiar requests, including the FTLT series, able to produce thermoformed panels for cooling towers (PVC or PP) and the FFG-E e VK-C series for the production of PS foam packaging.

Düsseldorf, Netstal said it aimed to present the “four core elements required to successfully reduce unit costs in the packaging sector.”

“A sound machine design developed for continuous high performance and exceptional injection performance coupled with a high-precision controller and energyefficient drive concept form the basis for positively influencing unit costs,” explained Markus Dal Pian, Vice President Sales at Netstal.

In addition to a state-of-the-art injection moulding machine and high-quality, multicavity mould, Netstal says a typical packaging system using IML also requires complex automation with integrated parts, quality control and product stacking.

“Only perfect interaction between all the individual system components can guarantee a high OEE (overall equipment effectiveness) index,” said Patrick Scharpf, Area Sales Manager for the PAC business unit at Netstal.

The OEE index is defined by availability, output and quality rate to describe the overall efficiency of a system. Netstal says the typical availability of its injection moulding machines is around 98 percent, with functional interaction with system components such as moulds and IML handling systems meaning Netstal IML systems achieve an OEE factor of around 94 percent.

The packaging team at Netstal says in order to get a clear picture of availability, output and quality rate, it is essential that all information on rejects, downtimes, etc., is precisely recorded and documented in detail. “Ultimately only a sound factual basis will enable the derivation of the relevant measures and system requirements needed to maximise optimisation of the OEE index as a key success factor,” says the company.

Examples of thin-walled packaging, produced on a system from Netstal

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Packaging System

New robot makes packaging automation quick and accurate The demand for ever greater flexibility from automation has been one of the key driving forces behind the growth in the use of six axis robots within industry in recent years, with compact versions opening up new applications in the packaging industry. That is the message from Leicestershire-based ATM Automation.

The company has recently launched a flexible packaging system that includes its new MZ07 robot, which is said to have a compact footprint and is able to deliver high speeds when handling and packing a wide range of products with a minimum of changeover or operator intervention.

Product, for example in bags, pouches or cartons, is presented to the system on an indexing conveyor. For less demanding and random packing applications, the pick-up position is determined using a sensor and where greater accuracy or specific packing patterns are required, machine vision is used to identify the precise position and radial orientation of each item. An integrated check weigh system is used to determine whether the pack is within specification before being finally transferred by the robot to a carton within the cell.

Robot used within the system

The system also presents empty cartons from a magazine and holds a buffer of three on both the input and output sides of the system. Other features include the ability to segregate under or over weight packs and the capability to be enhanced by integrating additional equipment, for example label print and apply systems or ink-jet or laser marking and coding units.

Built upon a rigid steel fabricated framework and mounted on wheels, ATM says the system can easily be moved between production lines maximising utilisation and providing a cost effective alternative to dedicated packaging equipment. further information: www.atmautomation.com

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Illig, a supplier of production lines and moulds for thermoforming and solutions for the packaging industry, exhibited at the recently-held Interpack show in Düsseldorf with its latest form, fill and seal line with integrated in mould labeling (IML) technology. Here, Managing Director, Karl Schäuble, gives his insight into the current economy, demand and future of thermoformed packaging technology.

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Interview: Process reliability and high quality decoration hold the key to success for thermoformed plastic packaging

ing Karl Schäuble, Manag Director of Illig

packaging machinery

The plastic packaging sector… glad we can help.

ATM A TM T Automation Limited, Winchesterr A Avenue, venue, v Blaby Industrial Park, Leicester Leiceste LE8 4GZ sales@atmautomation.com | +44(0)116 2773607

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Interpack, the triennial trade fair for the process and packaging industries, attracted some 2,700 exhibitors from 60 countries to Düsseldorf last month, presenting ideas, concepts and technological visions – not only in equipment and machinery, but also in production tools, materials and services. The show, therefore, provides a useful indicator of the current economic situation and mood in the packaging sector.

“From an economic point of view, Illig concluded the last Interpack year, 2011, very successfully,” commented Schäuble, adding that the non-show interim years of 2012 and 2013 were also successful for the company and that 2014 has started with an increase in demand that he expects to last to the year-end.

“Pleasingly, we have seen a slightly increasing demand during the last few months, especially in the sector of packaging machines,” he commented. “However, I don’t expect a further, considerable increase compared to last year since the markets in Western Europe are still hesitant in terms of investments due to the financial crisis.”

Southern European countries, in particular, continue to show considerable investment weakness as a result of no, or minimal, economic growth, according to Schäuble, with the same also still applying to the Eastern European markets, which so far have not regained their pre-crisis level with regards to new investments. In his opinion, the current, politically instable situation will most likely affect investment confidence in the region even more.

Today, Illig delivers over 60 percent of its machines and lines to countries outside Europe, with customers in Asia, the Arab regions, as well as in North, Central and South America employing packaging technology to meet increasing demand. Illig says that process reliability, as well as availability of production lines, have gained more and more importance also in regions outside the traditional industrial countries.

“Requirements with respect to quality and hygiene of packs are continuously increasing in most regions,” continued Schäuble. “This can only be realised in an economical way with uniform, reproducibly high product quality and high productivity at the same time.”

Illig says in order to support processors in these requirements machines need to be equipped with innovative control systems.

At K 2013 the company launched its ‘Illig IC’ operating concept for increased productivity, reproducibility, availability and operator convenience of a thermoforming machine or complete thermoforming line.

Commenting on the future of thermoforming in packaging technology, Schäuble added: “The tendency for smaller packaging units – e.g. portion packs, coffee capsules, etc. – as well as increasing demands with respect to a high-quality decoration technology, and not least measures to fulfill nutritional information, will cause IML technology to be applied more and more in thermoforming. We presented our RDML 70b decoration unit, tailored for this, at the K trade fair last fall.”

At Interpack, Illig exhibited the integration of IML technology in a form, fill and seal line, in its new FSL 48 unit, which allows hygienic filling and packaging, as well as IML decoration of thermoformed cups of different shapes. “Illig expects that IML thermoforming will be more and more in demand in most markets in the future,” Schäuble concluded. further information: www.illig.de

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news Demands of ‘just-in-time’ manufacturing see record sales of dryer A UK-based machinery supplier has seen record sales of a material dryer, which it says is down to the demands of ‘just in time’ manufacturing.

Eastern Plastics, based in Essex, says that it’s supplier Matsui is producing more than 290 MJ3 dryers, per month, thanks in part to a recent redesign that has seen the incorporation of time and cost saving efficiencies that reduce production downtime. “The MJ3 is completely self-contained it incorporates the loader and the dryer in one compact unit,� explained Chris Siddall, Managing Director of Eastern Plastics Machinery. “If you want to change two materials quickly you have two dryers, one with each material, the drying is done ‘off line’. Whilst the machine is running with ‘Dryer A’, the material change and pre-drying of the next material is being

a best seller for The MJ3 dryer has been tograph shows a large Eastern Plastics. The pho a customer in 2014. to d vere deli batch of dryers

done at the same time in ‘Dryer B’.

