British Plastics
and Rubber
bp&r may/june 2016
LIFE ON MARS Haitian’s UK moulding machinery sales reach new high
THE GOOD GUIDE TO INJECTION MOULDING VALIDATION
CHINAPLAS REVIEW: COMMITMENT TO “IMPORTANT MARKET”
PVC INDUSTRY’S “HISTORIC” ACHIEVEMENTS OUTLINED
£1895 Compressed Air Dryers from just
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bp&r BRITISH PLASTICS &RUBBER
www.britishplastics.co.uk EDITORIAL
group Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com
SALES
Group Advertising Manager: Lisa Montgomery T: +44(0)1244 680222 E: lisa@rapidnews.com
ART SAM HAMLYN T: +44(0)1244 680222 E: sam@rapidnews.com
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PUBLISHER
duncan wood T: +44(0)1244 680222 E: duncan@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rate: UK, Europe and rest of the world £249 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (01244) 671074 © 2016 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.
facing the possibility of brexit
T
his time eighteen months ago I was pondering the possibility of writing an Editor’s letter for a British plastics magazine that did not include Scotland as part of that Britain. Now, I am pondering the possibility that this may be my last Editor’s letter where Britain remains as part of the European Union. The vote on the country’s place in the EU takes place on the 23rd June and it’s fair to say that the campaign is ramping up - with both sides turning up the noise as polling day approaches. From the perspective of the British plastics industry, the straw polls that have been done recently suggest respondents feel that staying in the European Union will be best for business, however, as one CEO of a global injection moulding machinery manufacturer told me this week “life will go on” if the UK should choose to leave. Looking out beyond the boundaries of Europe, this issue features our review of Chinaplas. Our report on pages 18 and 19 includes an overview of some of the key announcements from the show, as well as insight as to how the exhibitors on the UK Pavilion fared. The general consensus is that the huge fallout predicted by some experts as a result of China’s overall economic slowdown has seemingly not impacted negatively on the country’s plastics industry, which is very much still being regarded as a key and important market.
Finally, I cannot end without saying that it was a sad day for the UK’s plastics recycling industry recently when the announcement was made that the troubled plastics bottle reprocessor, Euro Closed Loop Recycling, had been put into administration. For a company with so much promise to endure such a fall from grace is difficult to watch. We can only hope that this incident does not undermine the confidence of investors in the UK plastics recycling sector.
I am pondering the possibility that this may be my last Editor’s letter where Britain remains as part of the European Union,
Enjoy the issue.
Leanne Taylor, Editor
bp&r
THE BIG STORY WITH SOARING SALES AND STRONG DEMAND, THIS IS SET TO BE AN UNPRECEDENTED YEAR FOR PREMIER MOULDING MACHINERY, THE UK SALES AND SERVICE PARTNER FOR THE WORLD’S LARGEST INJECTION MOULDING MACHINERY MANUFACTURER, HAITIAN INTERNATIONAL. LEANNE TAYLOR REPORTS ON THE NUMBERS, THE NEW INITIATIVES AND THE NEXT STEPS FOR THE COMPANY.
LIFE ON MARS
Haitian’s UK sales reach new high
T
his year is certainly a numbers game for Premier Moulding Machinery (PMM). As Haitian International – the company for which it is sales and service partner in the UK – celebrates its 50th anniversary, the Buckinghamshire-based business is celebrating a 32 percent increase in sales. This is a record for PMM and exceeds the UK trend for injection moulding capital equipment sales. “Conversion of small tonnage hydraulic machines to electric solutions, strong sales of the highest selling Mars Series and increased spare part availability has greatly assisted our customers,” explained Richard Hird, Sales Director at PMM. “Ex-stock machines from Haitian’s European stock holding of some 250 machines have been a large factor in our sales success, with many customers taking advantage of this immediate stock availability.”
Breaking new ground
Haitian’s growth across Europe, along with increasing demand, has seen it invest more than ten million euros (approx. 7.8 million GBP) in its German production facility in Ebermannsdorf. In March this year the company officially inaugurated its new 7500m2 production hall, which will be the focal point for an opening ceremony on June 6.. “With the construction of the new production hall, Haitian International Germany will be able to offer Zhafir and Haitian machines for the European market, mainly out of Ebermannsdorf. Thus we ensure greater availability and can react to customer needs even more quickly,” said Xiang Linfa, General Manager of the new Haitian German subsidiary. Haitian Mars II 90t
Technology to the Point
Haitian’s increasingly popular servo-hydraulic Mars Series is available in clamping force categories from 600 to 10,000 kN in machines that offers competitive production of simple standard parts with high energy efficiency, repeatability and precision. The machine continues to be Haitian’s bestseller, with sales of 150,000 units since its launch in 2007. The Mars benefits from an optimised clamping unit, which provides lower energy consumption and faster movements for reduced cycle times, as well as redesigned toggle kinematics for higher efficiency and lower energy consumption for small and large machines. The redesigned clamping unit provides lower platen stress and higher mould force stability, reducing mould wear and improving moulded product stability. The machines also benefit from a drive system with patented servomotor-to-gear pump design. “The patented servo motor/gear pump drive system was designed as a system and is not the combination of standard market components,” explained Hird. “This translates into a significant advantage for repeatable high precision and low energy consumption for different moulding applications and processing materials.”
A winning formula
As a result of its record sales, PMM is now actively recruiting additional service engineers and regional sales managers in order to cope with the increasing demand. This process, however, also coincides with the company’s decision to increase the manufacturer’s warranty on all new Haitian machines sold in the UK. “Making the decision to increase the manufacturer-backed warranty from the current two years to a three year parts-andlabour warranty from installation was an easy one to make,” continued Hird. “We have total confidence that these energy-efficient machines pay for themselves and that they deliver in terms of both reliability and performance. It’s a winning formula.” WWW.HAITIAN.CO.UK
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bp&r BRITISH
contents
PLASTICS &RUBBER
MAY/JUNE 2016
on the cover Life on Mars: Haitian’s UK sales reach new high With soaring sales and strong demand, this is set to be an unprecedented year for Premier Moulding Machinery, the UK sales and service partner for the world’s largest injection moulding machinery manufacturer – Haitian International. SEE PAGE 4
PVC’s achievement in lead-based stabiliser replacement concludes a “challenging journey”
3
37 feature
EDITOR’S LETTER Facing the possibility of BREXIT
18-19 feature
Chinaplas Review: Longterm commitment shown to “important market”
The world’s second largest trade fair for the plastics and rubber industries, CHINAPLAS, marked its 30th edition with growth in visitor numbers and a commitment to the market from some of the industry’s biggest names. Leanne Taylor reports.
31 feature
WHAT ARE FEEDSTOCKS, WHAT DETERMINES FEEDSTOCK PRICES AND HOW DO THEY INFLUENCE POLYMER PRICES?
In the second installment of our latest column, @polymerman, aka Mike Boswell, looks at the influence of feedstocks. 6
32-33 REGULARS INDUSTRY NEWS feature MATERIALS
The PVC industry’s 4th Vinyl Sustainability Forum saw the discussion, review and celebration of the “historic achievements” made in 2015.
08 30 mo’s corner 38 machinery 39 Reclamation and Recycling 43 BUYERS’ GUIDE 47 SOFTWARE 49 NEWS FROM THE FRONTLINE 50
How colour management made Trunki’s development an easy ride
Following an appearance on BBC’s Dragon’s Den, children’s ride-on suitcase brand, Trunki, is a household name. The brand is now celebrating its 10th birthday and BP&R looks at how consistant colour management in the plastics used to create the cases have helped it succeed.
40-41 feature
The good guide to injection moulding validation
When it comes to product quality in injection moulding, machine and tool validation is fundamental to creating a stable manufacturing process and de-risking the project. Yet, it’s often bureaucracy rather than methodology that drives companies to validate. James Hines of Sumitomo (SHI) Demag explains.
WWW.BRITISHPLASTICS.CO.UK
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NOW HERE’S A NEW INJECTION OF INTELLIGENCE
ACCURATE AND RELIABLE TCU SOLUTIONS FOR YOUR PLASTIC PROCESS. T HE T EMPER ATU R E CO NTRO L SPECIAL ISTS. SA L E S. H I R E. S ERVIC E.