Because the units are self-contained the material change can be carried out in just a few seconds.�

Another benefit of the unit is the reduction in material loss upon changeover, says Siddall. “Matsui’s APH hopper and dryer work together to only load a small amount of material to the

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machine at any one time, little and often.

With this system we can reduce the volume delivered to the machine to just two shots if required, the smaller volume, the less material being wasted and therefore the less time it takes to clean out on the changeover,� he commented.

The MJ3 unit also removes dust and fines from the material during loading, as well as being equipped with a cyclone dust separator that collects the dust and drops it into a catch container. This dust is often responsible for so-called ‘black specs’ caused by the small particles overheating when they hit the screw. By removing these during loading the problem of ‘black specs’ can be eliminated. “This MJ3 dryer has become a best seller for us and Matsui globally, as it solves the challenges faced by the trends towards smaller batch production and, at the same time, saves time, material and resources and improves product quality.� Siddall concluded. further information: www.easternplastics.co.uk

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The MJ3 dryer has cost-efficient technology incorporated into its design

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io r extens h hoppe it w r e VBD dry

attributable to a far more efficient method for extracting moisture from resin pellets — so much more efficient that vacuum dryers reduce energy consumption by up to 60 percent in comparison with desiccant dryers.”

The VBD vacuum dryer uses gravity to move material through three vertically arranged vessels, with the discharge of material from one vessel to the next controlled by slide-gate valves. From top to bottom, the vessels include a heating hopper that brings resin to a target temperature; a vacuum vessel in which vacuum reduces the boiling point of water, causing moisture within the pellets to volatilise and be forced out of the pellet into the low-pressure environment surrounding it; and a pressurised retention/take-away hopper that is continually purged by a membrane air dryer to maintain the target level of dryness until the material is discharged. This system eliminates most moving parts, in particular the three-station indexing carousel mechanism of the Maguire LPD vacuum dryer introduced in 2000.

The new EasySlide feature involves the vacuum vessel, which slides out in the style of a drawer and is held in that position during cleaning. The feature gives access to the retention hopper as well as the vacuum vessel. further information: www.maguire.com

Vacuum dryer claims increased moulding productivity Extensive production-scale demonstration runs with a wide range of resins have reportedly shown that a new type of vacuum resin dryer introduced by Maguire Products, Inc. less than a year ago exhibits greater throughput than originally specified and achieves required dryness in 35 minutes after a cold startup, the company has announced.

The Maguire VBD 150 vacuum dryer, originally rated for a throughput of up to 68 kg per hour, has reportedly achieved 90 kg per hour with hygroscopic materials such as ABS, acrylic, nylon, polycarbonate, polyetherimide and PBT, according to Pat Smith, Maguire Vice President of Marketing and Sales.

Two additional features have now been developed for the dryer: an ‘EasySlide’ mechanism that enables the vacuum vessel to slide out, giving ready access for cleanout; plus, an optional hopper extension whose 0.028 m3 capacity extends the throughput of the dryer by 25 percent.

“Vacuum drying is six times faster than with desiccant systems, which not only makes possible much shorter cold startups but also reduces the risk of material degradation, since resin is exposed to elevated temperature for 80 percent less time,” said Smith. “This remarkable drying speed is

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news Materials handling installation has a clear focus UK-based ancillaries supplier, AB Systems, has installed a new materials handling system for a major international contact lens manufacturer.

The lens manufacturer makes hundreds of thousands of contact lenses each week at its UK plant on the south coast, a process that involves the injection of a polymerisable feed material into a mould, which is then oven-cured. It is the manufacture of the plastic mould assembly – which in reality comprises a male convex and female concave mould surface – for which AB Systems designed and installed the material handling system.

The new installation uses equipment from OEM, SB Plastics, for whom AB Systems is UK distributor. It includes three material loaders, a desiccant dryer, an

d a new materials AB Systems has installe or international handling system for a maj cturer. ufa man lens t contac

materials handling

think materials management

insulated drying hopper, a vacuum pump and a central system vacuum filter to remove debris. AB Systems says it also designed and installed a bespoke touch screen panel that enables operators to quickly and easily pre-programme and control processes such as conveying times and filter cleaning.

Mould manufacturing standards must be nothing less than exacting when it comes to the production of lenses, as any

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formation of surface voids would render the cast object unsuitable as a lens. “We have installed several materials handling systems at this particular UK facility,� commented Jeff Day, Managing Director of AB Systems. “It is fantastic to work with a client that is so active in ensuring that the highest standards of manufacturing are achieved.� further information: www.ab-ltd.co.uk

Blue Sky thinking from Genesis Process Solutions UK-based Genesis Process Solutions has recently completed a supply and installation contract for Blue Sky Plastics in Bourne, Lincolnshire, as part of the latter’s recycling and reprocessing facility for plastic recovered from Waste Electrical and Electronic Equipment (WEEE). “As part of an on-going investment plan, Genesis Process Solutions won a contract to supply two Brabender feeders with refill systems for a new extrusion line. These feeders have been set up to meter two tonnes per hour of flaked recycled plastic together with a coloured masterbatch. In addition to the feeders, Genesis has also provided a vacuum conveying system and a mezzanine floor,� said Chris Riddle, Managing Director of Blue Sky Plastics.

Blue Sky Plastics has just completed the latest phase of a major investment programme, which saw it install a state-of-theart cleaning system that recovers large volumes of mixed plastics, which are then reduced in size to a 6mm regrind flake. With the additional installation of the new extruder, Blue Sky says it is offering a closed-loop service to electrical goods manufacturers by recycling the bulk of plastic components back to what it says is a near-virgin grade of ABS, Polystyrene and Polypropylene. “The Flexwall 120 feeder supplied is particularly effective with a flaked material, unlike old equipment that was replaced, meaning production engineers at Blue Sky could increase flow rates for increased production without feeding issues,� said Phil Cameron of Genesis Process Solutions. “While the smaller Flexwall 40plus feeder is currently handling black masterbatch at the rate of 25kgs per hour, greater throughput is easily achievable.� further information: www.genesisps.co.uk

Q: How do “loss-in-weight” dosing systems work?

mo explains: In the context of continuous gravimetric dosing, “loss-inweight” systems work by weighing the entire dosing module, the dosing hopper and its contents, the dosing device and drive unit and measuring the decrease in mass as the material is metered.

MO’S CORNER

www.motan-colortronic.co.uk

The load cell measures the loss in weight in the supply hopper of the dosing module

Continuous gravimetric dosing station (loss-in-weight)

“L

oss-in-weight” gravimetric dosing systems begin by weighing the entire dosing module, including the dosing device, the supply hopper and its contents. As the material is dosed, a weigh scale measures the difference in weight per unit of time.

Because all components are dosed at the same time, each dosing module is fitted with a high-resolution load cell. The control system monitors and regulates the flow rate based on a signal emitted by the load cells. Weight loss in the dosing hopper is measured at fixed intervals in very quick succession, and these values are transmitted in real time. On the basis of the loss-in-weight measurement, the system is able to calculate the actual throughput.

By comparing actual throughput with the defined “target” throughput, the control system can immediately detect any discrepancies. These can then be corrected by adjusting the dosing screw speed of the dosing module.

Each material is continuously dosed into a collecting bin, and all ingredients are dosed simultaneously. As a result, the ingredients are already mixed by the time they enter the feed throat of the processing machine – so segregation issues do not arise.

Once the material in the supply hopper of the dosing module has reached the minimum level, it must be refilled – usually from a refill hopper. The loss-inweight dosing process can be broken down into three stages: refilling, calming and dosing. Because the weigh cell cannot differentiate between dosing and refilling, the system switches to the volumetric principle during the refill and calming stages, and then back to the gravimetric method during the dosing phase.

When using loss-in-weight systems, variations in bulk density, grain size and rheology have virtually no impact on the accuracy of the outcome, as the flow rate is continuously monitored and regulated on the basis of weight. However, it is important to ensure that the dosing devices are sufficiently full of material – this is why high-quality systems feature integrated, fully automatic material refilling systems.

Gravimetric dosing enables precise calculation of the amount of material used and seamless quality monitoring. It is also possible to specify and document the composition of finished products for the entire production cycle, in terms of the type and proportions of individual ingredients used. further information: askmo@moscorner.de

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colour management

news

bp&r

// Materials Technical //

Blog Faster colour development with new custom formulation and supply system At Chinaplas 2014, PolyOne ColorMatrix launched its newest liquid colour system, which its says gives manufacturers greater control of their colour development and supply chain.

This advanced system, says the company, enables customers to respond rapidly to shifting market demands, while also increasing their speed to market.

By combining cloud-based colour creation software, unique liquid colour technology and a global network of ColorMatrix facilities, the new platform is said to enable the creation and order of custom colourants quickly, reducing development and supply turnaround time from weeks to days – or even hours.

Steven Chai, General Manager for ColorMatrix Asia Pacific, said: “This system redefines liquid colour development. It empowers our customers by placing custom colour creation capabilities at their fingertips. PolyOne adds value by streamlining the design stage, then backing that up with consistent, on-demand and swift global supply to help them gain a competitive advantage and profitably grow their business.”

Each custom colourant formulated in the new system relies on an array of globally standardised base-sets that are compatible with PET and polyolefin end-use applications. further information: www.colormatrix.com

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In association with Hardie Polymers – www.hardiepolymers.com

This month, polymer expert and technical blog author, Dr Charlie Geddes, looks at what determines colour in thermoplastics

Colour your thinking on the Optical Properties of Thermoplastics Very few commercial polymers have chemical groups (chromophores), which absorb light in the visible region of the spectrum.

Consequently, the base polymers are colourless. If you need colour, you have to add dyes (soluble in the polymer phase) or pigments (insoluble). Dyes fell out of favour because of problems of migration out of the polymer into other materials (‘bleeding’) and because of the development of a wide range of efficient organic pigments, with appropriate heat and weathering resistance. Mixing of pigments can match any specific combination of hue (shade), chroma (intensity) and lightness.

To generate colour in a natural thermoplastic, the preferred method is to add granules of the same polymer (or a compatible polymer) loaded up with a high concentration of pigment (colour concentrate or masterbatch). The secret of consistent, efficient colour is to ensure the pigment is broken down into very small particles (dispersion) and evenly mixed (distribution), both requiring careful application of shear in the melt state.

Colourants are added in such small amounts that they do not affect mechanical properties significantly. The exception is impact resistance. Different shaped pigment particles can affect crack initiation. It was a standing joke with a colleague that, after impact test results from one particular consultancy project, we politely declined green hard hats on factory visits.

Although the base polymer is generally colourless, a slight yellowish tinge can appear from polymerisation residue, polymer decomposition during processing and service and, more commonly, from other additives. This yellowness can be cancelled out by optical brighteners, a special class of colourant, which absorb UV light from the invisible part of sunlight or artificial light and emit it in the blue region, giving a cleaner transparency or more intense white and sharper colours. To check for optical brightener, just observe the thermoplastic under a UV lamp.

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

Datacolor launches new family of spectrophotometers for colour management Datacolor, a manufacturer of software and instruments for effective colour management, has launched a new family of hand-held, high-accuracy spectrophotometers it says is tailored to meet the critical colour and gloss measurement needs of automotive-interior, hard goods, large appliances and building materials industries.

Developed to address the specific needs of colour supply chains, the new Datacolor 45 handhelds, the 45G, 45G CT and 45S, are said to enable colour appearance control with confidence, ease-of-use and value while improving the overall accuracy and efficiency

The new Datacolor 45 handhelds

of the quality control process.

“By looking closely at the needs of our partners in a number of manufacturing industries, we made the necessary enhancements to deliver instruments specifically tailored to their various workflows,” said Diane Geisler, Director, Global Market and Product Management for Datacolor.

“We are committed to providing our customers with high quality products built using the most innovative colour technology and believe the Datacolor 45 handhelds will become a benchmark in digital colour communication across multiple markets.”

The Datacolor 45 instruments are said to provide uniform circumferential illumination that guarantees best-in-class repeatability, even on textured surfaces. Designed with features such as a low-profile measuring head, dual measurement buttons and a livenavigation based colour user interface, Datacolor says the instruments “maximise overall usability and provide an intuitive user experience.” further information: www.datacolor.com

High performance packaging solutions -

Correct colour? There’s an app for that!

UK manufacturer of masterbatch, Silvergate Plastics, has launched a new mobile app that will enable customers to request a colour match via their iPhone.

The company says masterbatch customers can now easily log a colour match request to Silvergate from “anywhere in the world” via their iPhone. By inputting the required information, requests will be sent to Silvergate’s team of experts who will work closely with the customer to perfect their exact colour match.

The Silvergate app can be found on the Apple app store (an android version is yet to be launched) by searching for “Silvergate”.

“This new innovation has been launched as part of Silvergate’s ongoing growth strategy in the international plastics market,” the company said on launching the product.

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Comment: Colour and Colour Management in Masterbatch

By Josephine Bagnall, Sales and Marketing Director, Colloids

“Colour - and colour management - is a subject that is both immense and intense.

Any discussion or article on the subject inevitably risks opening issues and questions that remain unresolved until focus is brought to bear on a specific technical or commercial requirement,” - Bagnall ur of colo allenges poke s e b The ch erbatch in mast e-shelf th or off

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About the Author: Josephine Baganall is Sales and Marketing Director at Colloids Ltd, part of the Tosaf group of companies, a multinational supplier of masterbatch / concentrates for the plastics industry. Josephine is based in Colloids’ UK headquarters in Knowsley, North West England.

diagram The quadrant me of the so ts represen of colour key aspects t en managem

processes and applications, calls for even stricter discipline.