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INDUSTRY | NEWS
Twoof Brush Ball: a ball for dogs that combines play with toothbrushing, designed by Paige Hobday, Coventry University
Medi-Play medication dispenser: designed by Suraj Soren, Northumbria University
‘WILD’ IDEAS REVEALED AS STUDENT PLASTIC DESIGN FINALISTS ARE ANNOUNCED Students from universities across the UK have come up with some ‘animal magic’ in response to the brief for this year’s Design Innovation in Plastics (DIP) competition. The theme of the competition, which is the longest running student plastics design award in Europe, changes each year. The focus for 2016 is ‘Products for Animal Wellbeing’. According to Sylvia Katz, Award CoOrdinator, this year’s entries were so strong that seven entries were chosen to go through to the final judging stage, as opposed to the usual six. “We received a very broad range of entries including an emergency paw aid kit and an aquarium vacuum
that CribBite: A product rses, ho in ng bbi cri ts preven , Tan c designed by Eri y Northumbria Universit
Petect: a lungworm preventive outdoor dog feeder, designed by Karl Martin, Dublin Institute of Technology
cleaner,” explained Katz. “Almost every competition entry addressed a different problem involving a very broad range of animals, from horses, cats and dogs to reptiles, chickens, hedgehogs and even fish.” Following the final round of judging in late May a winner will be chosen – to be unveiled at the competition’s awards ceremony in early July. The prizes on offer are highly sought after by the students – with a monetary prize and two work placements at Headline Sponsor, Covestro, and Design Agency, PriestmanGoode, on offer. With the overall UK pet market valued at £5 billion annually, with 16 percent accounting for accessories, there is an obvious opportunity for the students to commercialise their ideas after the competition ends. Help in this regards is something which is uniquely offered by the Awards and has been utilised by many of the past winners to take their ideas to market. WWW.DESIGNINNOVATIONPLASTICS.ORG
PetStep: a ramp for injured, disabled or elderly pets designed by Alex Wyman, Nottingham Trent University 8
WWW.BRITISHPLASTICS.CO.UK
Unicomb: an ‘all in one’ grooming product, designed by Ciaran Brennan, Dublin Institute of Technology
ase uick-rele Flex: a q ed n ig s de surcingle, urton, B el ab n by A am Trent Nottingh y Universit
Polymer Zone’ site is the brainchild of the BPF’s Skills and Education committee
NEW INITIATIVE LAUNCHED TO GET CHILDREN AND TEACHERS ‘IN THE ZONE’ The British Plastics Federation (BPF) has launched an educational website for both schoolchildren and teachers specifically aimed at bringing plastics into the classroom. The ‘Polymer Zone’ site is the brainchild of the association’s Skills and Education committee, which decided a resource-based outlet was needed for schools so that the perception of plastics could be improved, the range of careers in the industry highlighted and, as a result, the current skills gap closed. “We are absolutely thrilled to be launching ‘Polymer Zone’, as we feel there is a huge need for such a resource among school children,” explained Stephen Hunt, BPF Membership Services Director. “We are extremely passionate about education and skills and we would like to see more young people entering into the industry.” The Polymer Zone is an
‘educational hub’ containing resources including education kits that can be used in schools, over 50 videos about plastic as a material, activities and experiments suitable for classroom use as well as a series of 12 downloadable PowerPoint presentations provided by PlasticsEurope, that can be viewed directly on the site as well as downloaded and tailored for individual teaching use. In addition, the BPF has worked closely with an educational specialist to create a lesson plan aimed at Key Stage 3 children (pupils aged between 11 and 14) studying Design and Technology. The lesson plan, which is curriculum linked, allows children to match plastic products with the processes used to create them. All relevant support material is available to download free of charge from the site. ‘Polymer Zone’ can be found by visiting: WWW.POLYMERZONE.CO.UK
It’s K Time
After 3 years, we’re ready to go again. K 2016 presents you the best that engineers, chemists and researchers currently have on offer: machinery, technology, materials, tools, applications, and forwardlooking products, processes and solutions. The best basis for global business, the perfect decision-making platform for investment. With some 3,200 exhibitors in 19 exhibition halls on more than 171,000 sqm of exhibition space, the world’s premier trade fair for the plastics and rubber industry will once again be presenting the entire range of products and services that the industry has to offer. Everything that will move the world in the future. Plan your visit now.
SIR JAMES DYSON DONATES £8M TO NEW “INVENTION POWERHOUSE” AT CAMBRIDGE UNIVERSITY One of the world’s most advanced engineering facilities for prototyping, inventions and collaboration on cutting-edge research has been opened at the University of Cambridge. The development has been funded by a £8m donation from the James Dyson Foundation and will accommodate student-led projects focusing on areas including advanced materials development, smart infrastructure and electric vehicles. “Developing the intellectual property that will help
Britain succeed in the global technology race depends on applying our brightest minds to ambitious and exciting research projects,” commented Sir James Dyson upon opening the building. “I’m hopeful that this new space for Britain’s best engineers at the University of Cambridge will catalyse great technological breakthroughs that transform how we live.” The facilities, separated into the ‘Dyson Centre for Engineering Design’ and the adjoining ‘James Dyson Building for Engineering’ are located at the heart of the Cambridge cluster, Europe’s largest. WWW.CAM.AC.UK
Time for Decisions
For further information contact: International Trade Shows Link Ltd. Ramsay House, Marchmont Farm _ Link Road Hemel Hempstead _ Hertfordshire HP2 6JH Tel. +44 (0)1442 23 00 33 _ Fax +44 (0)1442 23 00 12 info@itsluk.com
k-online.com
www.itsluk.com
Lorna with her medal
“We are absolutely amazed by the generosity of everybody more than doubling our fundraising target. The marathon was incredibly hard but I felt I had no choice but to complete it for Leo and everyone who put their faith into us,” Hopkin explained. “There were more than a few tears shed by the whole family at the end. We hope the money provides beneficial support to families enduring the pain of SIDS.” To donate to the charity in recognition of the achievement, please visit:
LORNA’S MARATHON EFFORT FOR CHARITY IS ‘SUMMIT’ ELSE Summit Systems’ Marketing Manager has raised an incredible £8,500 for charity following her participation in the London Marathon on 26th April. Lorna Hopkin and her brother, Gavin Aiken, ran on behalf of the Lullaby Trust, a charity that supports families affected by Sudden Infant Death Syndrome (SIDs). The charity is close to Hopkin’s heart following the loss of her fiveweek-old son, Leo, to the condition last year.
WWW.LULLABYTRUST.ORG.UK/
Kevin Horne, Renmar Managing Director
Omega Plastics Group Quality Manager, Paul Anderson (left), and Group Managing Director, Dave Crone
OMEGA CELEBRATES 10TH ANNIVERSARY WITH AUTOMOTIVE ACCREDITATION North East-based tooling and plastic injection moulding manufacturer, Omega Plastics, is celebrating its tenth year in business with the recent awarding of ISO/TS 16949:2009, the global standard for the automotive sector. Since its launch in 2006, The Omega Plastics Group has experienced significant growth in the sector by producing components for Tier One suppliers to various manufacturers, including Aston Martin and Nissan. “The automotive sector is hugely competitive throughout its supply chain and any business that has aspirations to succeed and grow within it has to consistently deliver the very highest standards.
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RENMAR ACHIEVES “BEST EVER” YEAR WITH 40 PERCENT INCREASE IN TURNOVER
By securing this prestigious quality award in our tenth year of operation, The Omega Plastics Group has demonstrated it has the capability and experience to work alongside some of the biggest names in the industry,” commented Paul Anderson, Group Quality Manager at Omega. Since the business started, The Omega Plastics Group has operated under ISO 9001 and has supplied a wide range of sectors, experiencing strong growth across its portfolio particularly in automotive, medical devices and FMCGs. Last month, the company announced it was forecasting a 50 percent increase in turnover this year to around £8.5m.
Wellingborough-based ancillaries supplier to the plastics industry, Renmar, has revealed the year ending 31st March has been its “best ever”, with an increase in turnover of 40 percent. The company attributes the success to a number of factors, including full time representation in the North of England, a significant increase in marketing activity as well as the policy of bulk purchasing and stocking faster selling products, such as mould heaters, to ensure quick delivery times. “While last year was an excellent one for Renmar we have no intention of standing still,” commented Kevin Horne, Managing Director. “Last year we took on the Marse range of dryers and hopper loaders and it always takes time to establish new products in any market. We expect the Marse range to make more of a contribution this year and we are also looking at other products to further enhance our current ranges with the intention of making next year, our tenth anniversary, our best yet.”
WWW.OMEGA-PLASTICS.CO.UK
WWW.RENMARLTD.COM
WWW.BRITISHPLASTICS.CO.UK
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PDM directors Kate Richards and Douglas King, with their Bloccs protector
RUBBER PRODUCT MANUFACTURER AWARDED ROYAL SEAL OF APPROVAL A Bristol-based manufacturer of rubber products for a variety of industries has been awarded the Queen’s Award for Enterprise for an invention that keeps plaster casts and dressings dry in water. Precision Dippings Marketing Limited (PDM) was awarded the accolade for its ‘Bloccs’ product – a range of reusable, waterproof arm and leg protectors for patients with plaster casts and dressings. When fitted with a plaster cast, patients are advised to keep their casts away from water so they do not become soggy and fall apart or cause infection. Bloccs keep injuries bone dry by slipping over an injured arm or leg like a glove or stocking. Their rubber seals combine the same technology PDM used to put the stretch into the iconic Stretch Armstrong toy in the 1970s, with the watertight wrist, ankle and neck seals it also supplies for the world’s top drysuit manufacturers today.
“Bloccs are popular with injured children who want to swim on their summer holidays, side-lined athletes who need a speedier rehabilitation through aquatic non-weight bearing exercise and anyone who wants to bathe or shower independently after surgery or in spite of having a dressed wound,” explained Kate Richards, co-director of PDM. “It’s the first consumer product we’ve taken to market since starting in 1964, so we’re incredibly proud.”