Anticipating trends throughout the market identifies emerging colours which need to compete to “earn” their place in a pre-set palette. Maintaining that pre-set palette, with new additions being introduced, also means managing the full range in line with “what is hot, and what is not.” Stocks need to be maintained at the right levels to meet off-the-shelf orders immediately, without building up an undue backlog of potentially unwanted material. Recognising variations based on geography, fashion and season means that some colours must be retired to maintain commercial viability.

Matching a specific colour while recognising specific manufacturing practices and regulatory requirements is of course made easier with an extensive database of colour formulae. So is maintaining colour consistency through time across multiple resins.

Yet both are also far more involved. Take a shampoo product with a bottle in high-density polyethylene and a cap in polypropylene.

Achieving the same visual colour – because of the inherent differences in the base polymers, further requires skill and dedication and when it comes to avoiding warpage and/or differential shrinkage a high degree of technical expertise. Then there are always cases - such as metamerism, where an object appears a different colour under different light sources - where technological measurement alone will never suffice.

Colour - and colour management - is a subject that is both immense and intense. Any discussion or article on the subject inevitably risks opening issues and questions that remain unresolved until focus is brought to bear on a specific technical or commercial requirement. Often that focus is reactive: responding to clients’ identified needs. But even greater rewards come when the drive is proactive: identifying new opportunities that will give competitive advantage over the rest of the field. In any case, both are as satisfying as they are challenging.

colour management

W

orking in the masterbatch sector is technically challenging.

Clients expect and deserve the best for whatever polymer is concerned, with all the right properties, in a formulation matched to the specific processing involved - at a price that supports their own commercial goals to be competitive. This requires expertise, as well as keeping up to speed with innovations that continue to transform the industry. This is especially true when it comes to colour, only the challenges here are even greater.

Some might be tempted to think of colour in masterbatch as “only another property.” Just as you can measure ultraviolet resistance, the coefficient of friction, corrosion inhibition, flame retardancy and so on, so you can measure colour scientifically. With all the technology available today, it has never been easier or more precise.

But reaching the highest standards of colour - and colour management - in masterbatch needs more than access to analytical, matching and modelling software, spectrophotometers and so on. All the top players make full use of such equipment in the hands of highly skilled operatives. They are essential tools of the trade. Every day there are thousands of colour samples being scientifically analysed, measured or matched precisely. But what sets the leaders apart is not just the accuracy with which they work in colour, but what they do with the expertise, experience and equipment available - within a framework where both the scientific and the creative contribute to commercial success.

Working round a straightforward quadrant diagram illustrates some key aspects of how colour is about so much more than a readout on a display or a screen - if the masterbatch supplier is going to add maximum value to clients and the industry.

Every day, labs work on creating new bespoke colours and formulations for a wide range of carriers. But the work involves much more than careful scientific analysis alone, it also involves assessing colour trends from our own industry and others, and engaging proactively with clients and their designers to look into future trends.

In many ways, working with a pre-determined range of set colours, available as a universal masterbatch adapted to a variety of

further information: www.colloids.co.uk

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eastern machinery special: hot runners

Plastics Machinery Ltd

www.easternplasƟcs.co.uk

news New swivelling hot runner manifolds “move melt anywhere” MHS Mold Hotrunner Solutions has launched what it describes as a “revolutionary” new type of hot runner system with rotating melt transfer joints that allows linked manifolds to move freely in order to distribute plastic anywhere inside the injection mould.

The new Rheo-Pro Slide Manifolds are said to make it possible to create injection points, or gates, directly inside the slides of a mould and also allow moulders to create continuous melt transfer connections that maintain contact, and therefore flow, even when the mould plates separate.

MHS says the patent pending hinge design allows its rotating joints to maintain a constant seal while linking

system is The new crease said to in ty and vi producti e reduc ce, scrap maintenan , and peak generation and energy dem

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01376 562288 Selling the science of injecƟon moulding

The hot runner‘s articulating manifold arms “swing” to allow melt channels to move freely during operation

together multiple hot runner manifolds to create an uninterrupted, continuous melt path that is able to bend and move inside the injection mould. The technology enables the melt channel to deliver material to the cavity across moving mould elements, such as slides and lifters.

The Rheo-Pro Slide Manifolds are said to be beneficial when demoulding complex parts with exterior undercut side features by allowing entire sections of the mould to move, without interruption to the flow of material in the melt channel. This

flexibility, says MHS, also makes the systems ideal for new part designs using stack moulds, tandem moulds, as well as rotary and cube moulds.

“The process can be compared to running your melt channels through a flexible hose, only pressure inside the melt channel of an injection mould typically reaches between 10,000 and 20,000 psi, or upward of 1400 bar,” explained the company when launching the product.

“That’s roughly 600 times the pressure inside a car tyre, or 1.3 times the pressure of the Mariana Trench, the deepest part of the ocean, which has a pressure of 1,086 bar (15,750 psi). This is the first and only technology that exists to keep liquid plastic flowing through flexible runners, let alone under such extreme processing conditions.”

By allowing moving manifolds in a hot runner, the Rheo-Pro Slide systems are also said to offer new opportunities for injection moulders and mould designers, as well as overcoming the the challenge of flow path vs. wall thickness ratio in large thin wall parts. further information: www.mhs-hotrunners.com

New modular controller for hot runner systems yields early return on investment A new modular controller for hot runner systems yields an early return on investment by helping moulders to increase productivity and reduce maintenance, scrap generation, and peak energy demand, says UK-based Fast Heat.

The company, which is a supplier, stockist and manufacturer of hot runner systems and controllers, says the new Ion Series system is designed to control up to 24 zones, making it possible to save a large fraction of its initial cost by virtue of its “accuracy and operator-friendliness.”

The key features, says the company, are a user interface that is easy to navigate and PID software that takes temperature readings 30 times per

second, using that data to maintain temperatures within narrow tolerances.

“The Fast Heat software in the Ion Series controller removes many of the variables inherent with standard modular controllers, and the operator interface is designed so that you are never more than one click away from the main screen at all times, commented Fast Heat’s Colin Newall. “This new system works largely behind the scenes, enabling users to set it and forget it.”

A conservative estimate by Fast Heat indicates that within one year, moulders could recover a minimum of nearly £2,500 of the initial cost of the system as a result of its features and capabilities. further information: www.fastheatuk.com

www.easternplasƟcs.co.uk

eastern Plastics Machinery Ltd

Hot runners play out a positive growth story in the UK Thermoplay FN nozzle range

T

he UK director of Italy-based manufacturer and developer of hot runner systems for plastic injection moulding, Thermoplay, is reporting a positive growth in sales in the country over the last 12 months.

After a year in post, Chris Whitlam says he has seen a period of steady commercial growth and innovation with a steady stream of new Thermoplay products over the past nine months.

“There is much good feedback from the UK market currently and quality enquiries are now steadily converting into growth of the UK turnover,” Whitlam commented.

Whitlam said the K 2013 exhibition last October was an important milestone for the company, with a number of important product innovations introduced to marketplaces worldwide. “These new Thermoplay products have been well received in the UK,” he added.

One of the new products launched was the new FN series nozzle family, to replace the current F series. The principal reason for Thermoplay’s innovation, says Whitlam, was to reduce the maintenance time to replace the heater and the thermocouple.

“This operation can now be performed without having to remove the nozzle tip,” he explained. “The FN nozzles are available in the diameters 16, 24, 32, 46 and 60 (single nozzle) mm with the same standard lengths of the F- series.”

In addition, the versions with diameter 16, 24 and 32 mm are provided with a special bimetallic insert in titanium and tempered steel inside the tip group, thus allowing a wider area of contact with the mould. This feature is intended to reduce the risk of wear in the gate area and possible plastic leakage and also

decrease the thermal exchange between the nozzle and the mould. The end result, according to Whitlam, is decreased power consumption for the user.

The gate geometry of the FN series is also unchanged in comparison to the F series. Another benefit is that the old FNs can be replaced with the new nozzles without any additional machining in the mould.

Thermoplay’s global ambitions stay on the move with the recent opening of a new operation in Canada. “We are an extremely internationally focussed company,” commented Whitlam. “It really helps my job in the UK and Ireland to be working for a global brand with pedigree and with continuing R&D in the service of the customer.”

Whitlam said one of Thermoplay’s UK tasks is to help moulders who are running

machinery special: hot runners

01376 562288 Selling the science of injecƟon moulding

multi- cavity tools and for whom fast cycle times are a priority, including many packaging operations and high-volume medical moulding companies.

The renaissance of the UK automotive industry has certainly helped the company’s figures for 2013, as has the increased activities in medical device moulding; typically not shy of committing production cost in order to get the project right.

Thermoplay UK also continues to play its part in the moulding industry at large, by stressing the benefits of hot runner technology itself. “We have a wealth of production data about hot runner technology, which always helps to build a factual case for its adoption by moulders,” Whitlam added.

Thermoplay also offers an online web design configurator, which it says can play a helpful role in instantly mapping out projections of production time and cost for potential users. further information: www.thermoplay.com

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01376 562288

machinery special: hot runners

Selling the science of injecƟon moulding

news Husky adds two new products to its hot runners and controllers portfolio Husky Injection Moulding Systems has introduced two new products to its hot runners and controllers portfolio that it launched to market at Chinaplas 2014.

The new Altanium Matrix2 temperature controller and Unify Manifold Systems technology are said to be “innovative products and services” that Husky has developed in as part of a strategic drive to solve the “key challenges” facing injection moulders.

“Our new Unify Manifold Systems and Matrix2 hot runner controller continue to prove that we are world leaders in the industry by continually driving innovation,” said Gerardo Chiaia, Husky’s President of Hot Runners. “Customers continue to benefit from our technology with improved gate quality, balance, ease of use and maintainability.”

The Matrix2 controller is said to provide additional functionality to other

controllers in Husky’s range, as well as offering an integrated and intelligent platform for two to 254 zones of control for improved part quality and increased uptime.

“The introduction of Matrix2 to Husky’s Altanium family of controllers allows us to provide premium performance and functionality over our competitors,” commented Matthew Cummings, Husky’s Product Manager for Altanium.

“Maxtrix2 is designed with a new intelligent feature set, which makes it smarter and more intuitive than other controllers on the market. This enables a more customised moulding solution and helps customers achieve the most consistent, repeatable and accurate temperature control possible, regardless of their moulding needs.”

The Unify Manifold Systems technology is said to provide a simple, one-step installation of a hot runner manifold into a mould without the need to pre-heat the system. This, says Husky, provides a saving on installation time of up to 70 percent. The Unify system is said to allow for simple hot runner maintenance, therefore reducing downtime. further information: www.husky.co

INTAREMA The new system generation from EREMA.

Efficiency at the fore.

High capacities have never been as easy to achieve as with the new INTAREMA®.

Counter Current technology makes it possible. Because the extruder handles more material in a shorter time. And this means for you: constant, top throughput within a considerably larger temperature range. For more productivity, flexibility and process stability.

34 bp&r

CHOOSE THE NUMBER ONE.

www.easternplasƟcs.co.uk

eastern Plastics Machinery Ltd

HRSflow opens production plant for hot runner systems in USA INglass-HRSflow has announced it will open a new production plant in Michigan for the manufacture of hot runner systems for the American market in the first half of 2015.

The company says it made the decision in order to better support its local customers, enabling them to offer “just-intime delivery, prompt service and a closer sales relation.”

Maurizio Bazzo, President of INglass group, said: “In the following years, this decision will lead the company to a growth equal or greater to the one that we achieved in the past. Grand Rapids in particular was chosen due its strategic position for the plastic injection market.”

The company says it chose to open the new workshop in the US in order extend the supply of its hot runner systems to Europe, Asia and America, enabling its customers to reduce their time-to-market and improve their overall operating efficiency. further information: www.hrsflow.com

A focus on India: A From The Front Line Special

W

Fig 1: End-use applications for polymers - India

ith a population of over 1.2 billion, of which 66 percent are in the working age group, and a GDP growth of nearly five percent in 2012 according to the World Bank, India offers significant opportunities for British Recruitment for the largest exporters. plastics fair in India, Plastindia 2015, has recently opened. The Overview of the plastics event takes place every three industry years and UK firms may be The Indian plastics industry interested in looking at is growing at a rate of 13 opportunities for sales expansion percent p.a. according to the and new business ventures in the Plastindia Foundation, the market. The event attracts key Indian plastics trade approximately 125,000 visitors, association. Particular which provides an excellent growth points are opportunity to network with local packaging, construction and buyers. infrastructure, electronics, In the following article, Justyna transport, agriculture and Elliott, Senior Business consumer goods. Currently, Development Executive at the the polymer consumption in British Plastics Federation, writes India is approximately 8kg exclusively for BP&R on the rising per person, an increase opportunities India presents to from 5kg in 2005. Given the UK plastics industry, giving a that the average European market overview, important demand per capita currently information on modes of entry and reaches approximately advice on where to find out more. 75kg, there is strong potential for further growth.

Nearly 25 percent of polymer consumed in India is in the construction sector, followed by flexible packaging and rigid packaging as the above chart by AMI indicates. (Fig.1) The packaging sector in India consumes 9.7 million tonnes of polymer and is likely to triple in the next 10 years, according to the Plastindia Foundation. This is due to a growth in the quantity of food sold packed, as well as pre-processed.

High demand for polymer material, machinery and goods are to a large extent met by imports. According to the Plastindia Foundation, in 2012/2013, the most imported material was PVC, at 1,135 KT, followed

by LLDPE at 520 KT, HDPE at 455 KT, PP at 430 KT and EVA at 130 KT. In bp&r terms of the machinery, during the same period, 46 percent of equipment came from abroad, providing UK exporters with some interesting

36

prospects. The majority of the processing equipment installed in India is injection moulding machines, followed by extrusion and blow moulding. In terms of the process capacity, however, extrusion generates the bulk of products manufactured, with about 19,000 KTs reported in 2012/2013 (Fig.2).