The Addmaster Bag for Life will be available on the high street later in 2016
ANTIBACTERIAL PLASTIC BAG NAMED ‘BEST NEW IDEA’ A plastic ‘bag for life’ produced using antimicrobial technology has been awarded the accolade of ‘Best New Idea’ at a recent industry event. The bag, produced by UK-based Addmaster, was recognised at Foodex 2016, a trade event for the
food and drink industries, beating 73 entries representing new trends across the manufacturing sectors. The bag is produced using the company’s ‘Biomaster’ antimicrobial technology, which protects contents from common types of harmful bacteria such as E.coli, MRSA, Listeria, Salmonella, Campylobacter, WWW.BRITISHPLASTICS.CO.UK
Sales and export figures for Bloccs have increased year-onyear since it was launched in 2013 (including a 25 percent rise in 2016). Kate said the product’s growth had “exceeded all expectations” and the Queen’s Award could provide a springboard for further success, potentially in Australia and the United States. WWW.PRECISIONDIPPINGS.CO.UK
Legionella and Pseudomonas. Since the introduction of the 5p single-use carrier bag levy in England last October the use of reusable shopping bags has increased, however, so too have the challenges relating to food poisoning, given the ability of bacteria from food packaging to breed inside the bags and potentially contaminate future products, food preparation surfaces, or human hands. Independent tests show that bacteria can survive in an ordinary resusable shopping bag for up to eight weeks, however, the Biomaster bag for life contains inbuilt technology proven to inhibit the growth of dangerous bacteria and helps prevent cross-contamination. “The product demonstrates that Biomaster antibacterial technology is a simple and safe solution to bacterial cross-contamination and can easily be incorporated in every day products bringing permanent protection for consumers without a significant cost impact for the retailer,” commented Sandrine Garnier, Addmaster’s Sales Director, upon collecting the award. WWW.ADDMASTER.CO.UK
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FINISHING, PRINTING & DECORATING | NEWS
CORONA TREATMENT IMPROVES PRINT ADHESION ON MEDICAL PLASTICS The use of high frequency corona treating equipment been implemented by a large UK healthcare company to improve the print adhesion on its medical plastic products. Albert Browne, part of the STERIS Healthcare Corporation, approached Lichfield-based Dyne Technology to improve the adhesion quality of its printing ink on sterile indicators widely used in hospitals throughout the UK and Ireland. The sterile indicators are vital for process control to prevent the mixup of processed and un-processed packs (either container, pouch or wrapped tray) and enhance patient and personnel safety. Dyne Technology undertook a series of tests on sterile indicator tabs and found that the surface of the plastic material would achieve a stronger level of adhesion with plasma surface activation, which would allow the printing ink to fully wet the surface and achieve the high level of adhesion required.
14
“Dyne Technology has worked very closely with us to provide a cost effective and robust solution. The treatment system installed has improved the print adhesion enormously and therefore the overall quality, reliability and performance of our Process Control Products,” — Jonathan Coleman, Deputy Manufacturing Manager at Albert Browne. WWW.BRITISHPLASTICS.CO.UK
From this, High Frequency Corona Treating equipment was chosen as the most effective treatment method for both the part requiring treatment and the manufacturing process utilised. This has now been installed on the current printing line for surface modification at Albert Browne’s manufacturing facilities. The high frequency corona treating equipment system supplied is designed for the pre-treatment of conductive and non-conductive narrow webs and can treat either one or both sides of the web as well as accommodating production speeds of up to 150m per minute. The compact design and construction enables the equipment to be mounted directly onto the treating station, which completely removes the need for trailing high voltage cables. Running from standard 230Volt, 13Amp socket outlets the corona treating equipment easily fits to new or existing production lines and presses. WWW.PLASMATREATING.CO.UK
PE-6C
CUSTOM DECORATED CLOSURE ADDS THE FINISHING TOUCH TO LUXURY FRAGRANCE A custom-designed, multiple-part closure has been manufactured for a premium perfume brand to give its latest fragrance a luxury finish. RPC Group’s subsidiary, RPC beauté, based in Marolles, France, designed the closure for the ‘Illicit’ fragrance by Jimmy Choo, which features a cap and neck collar injection moulded in ABS. Four component parts make up the cubeshaped cap, all of which are assembled automatically. Post-production, the cap and collar are electroplated with a metallic white gold finish,
0845 34 54 560
LVS ADDS IN-HOUSE PAD PRINTING FACILITY TO DECORATIVE FINISH PORTFOLIO Specialists in the supply and decoration of plastic components, LVS Small Plastic Parts, has added an in-house pad printing facility to its portfolio. The Shropshire-based company has invested in a PE-6C single colour pad printer, meaning that it can undertake simpler printing jobs on its premises as opposed to using a specialist subcontractor. Initially the new unit will be used for the decoration of a new product being launched by a leading domestic appliance supplier, but LVS says additional capacity will be available for new projects. The printer will be connected to the companies ‘Intouch’ production planning and monitoring system, meaning that components can be easily tracked during the various stages of the manufacturing process. Managing Director, Simon Anderson, explained that the production of plastic components that undergo a secondary decorative process require particularly stringent quality and housekeeping regimes. “Most people are aware that applying a decorative finish to a plastic component can highlight even the smallest surface defect. Once the surface finish is applied, it is then impractical to recycle the component, so we have to be particularly vigilant when it comes to sink marks and other imperfections,” he said.
while the cap is weighted with injected zamak to provide the luxury finish required by the brand. WWW.RPC-GROUP.COM
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09/05/2016 08:04
15
Chrome shines on IN CONSUMER CAR TASTE
David Brereton says consumer tastes are difficult to predict
O
ver the years, car design has changed to incorporate advances in technology, changes in legislation and trends in fashion, but the use of bright chrome is one aspect of design that has remained David Brereton, Sales consistent, across models and Director at Borough, brands. In the past the bright chrome a UK-based plastic injection moulder plating was typically produced and chrome plater by electroplating a thin layer of chromium onto a metal of plastic, looks at substrate, providing corrosion the use of chrome in resistance and increased vehicles and advises hardness in addition to the on what designers and decorative appearance.
manufacturers should consider when choosing Plating plastic to plate a part. components
The same results now can be achieved by metallising plastic components, which remain tough and durable, but have the added advantage of being much lighter. To increase surface durability for automotive applications, the metal must be integrated with the plastic surface. Metal layers are applied to the surface through electrolytic deposition, which requires the plastic component to be made electrically conductive. First a layer of nickel is deposited in a chemical dipping process, applied over a catalytic palladium layer, which must become integral with the surface of the material for the bonding to be effective; one of the restrictions of plating plastic. It is essential that automotive designers understand the effect this plating has, which effectively bonds a skin of very hard and inflexible chromium to the surface of the plastic. Plating ABS makes it brittle and best practice dictates, if the component has to bend, it should not be plated. When designing long thin sections to be moulded and plated, rather than created in metal, they will need to be over-engineered, with thicker sections and strengthening webs to compensate for the reduced strength of plated plastic. To guarantee the high quality finish of plated plastic components, the design must allow for gently curved convex surfaces and radiused angles, whilst minimising protrusions.
16
Satin where it’s seen
Fortunately, most of these requirements can be easily addressed when designing assemblies and components for the interior of modern cars. It is here that designers are reflecting changing consumer tastes, or perhaps influencing them, by including more components with a satin chrome finish than the more traditional bright chrome. Products and components with a bright chrome finish, from kettles to car bumpers, have always been less tactile, with fear of leaving finger prints on the highly polished surface enough to make most people avoid contact. This aversion is something of a problem for automotive interiors, where components are included for function, rather than form – touch is essential.
Behind the chrome
Changing the deposited nickel layer from bright to satin nickel in the electroplating process is the first step in achieving the satin finish. The colour and finish of this nickel layer is affected by the organics used in the dipping process, which requires greater control and maintenance than a conventional bright nickel system. Careful adjustment of the organic material used in the dipping solution allows the colour to be varied according to customers’ requirements, with a large shade range possible, resulting in the more tactile look and feel wanted for cabin interior switches and trim. The satin nickel components still have a chrome surface layer applied for durability and although chrome isn’t really transparent, it is relatively thin at only 0.3 micron so the satin effect underneath shows through.
The future
Consumer tastes are difficult to predict, but whilst the degree of shine inside the car may have been reduced, partly for practical reasons, partly for fashion, there seems little public appetite for a return to the chrome-less cars of the eighties. Solving the necessary technical and quality issues associated with the different finishes and shades of satin chrome required by automotive manufacturers has ensured the future of chrome is bright, satin and also, perhaps, coloured? WWW.BOROUGH.CO.UK
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CHINAPLAS REVIEW: LONG-TERM COMMITMENT shown to an “important market” Words: Leanne Taylor
T
he world’s second largest trade fair for the plastics and rubber industries, Chinaplas, marked its 30th edition with growth in visitor numbers and a commitment to the market from some of the industry’s biggest names. The 2016 show attracted a total of 148,575 visitors over the course of the four-day show. The exhibition area reached a total 240,00 sq. m with 3,300 exhibitors in attendance, yet the show remains oversubscribed, with more companies vying for space. The opportunity for growth in China for plastics is huge, as many sectors are only just discovering the potential for the material to transform products, markets and lives. Capitalising on this was apparent in the long-term plans outlined by both machinery and materials exhibitors. Engel, for example, said that business activity in Asia was a “strong contributor” to the global success of the corporate group, contributing to almost a quarter of its worldwide turnover. “With its very large markets and often very dynamic development, Asia is a major pillar in Engel’s worldwide success, thus also contributing to the growth of our Austrian locations,” explained Dr. Christoph Steger, Chief Sales Officer at Engel. The company is expanding its production capacity in Shanghai, with
DATE
VISITORS
a facility for a heavy duty machining centre for platen manufacturing, as well as more office space and training facilities expected to be completed by autumn/winter 2016. “Although we do not have a great deal of space left in Shanghai, we are now making full use of the space we have,” Wilhemoth continued. “This is the only way for us to meet rising demand.” Arburg used the show to introduce its new series of all-electric injection moulding machines in Asia, following the launch of the range in Europe in March 2016. The company said that the decision to introduce its ‘Golden Electric’ machines at Chinaplas was the “perfect choice”, owing to the show’s focus on highend plastic technology to reflect the region’s market and economic changes. KraussMaffei Group exhibited at the show for the first time under its new owner, ChemChina, and said its portfolio, including locally produced injection moulding machines, combined with the new market entry opportunities brought by its new parent company, were an “ideal match” for its development plans. “So you will be aware of our change in ownership which is highly releavant in the Chinese market,” said Frank Stieler, CEO, KraussMaffei Group.