Fig 2: 2 Polymer Machinery India 2012-2013

Despite a general growth tendency in the Indian plastics industry, local firms face the same challenges as most of their competitors abroad when it comes to finding skilled labour. There is a general shortage of skilled and trained workers, many of which come to UK universities and other learning centres.

Market research India is such a large and diverse market it cannot be seen as a whole and must be viewed as an assemblage of specific regions with their own unique customers and local competition. UK companies can certainly try to do their own market research, but in such a large territory may prove difficult. UK Trade & Investment offers part-funded, custom-made reports put together by their staff in the market. These OMIS (Overseas Market Introduction Service) reports, list local potential customers for particular products and potential business partners, and the staff can also line up meetings with potential customers.

Indian market entry modes Some British companies may find it hard to navigate the legal and bureaucratic hurdles of doing business in India. Visiting Plastindia will help interested businesses meet competent and compatible people who could be potential agents. Networking with other UK firms, such as those on the BPF’s British pavilion at the event, can often lead to recommendations of agents who are already introducing complementary British products into the Indian marketplace. Plastindia attracts a large number of senior Indian decision makers and can be a good starting point to explore the possibilities of a joint venture.

Learning more about the market The British Plastics Federation is organising a seminar, entitled ‘Opportunities in the Indian Plastics Market’ to be held on 20th June in its London office. It will feature presentations by the Plastindia Foundation and other industry experts. Alternatively, companies can visit one of the two major exhibitions in India: the upcoming Plastindia already mentioned, which will be held in New Delhi between 5th and 10th February 2015, or Plastivision, based in Mumbai, which is due to take place in January 2017. UK firms wishing to exhibit at Plastindia can apply for the Government grants of up to £3,000. further information: www.bpf.co.uk

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

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30 September-2 October 2014

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www.interplasuk.com

engineering materials

news Sleep on it: Bayer ploughs €15m into CO2 ‘Dream Production’ Bayer MaterialScience has announced plans to invest €15m into commercialising its technology platform ‘Dream Production’, for turning waste CO2 into useable polymer.

The platform promises to turn greenhouse gases into a basic building block for plastics.

“The first major field of application will most likely be mattress production,” said Dr. Karsten Malsch, Dream Production Project Manager at Bayer MaterialScience.

The latest injection of cash will go towards the construction of a production line at the group’s Dormagen site, which will use CO2 to produce a precursor for premium polyurethane foam. The line will have an annual production capacity of 5,000 metric tonnes. The permit application will be submitted to the Cologne district authority in the next few weeks.

Bayer claims that the first CO2-based polyols should enter the market as early as 2016, and says that processors of polyols and polyurethanes have already expressed “considerable interest”.

High-quality polyols based on CO2 are not currently available on a commercial scale. The new polyols from Bayer MaterialScience are said to display the same level of quality as their ‘conventional’ counterparts.

In addition to putting waste CO2 to use as a chemical building block, the process also permits a reduction in the amount of the petroleum-based raw material propylene oxide, which polyols are normally made entirely from.

“Improving the sustainability of everything we do is an integral part of our business strategy and this principle is implemented in our Dream Production project. We have succeeded in turning a waste gas that is potentially harmful to the climate into a useful raw material. That helps the environment and mankind, and we all benefit,” said Bayer MaterialScience CEO, Patrick Thomas.

Bayer MaterialScience developed the manufacturing process in collaboration with partners in industry and academia.

The company discovered the catalyst that

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The first major field of application is most likely be mattress production, according to Bayer MaterialScience

brings about the chemical reaction with the required level of efficiency, and developed it together with the CAT Catalytic Center, a research facility in Aachen, Germany. The process was tested extensively in a pilot plant at the Leverkusen site as part of the publicly funded Dream Production research project. This was accompanied by a study of market demand.

The new polyol is used for the production of polyurethane foam, which finds applications in upholstered furniture, shoes and automotive parts, and is also used to insulate buildings and refrigeration equipment. further information: www.materialscience.bayer.com

“Breakthrough technology” changes PET production A new titanium catalyst technology for the industrial production of polyethylene terephthalate (PET) polyester is now being adopted around the globe, as PET manufacturers and processors seek to eliminate the use of the heavy-metal catalyst, antimony oxide.

The technology has been developed by Catalytic Technologies Ltd. (CTL), a company established in late 2010 on Teesside in the UK. To date, CTL has invested over £1m on research and development and in 2013 it launched its patent pending UP-Technology platform that is said to “exhibit performance unlike any other PET catalyst.”

UP is a catalyst technology platform that allows CTL to produce catalysts with unique chemical composition and that eliminates undesired side reactions in this application.

In addition to eliminating antimony oxide, the new catalyst is said to offer high polymer thermal stability, improved brightness and clarity owing to lower impurity content, a significant net reduction in the overall process energy required to produce plastic packaging and lighter bottles without compromising on bottle strength.

The company’s UP-Technology platform is being exploited on industrial scale plants in Asia, with further commercial trials scheduled and worldwide pilot unit testing ongoing.

The group invested in a continuous pilot unit catalyst trial on Uhde Inventa-Fischer’s state-ofthe-art polyester 2R-MTR pilot plant. The trial reportedly enabled substantial testing of CTL’s new UP-catalysts by independent PET polyester production specialists to demonstrate the

Calling all elastomer producers and innovators…

Are you working in the UK and producing, using or innovating with elastomers? If so, you may like to read a recent roadmap regarding UK Elastomers, published by the Polymer Group within the KTN’s Materials Community.

The report was generated as an output from a workshop held in London in March. It highlighted that the important contribution made to the UK economy by elastomers is not currently visible as a significant part of the strategic materials sector. “‘Rubber’ is still often regarded as ‘old fashioned’; it perhaps needs re-branding,” commented Dr. Sally Beken, Elastomers Specialist at the KTN. “'Smart materials', or ‘flexible composites’, gives a more accurate description of elastomers as key enablers; and innovation and formulation are both key to the future of elastomers.”

The report also highlighted the need to consider a National Elastomers Centre to coordinate elastomer activities.

“Technically, elastomers have a very bright future, and the important technical advances will be in the areas of 3D-printing, nanomaterials (especially ones that are conducting), biomaterials, and smart materials,” Dr Beken continued.

The report highlighted that for SMEs, there should be a better awareness of funding opportunities through grants, from both the UK and Europe. The document is now open to comment and is available to download for free.

If you are working in the sector and have any queries regarding UK elastomer expertise, cross-sector innovation opportunities, research collaboration and or access to funding, please contact Dr Sally Beken: sally.beken@ktn-uk.org further information: www.matuk.co.uk

benefits of the catalyst technology compared to the industry antimony reference.

CTL’s new products target the markets for mainstream, high intrinsic viscosity PET resin and sheet used for the production of bottle and packaging plastics. Their use is currently greater than 30 million metric tonnes per annum.