WWW.CHINAPLASONLINE.COM
OVERSEAS VISITORS
25/4
40,264
10,664 [26.48%]
26/4
54,823
13,468 [24.57%]
27/4
38,757
10,634 [27.44%]
28/4
14,731
4,688 [31.82%]
Total
148,575
39,454 [26.55%]
Table showing visitor numbers over the show days
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“This change provides KraussMaffei with new opportunities it did not have previously. The relevance for us is having an owner that has access to markets that we, as a foreign company, do not have on the same level.” In terms of materials, Eastman said the strong pursuit of a better standard of living in China, driven by the country’s economic plan, will drive demand for its ‘Tritan’ brand of copolyester. Owing to the high growth of the film and packaging markets in China, as well as the desire for “innovative products”, ExxonMobil Chemical chose the show to launch its latest line of performance polymers. The company said its new ‘Exceed XP’ product line brings “step out” mechanical performance combined with extreme processability to benefit applications across sectors including packaging, construction and agriculture. Other new materials launches came from Dow Corning, which launched a new silicone masterbatch, MB25-035, designed to reduce the coefficient of friction (COF) in high-speed form-fill-seal (FFS) packaging operations. The next edition of Chinaplas will be held in Guangzhou from 16 to 19 May 2017.
Chinaplas turned 30 in 2016
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The visitors queue up to gain entry on the third day of the show
VIEW FROM THE UK PAVILLION:
A
s the visitor numbers indicate, Chinaplas is becoming something of a ‘go-to’ show for international visitors from outside the country, with MORE INTENT over a quarter INTEREST AS of the 148,575 CHINAPLAS RAISES that attended the INTERNATIONAL exhibition coming PROFILE from overseas. The growing international diversity was something that did not go unnoticed on the UK pavilion, where 12 companies were exhibiting. “Chinaplas as a show is getting much better and starting to fall in line with European exhibitions,” Stan Braycotton, Sales and Marketing Manager at Atlas Converting Equipment Ltd, told British Plastics and Rubber. “We have attended Chinaplas every year since it started and worldwide the show is becoming much more important. The biggest difference we noticed this year was the growth in the number of visitors from India, Bangladesh, Pakistan and South Asia to name a few – and they are looking to buy.”
Increase in numbers and leads
With passing traffic at an all time high, the UK exhibitors collectively agreed that there was not only an increase in numbers, but also in the quality of the visitors and the levels of enquiries received. “Chinese buyers have become very sophisticated - more like Europeans. They want the latest technology and don’t want to cut corners,” Braycotton continued. Agreeing, Simon Brookes, Sales Director at Boston Matthews, said they had received a lot more technical enquiries in Shanghai this year than in previous years. “The enquiries we have had are
BPF SECURES FUNDING FOR PLASTIVISION 2017 Staying with the theme of major overseas events with UK pavillions, the BPF has announced that it has secured grants of £2,500 for eligible British companies looking to exhibit at Plastivision, which will take place on 19th - 23rd January next year in Mumbai, India. “The BPF has been organising British Pavilions at Plastivision since 2011 and the show has always proved highly successful for British participants,
what we want to see. Visitors know what we sell, which is good, they are enquiring with a specific purpose in particular products,” Brookes explained. How quickly these enquiries convert, if at all, is a game of patience, according to Aerogen’s Global Sales Manager, Eddie Grant. “In the 10 years that we’ve been coming to Chinaplas the customer base has been distilled – many more know what they need and Aerogen can identify them,” he explained. “However, China is based on long-term relationships and it can sometimes take 9-12 months working on a enquiry before it will convert.” Grant advised that having a regional contact in China is a great asset in this regard. “Our local contact adds value as he is able to sell the bigger product. Without him here it would be difficult.”
Playing to the UK’s strengths
So, despite the much talked about slowdown in the Chinese economy is it still worth UK companies approaching the market? “We have a very clear conception of what we are really good at in the UK plastics sector and what makes us stand out from the international competition - specialist materials and products, niche processing machinery, ancillary equipment, expertise in energy efficiency, technical and rotational moulding, pipe extrusion, packaging solutions, innovative recycling technology and more besides,” explained Philip Law, DirectorGeneral of the British Plastics Federation. “It is definitely worth UK companies targeting China. I think whilst the generic trend of the Chinese economy has not been good recently, it seems obvious that particular subsectors are still registering successes. From being here at the show we can see there is more intent interest, as China becomes a bigger and more
“explained Stephen Hunt, Membership Services Manager at the BPF. “When we first attended in 2011, the show was growing rapidly and had a real buzz to it. That year the show attracted 75,000 visitors, when we returned in 2013 the number of exhibitors had significantly increased to 110,000 visitors.” The exhibition is now one of the largest events in the global plastics calendar and due to the increased level of demand the exhibition space for the show has already sold out, with space
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developed industry with greater buying power and more specific needs. It is also apparent that Chinese machinery is developing in quality and attracting global attention,” he added.
Higher quality driving demand
As the overall market in China is shifting to more high-end, quality products, the machinery and processing equipment required is in itself becoming more technical. This is where the UK can really come into its own, thinks Braycotton. “You need a niche or technical product that isn’t made in China, as they are getting technically better over here and their marketing of products is getting stronger,” he explained. “But, if you do have the product then I would suggest trying the market. China is one of our biggest marketplaces. We have a good reputation here - people come to see us and our show days are really busy, with existing customer visits on top. We want to take a bigger stand next time.” However, despite the positive benefits of China’s shift towards more high-end manufacturing, Brookes warns that it is “imperative” that the UK remains competitive in order to stand out internationally, particularly with regards to price. “There is a place for us here but competition is tough, we in the UK need to be more competitive. Either the way we manufacture or the components that we buy so we can be the best and fight the competition.”
reserved for companies interested in exhibiting at the British Pavilion. “We are delighted to have secured grants for such a successful show,” said Justyna Elliott, Senior Business Development Executive at the BPF. “However, with a limit of just ten grants and the fact that the show has already sold out we would expect the space we are holding to go quickly”. Those interested in exhibiting at the show should contact Justyna Elliott on 0207 457 5001 or email jelliott@bpf.co.uk
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FILM & SHEET | NEWS EXXONMOBIL “COMMITS TO GROWTH OF PE BUSINESS” WITH LAUNCH OF NEW PERFORMANCE POLYMER ExxonMobil says the launch of its latest line of performance polymers for demanding film applications shows its commitment to its polyethylene business, its customers and innovation. Speaking at the official launch of its ‘Exceed XP’ product line at Chinaplas, company representatives told press that the new product brings “step out” mechanical performance combined with extreme processability to benefit applications across sectors including packaging, construction and agriculture. “Exceed XP extends the performance and processing attributes of our extensive line of polyethylene resins,” said Cindy Shulman, Plastics And Resins Vice President, ExxonMobil Chemical. “Packaging films made with Exceed XP offer a high level of protection and preservation for a broad range of products. These unique polymers are especially wellsuited for demanding applications such as liquid and food packaging, construction liners and agricultural films, where extreme performance matters.” Developed through advanced catalyst technology, process research and applications expertise, Exxonmobil says Exceed XP is specifically designed to provide extreme performance in a variety of film applications and to run at faster production rates. For liquid packaging applications, including bag-in-box, pillow and stand-up pouches and flexi-tank
container liners, Exceed XP is said to produce “exceptionally strong” films that have excellent flex crack resistance and toughness that prevents product leakage and contamination, helping manufacturers and brand owners protect and preserve their products through to the consumer. For flexible food packaging applications for use in highly demanding environments, such as low temperatures or high volume, Exceed XP produces films with outstanding sealing performance, says Exxonmobil. Downgauging levels of up to 30 percent can be achieved with better packaging performance, the company added, while helping producers and brand owners protect and preserve food longer. The product can also be used for building and construction liners to help builders protect their structures. Liners using Exceed XP are said to
inhibit water vapour penetration to reduce the risk of mould formation. Finally, for thin agricultural films, Exceed XP can be used to wrap crops such as mulch and silage. The tough and tear-resistant films help farmers protect and preserve their crops and harvests. “Exceed XP has been developed within our global technology organisation and expands on the ‘Exceed’ and ‘Enable’ lines of polyethylene films we have launched previously,” explained ExxonMobil’s Thomas Deman. “Working with extruder manufacturers we have realised just how effective this product can be with regards to the applications we have highlighted. XP is globally available, however, we chose to launch it at Chinaplas because of the high growth of this market and its desire for innovative products.”
Thin agricultural film using Exceed XP delivers tough and tearresistant films that help farmers protect their crops.