Dr. Alan Cooper, Technical Director, said: “This new UP-Technology benefits everyone along the supply chain; PET resin manufacturers, resin processors and the packaging consumers. Importantly, all of these wide ranging advantages can be achieved without an increase in cost to the consumer.” further information: www.ctl8.com CTL’s new products are designed for PET production

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Words | Leanne Taylor

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t a reception held in the House of Commons, the leader of the Packaging and Films Association (PAFA) said the plastics industry needed “help from Government” if it is to successfully form long-term goals to achieve the UK’s recycling targets and compete with its neighbours in Europe.

Speaking at the event, which was organised by PAFA, the British Plastics Federation and Plastics 2020 and included a number of industry stakeholders, Barry Turner said “shortterm goal setting” was appearing “too often” in policy formation regarding recycling and “inconsistent signalling” was discouraging manufacturers from investing in the UK. Turner praised the progress the UK has made, highlighting those councils that had made significant headway in preventing waste from landfill. However, he warned that there were still “a number of challenges” ahead if the industry was to meet the targets set.

“Where we lack substantially is the overall diversion of landfill,” Turner said.

“The fact that some councils in this day and age do not offer any sort of collection or recycling is a sin.”

Turner said joined up targets on a local level, harmonisation of collection schemes and advice on best practice were some of the key actions with which the industry needs help from the Government in being able to achieve.

“We look to Government to show some leadership and strategic vision, again, we need leadership in specifying recycled content and recycling itself. It is more than setting targets.”

The reception was held at Westminster

reclamation & recycling

40

PAFA calls on Government support to make future progress

Barry Turner addressing the audience at the Parliamentary Reception

Turner also said that the UK needed to recognise there is a place for getting energy from waste, adding that the country fell “woefully short” in comparison to the “best in class” in Europe in this area. “Countries like Switzerland, Germany and Austria, in fact, there are 10 European countries that send less than 10 percent of their waste to landfill. We need to be joining them,” Turner said.

Also speaking at the event on behalf of the Department for Environment, Food and Rural Affairs (DEFRA), Dr Colin Church, a Director for climate, waste and atmosphere, said in terms of the industry meeting its targets, Government clearly had a “pivotal role”, but it was not one it “could or should be doing on its own” and that working together with the industry and businesses was “vital.”

Chairing the event was Mark Pawsey MP, Chair of the ‘All Party Parliamentary Group’ (APPG) for the Packaging Manufacturing Industry, who praised the industry’s progress in areas such as lightweighting, as well as the success of the ‘Fresher for Longer’ campaign, which he said was a “great example” of how packaging could help families in difficult economic times. §further information: www.pafa.org.uk

Erema headquarters in Ansfelden, Austria

Erema sees “sensational” sales of recycling system launched at K Manufacturer of plastics recycling machinery, Erema, says it has increased its order intake by 30 percent over the last two quarters compared to the corresponding period of the previous year.

The company says the strong result is largely due to the “sensational” initial sales figures of ‘Intarema’, the new generation of systems it launched last year during K 2013.

Plant sales in the period accounted for a turnover of EUR 57 million, says the company, and with the order books “remaining full” for the coming months, expectations for the current quarter and thus the fiscal year as a whole are said to be high.

“The new Intarema system, featuring innovative counter current technology, has been exceptionally well received in the market,” commented Erema CEO, Manfred Hackl. “Based on the current order figures we expect a record turnover of around 28 million euros for the first quarter of our 2014/15 fiscal year.”

Total sales for the 2014/15 fiscal year at Erema’s Ansfelden headquarters are expected to climb 10 percent to EUR 110 million, a result it expects to achieve solely with its core business of developing and building plastic recycling systems.

Frisbee helps resource recovery take flight A frisbee being sold by Marks & Spencer produced using plastics recycled from beach litter highlights the “huge potential” for reusing recovered resources in new products, says Axion Polymers, which processed a total of 88kg assorted plastics collected from six UK beaches to produce the toy. www.axionpolymers.com

further information: www.erema.at

Initial sales of the Intarema are said to have exceeded all expectations

41 bp&r

plastic films have got it covered... whatever â&#x20AC;&#x2DC;itâ&#x20AC;&#x2122; is!

T

he majority of our most valuable man-made resources and products have to be protected from the environment to prevent them from deterioration.

This month, Steve Shaw, From Executive Director at helicopters to RAPRA, looks at the role cucumbers, of plastics packaging the useful life and how R&D into new of items is technologies is crucial extended as global demand grows. considerably by placing a thin plastic barrier between them and the outside world.

It is this tremendously powerful benefit that has led to the phenomenal growth in the global plastic packaging industry, especially during the latter part of the 20th Century.

Global plastic consumption has roughly tripled in the past 20 years. In developing markets, population growth, rising disposable incomes, urbanisation and changing lifestyles will drive this demand even further â&#x20AC;&#x201C; particularly for plastic packaging, building and construction, automotive and healthcare industries.

As well as a steady growth of around 22 percent in global packaging between 2010 and 2016, by 2017, it is predicted that China will overtake the USA as the worldâ&#x20AC;&#x2122;s largest consumer of packaging and in the next five years, India is likely to double its current consumption1.

Despite the overwhelmingly positive impact of the use of plastic packaging, national and global leaders are increasingly focused on the fate of used packaging, with the sheer volume of redundant material seen as having a significant and detrimental environmental impact.

As ever, the really smart companies have been working for years to gain a commercial advantage, in anticipation of ever increasingly stringent national and international regulatory and legislative measures. They are keeping well ahead of competitors and securing a greater share of the current and future markets for packaging.

Clearly, there will be huge profits to be made from developing improved types of polymer-based packaging, however, not all companies have the financial resources as large multi-nationals to invest in

Plastics packaging for extending the shelf-life of food

exploring and commercialising leading edge technologies. This does not mean that this lucrative market is out of reach to businesses with pockets that are not so deep.

RAPRA can help SMEs with access to one of the most comprehensive technical support networks available, which includes universities, commercial laboratories, government agencies and relevant trade associations. further information: www.rapralimited.org 1

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events

BP&R takes a look ahead at some of the upcoming conferences, trade shows and industry events of 2014.

2014

JUNE

Printing up a storm The British Plastics Federation (BPF) will host its inaugural seminar on 3D Printing on the 4th June 2014, entitled ‘3D Printing and the Plastics Industry: What you Need to Know’.

The one day seminar, which will be chaired by James Woodcock, Group Editor and Conference Director for the leading industry title and show dedicated to all things 3D printing, ‘tct’, will feature a number of industry experts alongside three leading academics who will discuss the future of 3D printing and its implications for the plastics industry.

The seminar includes presentations on ’The Realities of 3D Printing Today’, ‘Tool-less Production and on demand Manufacturing’ and ‘How Moulders can Win Business by Investing in 3D Printing’.

“In the last few months, many of our members have expressed an interest in 3D printing,” commented Stephen Hunt from the British Plastics Federation. “Examples include moulding companies who are looking for ways to meet the needs of their customers by investing in top-end 3D printing machines and also equipment suppliers who are using 3D printed parts in their machines to allow them to continually refine their designs and innovate faster.”

The 3D printing industry is rapidly growing, with the Technology Strategy Board estimating the industry could be worth up to $100bn by 2020 (from $1.9bn in 2011).