WWW.EXXONMOBILCHEMICAL.COM Liquid packaging using Exceed XP delivers exceptional flex-crack resistance, toughness and outstanding sealing to prevent leaks
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Cutting-edge gas solutions for plastics PLASTINUM™ replaces nitrogen and chilled water with carbon dioxide in order to improve efficiencies within gas injection moulding and spot cooling processes. PLASTINUM carbon dioxide systems accelerate cycle times by 40% and reduce production downtimes with no further drying processes required. PLASTINUM provides carbon dioxide systems for cost-effective and environmentally-friendly blowing agents for the extrusion foaming of thermoplastics. CRYOCLEANŽ Snow is an innovative automated or manual industrial cleaning process, which converts liquid carbon dioxide into tiny dry ice crystals to be accelerated at plastic components for the purpose of cleaning; ideal for removing release agent residues, oils, dust, fingerprints and obsolete paint.
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TREOFAN AND BOREALIS WIN INNOVATION AWARD FOR ULTRA-THIN FILM BOPP specialist, Treofan and polyolefins specialist, Borealis, have received the award for ‘Best Lightweight Innovation’ at the first European Plastic Innovation Awards for their cooperation in creating the thinnest polypropylene capacitor film, down to 1.9 µm. New ‘PHD 1.9’ is the first European polypropylene capacitor film thinner than 2μm and is said to boost capacitor efficiency by 30 percent. The film was made with Borclean HC310BF, a high crystallinity, super pure homo-polypropylene with a novel molecular design that enables the production of ultra-thin, metallisable dielectrical film for dry capacitors with increased thermal stability. Polypropylene capacitor films are used in the production of dry, metalised capacitors for a variety of applications, but specifically in automotive applications for hybrid and electric motor systems there is a need for high thermal stability and low volume in order to save space and reduce costs for the cooling systems. Thus, extremely thin films with a high level of thermal and electrical resistance are needed. Treofan is developing these ultrathin capacitor films with a high level of thickness homogeneity, electrical field stressability, low energy losses and very good mechanical characteristics using Borealis’ Borclean super pure, high isotactic polypropylene homopolymer with a novel polymer design.
Wolfram Stadlbauer, Senior Application Marketing Manager, Marketing and New Business Development Borealis, (left) and Dr. Karl Heinz Kochem, Head of Innovation Capacitor Films, Treofan, (right) with the Best Lightweight Innovation Award. © Plastics Europe
The thinness of the film enables the capacitor producer to develop much smaller systems with the same electrical capacity. Treofan and Borealis are planning to further improve these films by further reducing thickness to increase volume efficiency, thermal resistance and voltage levels. “Developing ultra-thin capacitor films is the perfect reflection of our innovation strategy, which focuses on including the entire value chain - from raw materials and processing
to the end consumer,” explained Dr. Yvonne Düpre, Head of Innovation at Treofan Germany. The European Plastics Innovation Awards were created in 2015 by three organisations: European Plastics Converters (EuPC), PlasticsEurope and the Society of Plastics Engineers (SPE). The inaugural ceremony was held in Brussels earlier this year.
design constraints for items such as clothing. Benefits include the capability to relax internal stresses arising from stretch, returning to its
original shape, and withstanding repeated use.
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PANASONIC DEVELOPS A STRETCHABLE RESIN FILM FOR WEARABLE TECHNOLOGY Panasonic Corporation has developed a new soft and flexible polymer resin film intended for use in stretchable electronic devices. This newly developed product is an insulating film material, made from a thermosetting resin and unique design technology, that enables it to stretch and return to its original shape, a feature hard to find in conventional flexible materials. Crucially, the resin film is said to adapt to different ways of folding and to different surfaces, which substantially reduces
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23
CASE STUDY: LONDON’S HIGHEST ALL-WEATHER GARDEN MADE POSSIBLE WITH PLASTICS
has announced it is UK-based Innovia Group iness and assets to bus e han lop Cel its to sell Co., Ltd als mic Che Japan’s Futamura
INNOVIA GROUP SELLS CELLOPHANE BUSINESS TO FUTAMURA CHEMICALS CO. UK-based Innovia Group has announced it is to sell its Cellophane business and assets to Japan’s Futamura Chemicals Co., Ltd, a leading manufacturer of plastic and cellulose films principally servicing the food packaging industry. Innovia says the deal, which is expected to complete on or before 30 June 2016, will allow it to deepen its focus on its fast-growing polymer bank note business and on building on its ‘double bubble’ biaxially oriented polypropylene (BOPP) films business. “The sale of our Cellophane business is an important strategic step for Innovia. Futamura is an excellent long-term owner for Cellophane, with its core business focussed on cellulose and plastic films,” commented Mark Robertshaw, Chief Executive of Innovia Group. Innovia is well established as a provider of advanced polymer banknote substrate and, by the end of 2016, will have manufactured
more than 50 billion ‘Guardian’ banknotes for central banks around the world. From its new facility in Wigton, UK, Innovia will be manufacturing the new polymer banknote substrate for the Bank of England, beginning with the £5 note due to be issued in September 2016 and the new £10 note in 2017. In the BOPP business, Innovia says it will continue its focus and investment on differentiated product development for its core and new markets. “In line with our strategy, we will continue to focus on building our polymer films and banknote business where we see significant growth potential. In particular, the benefits of our polymer technology for banknotes have proven to reduce counterfeiting levels significantly and to reduce substantially the lifetime costs to central banks, which we expect will continue to drive long term demand for polymer banknotes across the globe,” Robertshaw added.
Nylon components and ETFE film are providing London’s highest all-weather garden with both a costeffective and weight saving solution that will give visitors protection from the elements as well as a clear view. The materials are being used in the form of 3D printed transitions and transparent film cushions for a rooftop garden situated above the new ‘6 Bevis Marks’ office building in the heart of the capital’s business and finance district. The 400 sq. m garden is protected by a baldachin made of transparent film cushions extruded from 3M Dyneon Fluoroplastic ETFE (ethylenetetrafluoroethylene) by German based processor, Nowofol.
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The
The building showing the structure in full
op rooft
The ‘NOWOFLON ET 6235Z’ films made from Dyneon ETFE are highly transparent, meaning that visible light and UV-A radiation – which is important for plant growth – is able to pass through. The film also has an extremely high resistance to chemicals, including the pigeon droppings ever present on London’s roofs. The material is so smooth that a normal rain shower is sufficient for effective cleaning, says 3M, meaning the operating costs over the entire lifetime are significantly lowered. The weight per unit area of the roof is just one twentieth of that of glass. This was a strict requirement of the architect, Fletcher Priest, as the new office building – which is a conversion from an existing 1980s structure that was only half the size – still uses the original foundations.
Components manufactured using 3D printing
Skanska UK, based in Rickmansworth, Hertfordshire, designed and manufactured the support structure for the garden. The structure consists of eight hollow columns with a diameter of 355mm, with up to seven additional support arms projecting from each to create a ‘tree-like’ shape to support the film canopy.
ture
struc
The rooftop garden
says the material has proven to be “extremely durable and resistant” in all climatic zones. Rated “Excellent” according to BREEAM
The transitions from the columns to the support arms were produced using 3D printing from architectural nylon, to create a smooth finish. This is thought to be one of the first construction applications to use 3D printing for structural components. The 4x4 metre film cushions inserted in the steel structure were made up by London-based Vector Foiltec — a specialist in structural film construction. The company uses a Texlon ETFE cushion system, which gives a high performance, long-life building envelope designed to cope with high wind and snow loads. The tensile strength of films made of Dyneon ETFE can reach 50 N/mm² and the elongation at break is more than 300 percent. Over more than three decades, 3M
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With regards to sustainability, the 6 Bevis Marks building has achieved an “Excellent” rating according to the widely used BREEAM certification system. Contributing to this overall rating is the film cushion for the baldachin, as the Texlon System used to produce it has been certified with the world’s first Environmental Product Declaration (EPD) for transparent building skins. Also, thanks to the overall low weight of the film canopy the support structure was able to have a much more slender and resource-saving design than if glass was used in the design. On top of that, additional sustainability credentials were earned as Dyneon ETFE requires no softeners during production and is completely recyclable. WWW.DYNEON.EU
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3D PRINTING | NEWS Y e at BO n hous nthal 3D ope r e F tadtin Neus
BOY SHOWCASES OPPORTUNITIES FOR INJECTION MOULDERS USING 3D PRINTERS BOY has demonstrated the prospects of using 3D printing to produce mould inserts for the production of plastic parts. The company, which manufactures injection moulding machines with clamping forces of up to 1,000 kN, held an event at its site in Neustadt-Fernthal, Germany, to showcase how both 3D technologies and traditional injection moulding techniques can work in sync for the benefit of manufacturers through the production of mould inserts. “The mould inserts, which are produced quickly and cost-effectively with Stratasys printers, are installed into the mould and the production of injection moulded plastic parts can start,” explained Alfred Schiffer, BOY
Managing Partner. “Thus, prototypes and components in small batches can be produced considerably more efficiently. The chemical and physical part properties correspond exactly to those of a mass produced part in a conventional mould,” he added. Schiffer added that a significant advantage of using 3D printing technology to create mould inserts that go on to produce a part, as opposed to using additive technologies for part creation, is the ability to process a wide range of materials. BOY has partnered with Stratasys, a company leading in developing 3D technologies, to produce the mould inserts using its commercial 3D printers, as well as encee Systems (Stratasys Gold Partner), EMDE Industrietechnik as well as EMT Dorsiertechhnik and Hasco. Many of the visitors to the event
had application-based technical questions concerning the moulding process, the temperatures and pressures as well as design and service life of the 3D mould inserts. WWW.DR-BOY.DE
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POLYMAKER AND COVESTRO CO-DEVELOP NEW LINE OF POLYCARBONATE-BASED 3D PRINTING MATERIALS Producer of filaments for extrusion-based desktop 3D printers, Polymaker, has partnerned with Covestro to produce a new line of polycarbonate-based materials. Covestro provides the polycarbonate resins for the new ‘Polymaker PC’ material. To date, polycarbonate has only been available for applications in exclusive, industrial 3D printers or a small market for extrusion-based 3D desktop printers. “Thanks to Covestro’s experience, portfolio of products and industry leadership, we can achieve high performance, reliability and safety with the best materials,” said Dr. Xiaofan Luo, CEO of Polymaker. “The products should inspire our customers and expand our portfolio.” The first two products in the new line are Polymaker PC-Plus and PC-Max. The application was made possible by lowering the printing temperature from 300 to 320 degrees Celsius down to a moderate 250 to 270 degrees Celsius, as well as by a significantly reduced tendency to warping.