However, with any industry growing at this rate there are a number of problems to overcome including health and safety, the recyclability of material, intellectual property theft and of course the security issues raised by the well publicised issue of 3D printing of guns.

“At the current time, the UK is a global leader in 3D printing know-how and we feel this is something that could benefit the wider plastics industry,” commented Philip Law, Director-General designate at the BPF. “The BPF is holding this seminar to gives plastics firms an opportunity to better understand the technology and the ways in which it could affect their business in the future.”

4

further information: www.bpfevents.co.uk PMMDA flies the flag for UK plastics show Interplas has announced its partnership with supporting industry organisation, PMMDA. The show’s organisers, Rapid News Communications Group (RNCG), says it welcomes PMMDA’s endorsement, which sees the association flying the flag for British plastics at the event.

“We are delighted once again to have the support of the PMMDA and its members for Interplas this year,” commented Duncan Wood, COO and Event Director, RNCG. The PPMDA group has grown to more than 30 members in polymers, plastics and related technologies and continues to provide a mark of quality, with members fulfilling criteria proving their authority in the marketplace and working together to develop EU and ISO standards for the entire sector. It is this indicator of excellence that makes its endorsement of Interplas so significant, says RNCG. “Our members are confident that over the last 50 years Interplas has fully established itself in the UK, offering plastics industry professionals the opportunity to view and compare the widest range of machinery in action, covering every aspect of plastics manufacturing equipment,” said Nigel Flowers, PPMDA Chairman. www.interplasuk.com/register.html.

software directory manufacturing management directory ENTERPRISE RESOURCE PLANNING Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com Epicor’s ERP (on-site, hosted & SAAS) manufacturing software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution.

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

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

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses.

Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

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

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

Affordable and flexible MES system for the plastics/rubber industry.

Real-time production monitoring features wireless data units and OPC Ethernet machine connections.

“Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts.

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

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

Affordable systems available for all size of processor.

Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed.

Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.

A listing in the Software Directory costs £140 per programme per year. Call Lisa on 01244 680222 for details.

43 bp&r

buyers’ guide

materials

assembly

colour masterbatch

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

mould release

Elmatic (Cardiff) Ltd Wentloog Road, Rumney, Cardiff CF3 1XH T: 029 20 778727 F: 029 20 792297 E: sales@elmatic.co.uk W: www.elmatic.co.uk

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

equipment 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.

ultrasonic welding

control systems and equipment quality monitoring control

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

material handlinG InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

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

masterbatch

Telsonic UK Ltd

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

polymer distributors

vibration welding Branson Ultrasonics

ancillary

FLEXIBLE POLYMERS RIGID POLYMERS ADDITIVES PURGING SOLUTIONS

Motan Colortronic Ltd

FOR SALE for sale/WANTED

Reheat Stretch Blow Moulding Machine (PET) Make: Sidel, France Type: SBO 24/24 Year: 1994

44 bp&r

ROTOR WHEEL DRYERS The New Industry Standard Up to 70% Energy Saving Low regeneration No Chilled Water No Compressed Air Temp. range 55-180˚C 5 Year Warranty E info@summitsystems.co.uk W www.summitsystems.co.uk T 01827 265 800

chillers/temperature extrusion systems controllers

C.J.P. Sales Ltd, 8 Heol West Plas, Litchard, Bridgend CF31 1PA

Tel: 01656 644907 Fax: 01656 662 397 Email: sales@cjpsales.co.uk Web: www.cjpsales.co.uk

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

Energy Saving Dryers

- Preform Tipper, Hopper / Elevator, Infeed Rail - Oven & Heating Wheel - Electrical Cabinet (Siemens S5) - Operating manuals

For further details: 01925 596170 – 07838138342 Email: douglastrading@gmail.com

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

thermocouples

extruders and downstream equipment Cooper Plastics Machinery Unit 12, Harmill Industrial Estate, Grovebury Road, Leighton Buzzard, Bedfordshire LU7 4FF T: 01525 850610 F: 01525 218008 E: cooperplastics@googlemail.com W: www.cooperplastics.co.uk Extruders, 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.

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

granulators

dryers/dehumidifiers

secondhand and reconditioned

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

Rawmec (EEC) Ltd Rawmec Industrial Park, Plumpton Road, Hoddesdon, Herts EN11 0EE T: 01992 471796 F: 01992 471797 E: rawmec@btconnect.com W: www.rawmec.com

infra red systems

TransXL International Ltd Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

mixing, feeding, drying

screen changers

Motan Colortronic Ltd

heating equipment

Industrial Plastics Ltd

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

Injection Moulding

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

metal detection & separation equipment

static control

Motan Colortronic Ltd

Arrowquint Ltd

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

nozzles & nozzle tips

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

induction heating for platens and tools MF Induction Heating Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 F: 01543 574460 E: sales@mfinduction.com W: www.mfinduction.com BS EN ISO9001: 2000 registered.

BS EN ISO9001:2008

materials handling and storage Buy and Sell Cable and Plastics Machinery

gravimetric/volumetric blending

LABORATORY machines

Presently Available:

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

printing machines

Floatair tumble mixer 250kg capacity

pad

50mm x 24:1 Boston Matthews extruder 90mm x 24:1 Francis Shaw extruder Rapid Granulator type 4535/KV Please Contact:

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

hopper dryers

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

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

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

hardness - IRHD and shore MAPRA Technik Co — BAREISS For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers.

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

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

hot runner systems hot runner controllers

screws and barrels

hopper loaders

DTL Machinery UK We Buy / Sell all Makes, Age and Sizes of Injection Moulding Machines & Ancillaries Tool room machines and also complete factories / plants Factory Clearance Services Dismantling / Removal of obsolete plant and machinery T: 01925 596170 M: 07838138342 E: douglastrading@gmail.com

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

Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com

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

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

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

45 bp&r

buyers’ guide injection moulding

services

Contract cleaning Injection Moulding Extrusion

mouldflow analysis

• • • • • •

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

EXTRUSION parts & services Extrusion and Plastics Services Extrusion, Compounding, Wash Plant Installation, Maintenance, Removal New Factory Setups / Single Machine CAD work / Tooling Mods / Trials Product Development / Line Trials Downstream Equipment Repairs Chillers, Pumps, Pipework, Air etc Punching / Drilling / Foiling / Wrap Filtration / Settlement Systems Process Improvement / Training 07930 150120 extrusionandplastics@hotmail.co.uk

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

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

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

contact lisa montgomery 01244 680222

bp&r

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

printers

To advertise in this space

46

RECYCLING systems

CHOOSE THE NUMBER ONE.

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

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

www.netstal.com

Optimized parts weights Short cycle times At Netstal our aim is to help you produce the perfect thin-wall packaging.

You achieve maximum output and quality in the shortest cycle times. And thatâ&#x20AC;&#x2122;s no coincidence: our team of experts are specialized exclusively in plastic packaging â&#x20AC;&#x201C; and in machines made to perform.

Engineering Excellence