Based on a n with cooperatio olymaker P , o tr s ve Co troduce in to intends ct du o its new pr aker PC m ly o P e rang arket into the m
Polymaker PC-Max further exhibits improved mechanical properties – increased toughness, in particular – making it suitable for mechanically demanding applications. “We see the introduction of our high-tech polymers to the field of 3D printing as an important step for driving next-generation design and production solutions. We are looking forward to further collaboration with Polymaker for this burgeoning industry,” commented Tim Efthimiady, Senior Vice President of the Polycarbonate Business Unit of Covestro. Polymaker says Polymaker PC is characterised by high heat resistance compared to existing 3D printing materials. The products
can withstand temperatures of well over 100 degrees Celsius, making them ideal for lighting, engineering and all types of applications that require good structural stability when exposed to heat. They also retain their very good mechanical strength under nearly all different deformation modes while also exhibiting high impact resistance and hardness. Polymaker PC can easily be post-processed by sanding, coating or other methods. Additional advantages include intrinsic flame retardance, optical transparency and resistance to chemicals and solvents. WWW.COVESTRO.COM WWW.POLYMAKER.COM
Victrex is heading an industry consortium exploring the innovative use of new polymer grades for use in 3D printing applications.
VICTREX LEADS PROJECT TO DEVELOP PAEK-BASED 3D PRINTING MATERIAL Victrex is heading an industry consortium exploring the innovative use of new polymer grades for use in 3D printing applications. As part of its role, Victrex will develop new grades of highperformance polyaryletherketone (PAEK) polymer based on innovative
chemical formulations that are specifically designed to work in additive manufacturing processes. Although utilised in some AM applications today, current PAEK materials were originally developed for use in injection moulding or extrusion manufacturing processes. The new grades are targeted in particular at the aerospace industry, which is the consortium’s main focus, but will also consider applications in other areas, notably medical. Possessing IP (intellectual property) covering the new polymers being developed, Victrex was awarded funding from the UK’s agency for innovation, Innovate UK, to help drive the project forward. “Everyone is now keenly aware that additive manufacturing has the potential to revolutionise industrial production, since it no longer involves the high tooling and set-up costs of traditional manufacturing,” commented David Hummel, Chief WWW.BRITISHPLASTICS.CO.UK
Executive of Victrex. “It also allows the production of very complex shapes and geometries that cannot be made by conventional means. High value, lower-volume applications such as aircraft components are the type of application that could benefit the most, although there are other areas, including medical, that may also benefit.” A key objective of the overall project is the improvement of the recycle rate for powders used in the additive manufacturing technique known as ‘laser sintering’ (LS). This would significantly reduce polymer wastage in this type of additive manufacturing process and reduce costs. The project will also address unpredictability of inter-layer adhesion and parts surface finish in filament-based printing. WWW.INNOVATEUK.GOV.UK WWW.VICTREX.COM
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NEC BIRMINGHAM, UK | 26-28 SEPTEMBER 2017
INJECTION MOULDING
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www.3dprinting.co.uk ctures Filigree stru Amphora h it w d te ea cr
UK “INTEREST GROWING” IN 3D PRINTED MATERIAL SAYS ALBIS ALBIS UK has recently showcased a working application of a new polymer for 3D printing applications. Exhibiting at the PPME show in Manchester last month, ALBIS demonstrated the production of parts using ‘Amphora 3D Polymer AM1800’ from Eastman Chemical, which the ALBIS Group is now distributing across Europe. Ian Mills, ALBIS UK’s Managing Director said it was “early days” to judge the popularity of the polymer, as it has only been a part of the Group’s portfolio since April, however, he said “interest is growing.” Eastman’s Amphora 3D Polymer is a low-odour, styrene-free material for 3D printing applications that is said to differentiate itself through high dimensional stability, low shrinkage, outstanding toughness and resistance to hydrolysis. The material can be processed in most filament 3D printers – even at high printing speeds – thanks to its good flow properties. Eastman says its high layer-to-layer adhesion ensures mechanical strength, so that Amphora can be used not only for prototyping, but also for functional parts. The material can also be “processed flawlessly” in terms of
NEXEO SOLUTIONS LAUNCHES WEBSITE OFFERING DSM’S 3D PRINTING FILAMENTS Chemicals and plastics distributor, Nexeo Solutions, is now offering filament grades from DSM for the 3D printing market. Through a newly-launched, dedicated website, Nexeo is now exclusively supplying Arnitel ID and Novamid ID to allow customers to buy filaments or order samples, as well as determine the best material for their application needs. Arnitel ID is a highly flexible TPC (thermoplastic copolyester) used in electronics, sports and a wide range of other applications. DSM says it is a flexible polymer with very good UVand chemical-resistance compared to other flexible polymers such as TPU (thermoplastic urethane), reaching elongation at break of up to 400 percent. The company added that Arnitel ID exhibits no buckling, higher print speed, unbeaten layer-
deformations during printing or emission of nanoparticles, Eastman added. Amphora conforms with the food contact and medical product regulations of the American FDA, as well as the equivalent food product regulations in the EU. “3D printing offers us an expanded field of application possibilities thanks to the cooperation: the great “Eastman Chemical freedom was early to invest in of design the development of it provides, functional, harmless and to health polymers makes an for professional 3D ol made outstanding printing,” said Thomas Functional to a addition to Steinbrecher, Group from Amphor conventional Leader Technology, processing EMEA for Eastman Chemical technologies,” commented Heinz Speciality Plastics. Wessendorf, Director, BL Distribution “Our cooperation with ALBIS Advanced Polymers at ALBIS PLASTIC enables us to competently PLASTIC. serve our customers in the growing “We are pleased to be able to 3D printing market on a nationwide distribute these types for Eastman in level.” Europe. To do so, we are expanding ALBIS UK is planning on next our Eastman portfolio and also showcasing the possibilities with offering a plastic solution which Amphora at the PDM fair in Telford was specifically developed for this in June. processing method for the first time.” Eastman says it also welcomes WWW.ALBIS.COM
to-layer adhesion compared to ABS, PLA and TPU used in the 3D printing market. The second material, Novamid ID, is a very ductile, strong polymer suitable for harsh environments and high temperatures, up to 150°C, which DSM says offers excellent layer-to-layer adhesion, strength and toughness compared to other 3D printing materials. Since Novamid ID’s bridging performance is unique, the high crystallinity of the polymer allows designs with overhangs. Nexeo Solutions says that through manufacturing aids and end-use parts, there is a number of advantages for designers and engineers to maximise the benefits of 3D printing throughout their product-development cycle from fast, affordable concept validation to precise functional prototyping.
ns is Solutio ting Nexeo ering 3D prin f f o M now om DS nts fr ated filame ic d e d h a throug e websit
WWW.NEXEOSOLUTIONS.COM. WWW.DSM.COM WWW.BRITISHPLASTICS.CO.UK
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MATERIALS | NEWS NEW PP BASED ON MILLIKEN’S CLARIFIER TECHNOLOGY LAUNCHED FOR TRANSPARENT MOULDED PARTS Carmel Olefins Ltd (BAZAN Group) has announced the launch of a new polypropylene (PP) grade it says offers both excellent transparency and high impact performance for injection-moulded applications. The company says its advanced features are complemented with good resistance to
stress whitening, high gloss and excellent organoleptic performance. New Capilene CT 80A is a clarified and antistatic modified PP grade with a melt flow rate (MFR) 25, produced with Milliken’s clarifier technology Millad NX 8000. It is the first in a new series under development by Carmel to enhance its existing portfolio of PP copolymers based on Millad NX 8000. The grade is said to combine excellent flow
The new PP is said to produce highly transparent parts
with many of the typical advantages of PP random and heterophasic copolymers to achieve “outstanding transparency” plus very high gloss with a good stiffness/ impact balance. Its ability to maintain such high transparency with good impact performance at 0°C is of particular significance for refrigerated applications. Carmel Olefins says the overall performance advantages of the new grade create a step forward for converters looking to reduce breakage potential and avoid stress whitening of highly-transparent packaging and container solutions, for example, for thin wall packaging, clear containers for food packaging, caps and closures, and clear pails. It is also suitable for large storage boxes, crates, heavy-duty transparent toolboxes, appliances and toys. In addition, Capilene CT 80A is said to address converters’ sustainability requirements through its ability to deliver energy savings and shorten cycle times. The use of latest generation clarifier Millad NX 8000 allows a reduction in moulding temperatures compared to previous generation clarifiers. The temperature reduction delivers energy savings and also allows the cooling time of the part to be shortened prior to ejection from the mould. The resulting boost in productivity supports further energy savings, says Carmel Olefins. The new grade brings about viable opportunities for customers to replace regular random copolymers in applications where optical property and impact resistance are required, the company added, as well as to replace heterophasic impact copolymers in applications where transparency should be combined with high impact or high impact without stress whitening. WWW.CARMEL-OLEFINS.CO.IL/ WWW.MILLIKEN.COM 30
WWW.BRITISHPLASTICS.CO.UK
@POLYMERMAN ON PRICES: PART II What are feedstocks, what determines feedstock prices and how do they influence polymer prices? IN THE SECOND INSTALLMENT OF OUR LATEST COLUMN LOOKING AT SOME OF THE KEY ISSUES AFFECTING POLYMER PRICES, MIKE BOSWELL LOOKS AT THE INFLUENCE OF FEEDSTOCKS.
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he overwhelming majority of polymers (plastics and rubbers) contain significant quantities of both carbon and hydrogen atoms. Whilst it is possible to source these important building blocks from carbohydrates (plants) the more common and more economical route today is to use hydrocarbons (fossil fuels). Fossil fuels are available in the form of gas (natural gas*), liquid (crude oil) and solid (coal). On the basis that liquids are relatively easier to handle than solids, crude oil has become the mainstay of the refining industry and, the refining industry, by virtue of its scale, is the most significant supplier to the petrochemicals industry of which polymers and plastic raw materials is part. Therefore crude oil, being the dominant feedstock for petrochemicals, is also a significant influence on plastics prices. As you would expect, given the wide range of petrochemicals produced and multiple competing markets, the economics are complex. The intricacy of the plastics
Petrochemical Feedstocks
feedstock diagram you see on this page is self-evident, and those with chemical knowledge will be aware that there are other applications and sources for many of the so-called ‘intermediates’. Perhaps what is surprising is that until relatively recently the only ‘on-purpose’ product from the steam cracking process was ethylene. It is also interesting to note as
“As you would expect, given the wide range of petrochemicals produced and multiple competing markets, the economics are complex.”
polyethylene producers have turned to less expensive gas feedstocks, which produce almost exclusively ethylene. The amount of so-called ‘by-products’ has fallen behind demand and this in turn has both influenced the economics of steam cracking crude oil-derived naphtha to get ethylene and also resulted in more expensive on-purpose manufacture of these important hydro-carbon feedstocks. It should also be noted that oil prices have fallen significantly — relative to both gas and coal prices — and this has been a major influence on the European petrochemical industry where naphtha is the dominant feedstock. Although, given the likely recovery of crude oil prices in the mid-term, this is why some polymer producers are looking to import natural gas as a feedstock for polyethylene in order to ensure longterm economic viability. Of course the astute will have noted that the recent fall in oil prices has not been proportionately reflected in the price of some polymers and the topic of pricing will be considered in the next installment of @polymerman on prices. *Natural gas includes methane, ethane, propane, butane and ‘condensate’.
Who is @polyerman? Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group. He has a broad knowledge of both materials and the issues affecting the wider industry, with over 20 years experience in the field. @polymerman is the title used for announcements made via his Twitter account.
WWW.BRITISHPLASTICS.CO.UK
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CONFERENCE | REVIEW PVC’s historic achievement in leadbased stabiliser replacement concludes a “challenging journey”
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aking the theme of ‘Smart Vinyl for our Cities’, the Forum – held on April 28th – attracted more than 130 stakeholders from academia, government bodies, the UN, the European THE PVC INDUSTRY’S 4TH Commission, specifiers, VINYL SUSTAINABILITY designers, architects and all FORUM – ORGANISED BY sectors of the PVC industry. Featuring top-level VINYLPLUS AND HELD IN speakers from across Europe, VIENNA, AUSTRIA, AT THE presentations and panel END OF APRIL – SAW THE discussions centered on the DISCUSSION, REVIEW AND versatile role of PVC in meeting CELEBRATION OF THE the future needs of people “HISTORIC ACHIEVEMENTS” living and working in urban environments and how it can MADE IN 2015. HERE, WE make a significant contribution REVIEW THE KEY OUTCOMES to many aspects of the built OF THE CONFERENCE IN environment. Welcoming delegates, MORE DETAIL. VinylPlus Chairman, Josef Ertl, said: “European cities are forerunners in the transition Stephan Sicars speaking at VSF
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towards a low carbon and resource-efficient economy. 72 percent of the EU population lives in urban areas, using 70 percent of our energy. “To assure quality of life, future cities will need healthy and energy-efficient buildings, reliable water distribution and sewage systems, as well as affordable healthcare. Using PVC in place of other materials reduces costs, improves product performance and makes a positive contribution to sustainable development. “With our NGO partner, The Natural Step, we will revisit our Voluntary commitment and highlight the relevance and sustainability aspects of PVC products in 21st century cities.”
“Opportunities to capitalise on innovation” Explaining the main outcomes of the Sustainable Development Goals (2015-2030) and the Paris Climate Summit (COP21), Stephan Sicars, Director, Department of Environment, United Nations Industrial Development Organisation (UNIDO), said: “The shift of emphasis to designing products and processes for sustainability offers the plastics and PVC industry many opportunities to capitalise on innovation, as well as consumer demands for better environmental performance and smaller environmental footprint of products. These trends are said to allow USD three trillion in potential resource savings by 2030 amid an emerging USD one trillion global ‘green’ market.
WWW.BRITISHPLASTICS.CO.UK
“A historic achievement”
VinylPlus General Manager, Brigitte Dero, presented the 2015 results and highlighted lead-based stabiliser replacement as a “historic achievement”. This means, from 2016, products made from virgin PVC resin by European converters no longer contain lead. “Our progress and achievements in 2015 demonstrate how the VinylPlus Voluntary Commitment is contributing to addressing climate change, improving product sustainability and moving the European PVC industry towards a circular economy,” she explained. “Undoubtedly, the highlight of the year for VinylPlus was the replacement of lead-based stabilisers in the EU-28 by the end of 2015. This major achievement by the European Stabiliser Producers Association (ESPA), concluded a challenging journey that saw close cooperation along the value chain to solve technical constraints.”
An upward recycling trend
In 2015, VinylPlus recycled 514,913 tonnes of PVC waste – an upward recycling trend of which window profiles and related profile products accounted for around 45 percent. The greatest volumes - 508,154 tonnes – were registered and certified by Recovinyl, the PVC waste collection and recycling network comprising 177 companies Europe-wide. The target is to recycle 800,000 tonnes per year by 2020.
VinylPlus reaffirmed its commitment to addressing the issue of ‘legacy additives’ in recycled PVC in cooperation with regulatory authorities and is calling to propose realistic solutions for the continuation and development of PVC recycling, taking into account its resource efficiency benefits. VinylPlus is also intensifying its discussions with institutions in a committed effort to help find solutions amid ongoing concern from recyclers and converters over uncertainties in the implementation of relevant EU regulations, such as REACH, CLP and Hazardous Waste. Christos Fragakis, Deputy Head of Unit, DG Research and Innovation, European Commission, spoke about the new EU R&I policy initiative to promote the deployment of solutions to address the complex, but highly interconnected, urban challenges and underpin cities’ transition towards sustainability and enhanced resilience to changes. He also updated delegates on the new Circular Economy Package (endorsed in December 2015), the upcoming Plastics Strategy and the potential contributions of Horizon 2020 in underpinning innovation in all its forms. Reflecting on the Forum, Josef Ertl concluded: “Having heard some inspiring talks and presentations, I feel encouraged about the future of PVC as a material of choice offering numerous benefits for society which helps to serve people’s needs. We are well on track and on our way to the sustainable development goals we have set for PVC – making PVC a material of choice offering safe products, contributing to society welfare. Achieving this vision is worth all efforts in our industry. I encourage all of you to help us to contribute to this vision because it’s up to us to make it happen.” WWW.VINYLPLUS.EU WWW.STABLISERS.EU WWW.RECOVINYL.COM
“We are well on track and on our way to the sustainable development goals we have set for PVC – making PVC a material of choice offering safe products, contributing to society welfare,” – Ertl WWW.BRITISHPLASTICS.CO.UK
Brigitte Dero
“A circular economy is restorative and regenerative by design. The PVC production chain is making progress globally by reducing its environmental impact in areas such as chlor-alkaline production, energy and mercury use and VCM production. In addition, there are excellent developments in different regions and in Europe, especially.”
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COLOUR MANAGEMENT | NEWS 0 lor 85
ataco The D
DATACOLOUR MAKES NEW ADDITIONS TO SPECTROPHOTOMETER PORTFOLIO Datacolor has added two new benchtop spectrophotometers to its range that it says offer “unparalleled performance” for both reflectance and transmission measurement. New Datacolor 850 and 550 spectrophotometers join the 800 and 500 versions launched in October 2015 and are said to provide colour professionals in the plastics industry with ease of use, as well as reduced measurement time. The 850 is the market’s only trueclose tolerance spectrophotometer for both reflectance and transmission measurement, ensuring customers can confidently communicate colour digitally throughout their supply chain, says Datacolour. It features a built-in digital camera for precise sample placement and is said to be fully backward compatible with Datacolor’s prior generations of
NEW SYSTEM MEASURES COLOURS AND SHADES ‘ON-THE-FLY’ TO VERY HIGH ACCURACIES Precision sensor manufacturer, Micro-Epsilon UK, has launched an inline high speed colour measurement system, which measures the actual colour of the target by identifying its coordinates in the colour space. The new ‘colorCONTROL ACS7000’ colour measurement system identifies colours using any of the XYZ; L*a*b*; L*u*v*; RGB and Precision sensor manufacturer, MicroEpsilon UK, has launched an inline high speed colour measurement system
instruments. The Datacolor 850 and 550 feature colour LCD screens that display instrument settings and calibration status, which offers users confidence in their measurement results. In addition, an Ethernet port now allows for simultaneous connection of multiple computers to the same instrument. With an
DIN99 measurement definitions (user selectable). The system can be set up to continually monitor a production process and output via Ethernet, EtherCAT or RS422 and can also be taught pass fail/limits and then output out-of-tolerance alarms using digital I/O. Micro-Epsilon says the system is therefore suitable for a wide range of applications where colours and shades must be examined ‘on-the-fly’ and to very high accuracies. Existing applications include automotive paint inspection, colour measurement of car interiors, transparent film and sheet production, printing, packaging, medical technology and in the processing of plastics. The system is equally suitable for offline R&D laboratory applications. True colour measurement is required in many industry sectors. Measured objects can take the form of solids or liquids and the user may also have a need to recognise the colours of transparent surfaces such as coatings or labels, as well as LEDs or lamps.
WWW.BRITISHPLASTICS.CO.UK
embedded processor diagnostic data can now be easily shared with Datacolor Support, meaning issues are resolved faster. Measurement speed within a global Citrix or Terminal Server environment is also substantially improved, added Datacolor. “Through our commitment to provide customers with the highest quality colour measurement instruments, we developed the Datacolor 850 and 550 spectrophotometers to give customers enhanced ease-of-use and unrivaled performance,” said Diane Geisler, Global Director of Product Management, Datacolor. “With the embedded processor and advanced algorithms, users see at least a 25 percent reduction in measurement time and a quantifiable improvement in throughput.” WWW.DATACOLOR.COM
Chris Jones, Managing Director at Micro-Epsilon UK explained: “The accuracy of most inline colour sensors in the marketplace are typically defined with a ΔE of 1-1.5, which represents similar performance to the human eye. However, as the ACS7000 uses a spectrometer for colour measurement/evaluation, its performance is typically a ΔE of 0.1, which is 10 times greater. This enables users to solve applications that were previously not possible. “Traditionally, high performance colour measurement systems are only able to measure at slow speeds, meaning the product usually has to be measured offline. However, with the ACS7000 having a measurement speed of up to 2kHz, it is now possible to integrate the system into the production processes, improving automation, quality control, production efficiencies and product quality, whilst also reducing operational costs and waste.” WWW.MICRO-EPSILON.CO.UK
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THERE IS NO SUBSTITUTE FOR RELIABILITY Reliability and energy efficiency are the two main attributes of the TCU and VCU ranges of mould heaters from Renmar. The reliability can be measured by the fact that Renmar still receives spares requests for machines that were sold some twenty years ago and which have lasted this long with just simple routine maintenance. Energy efficiency is due to the high flow rates delivered by both TCU and VCU ranges. As water is delivered through the tool, turbulence occurs which increases the efficiency of the unit and gives better heat transfer. Because the water is delivered at a higher rate and at a potential higher temperature, the tool is heated more quickly and reaches the desired operating temperature in a much shorter time. The result is a mould heater that uses considerably less energy than many competitive heaters.
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• Off-the-shelf microprocessor basedPIO Eurotherm temperature controller with Process and Setpoint LED readouts • 9kw - 48kw heaters • 1HP-10HPPumps • Graphic control panel with indicator and warning lights • Compact cabinet • Independent high temperature safety thermostat • Flow rates of132 to 284 litres per minute with 2.0 to 3.7 bar pressure
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EXCLUSIVE How colour management made Trunki’s development an easy ride
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t was in 2006 that the creator of Trunki, Rob Law, ventured into the BBC’s Dragons’ Den with his ride-on suitcase concept for globetrotting tots. Ten years on, and with over 2.8 million cases sold, he hasn’t looked back. FOLLOWING AN INFAMOUS “It’s a tremendous APPEARANCE ON BBC’S achievement to have DRAGON’S DEN, CHILDREN’S reached such a momentous RIDE-ON SUITCASE BRAND, milestone; it’s been a 10 TRUNKI, IS A HOUSEHOLD year rollercoaster ride of NAME. THE BRAND IS massive highs and lows. Receiving the first container NOW CELEBRATING ITS of Trunkis at Avonmouth 10TH BIRTHDAY AND OVER docks in 2006 was the start THE LAST DECADE HAS of a very exciting journey and LAUNCHED A RANGE OF CASE a huge learning curve,” Law DESIGNS IN A RAINBOW commented. Wrexham-based OF COLOURS AND STYLES. manufacturer of colour, BP&R SPOKE TO SILVERGATE additive and fragrance PLASTICS – WHICH HAS masterbatches, Silvergate BEEN WORKING WITH TRUNKI Plastics, has been working SINCE DAY ONE-TO FIND with Trunki’s manufacturing OUT THE IMPORTANCE OF facility, Magma Mouldings since day one. As a vibrant, STRENGTHENING BRANDS hardwearing and fun piece of WITH COLOUR. kit, the integrity of the colours used in the mouldings has always been of extreme importance. Silvergate’s Managing Director, Tony Bestall, says during this time the company has “worked tirelessly” to not only develop exact colour specifications, but also provide essential support in pioneering products that satisfy all regulatory and operational requirements for all of Trunki’s component applications. By providing such valuable support, he says a successful working relationship has formed between the two organisations.
Continuing the Jurni
To coincide with its tenth birthday, Trunki is launching a brand new carry case for the next generation of connected travellers. The company’s biggest innovation since the arrival of the original Trunki, Jurni is a sit-on, carry-on suitcase which has a quick access pop-out pod for tech, a seat to rest on and in-line wheels that glide along when travelling through airports. Silvergate has been collaborating with Magma Moulding to provide more muted tones to appeal to an older market and Bestall says he is looking forward to providing the same support for the foreseeable future as it has done thus far. Concluding, Law added: “Looking back, my highlight has to be the people I’ve worked alongside over the years. The teams at Trunki HQ and at our factory Magma Moulding are passionate about making family travel fun. We work with a number of key suppliers who work with us to go the extra mile to make our customers happy. It is this approach that has made us so successful.” WWW.SILVERGATE.CO.UK WWW.TRUNKI.CO.UK
runki The T
Consistent colours and effects
From the outset of the relationship, Bestall explained that the development of new, aesthetically pleasing and innovative colours and effects was an essential aspect of creating a highly attractive and eye-catching product. The ongoing control of colour, batch-to-batch, has been vital to retaining the integrity of the brand and consumer appeal. The delivery of consistent colours and effects for over ten years has been achieved through the use of Silvergate’s computer-controlled production and quality control facilities, which mitigates the risk of any possible drift over time. “Colour masterbatches can be quite complex in composition and are often bespoke for a particular client,” Bestall explained. “By using our industry leading weigh management, we have been able to eradicate the risk of variation. Our reliable system ensures we use on the correct raw materials in the exact quantities for each and every order.”
WWW.BRITISHPLASTICS.CO.UK
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Engineering Passion Luxor Hot Air Dryer. Credit: motan-colortronic
H Q: What are the key characteristics of a hot-air dryer? A: IN THIS EDITION OF MO’S CORNER – OUR REGULAR FEATURE THAT AIMS TO ANSWER COMMONLY ASKED QUESTIONS ABOUT THE MANUFACTURE AND PROCESSING OF PLASTICS – WE LOOK AT THE POSSIBILITIES AND LIMITATIONS OF HOT-AIR DRYERS.
ot-air dryers are suited to preheating and drying non-hygroscopic or slightly hygroscopic plastics. These attractively priced systems use ambient air to dry plastics by carrying the surface moisture away, but without the use of desiccants. Use of ambient air means that drying results will vary depending on prevailing weather conditions. Hot-air dryers operate within an open cycle. Ambient air is drawn through a filter, heated, and then passed through the resin granulate in the drying hopper before being vented to the factory floor. Some dryers feature a changeover valve to allow partial recirculation of the humid air. Drying temperature and airflow rate can be controlled via the heater/blower unit. Hot-air dryers transfer heat via convection. The current relative humidity of the ambient air is a key factor when using hot-air dryers, as it has a direct impact on results. As ambient air is heated, its relative humidity sinks, increasing its moisture holding capacity. At a given drying temperature, the climate-dependent
moisture content of the ambient air and its temperature give rise to different relative humidities and thus to different equilibrium states. This means that the performance of hot-air dryers varies between summer and winter. For example, drying a nylon resin with hot air in the summer can cause the material’s moisture to increase rather than decrease. It is not possible to achieve very low residual moisture with hot-air dryers. It is theoretically possible to increase drying temperature, especially for materials with high initial moisture content; however, there is a risk of thermal damage to the material. Hot-air dryers are also suitable for preheating plastics to keep the thermal feed conditions constant. Often the hot-air dryer is mounted directly on the feed-throat of the processing machine. Preheated resin increases the energy efficiency of the system, improving productivity and reducing power consumption. ASKMO@MOSCORNER.DE
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MACHINERY | NEWS Pictured (Left to Right) Andy Tibbs, Managing Director, Boddingtons Plastics Limited, Karl Miller, Managing Director, Motan Colortronic Limited, Paul Bowles, Operations Director Boddingtons Plastics Limited
DS BROOKES LTD. RENAMED DAVIS-STANDARD LIMITED DS Brookes Ltd., DavisStandard’s UK subsidiary in the West Midlands, is now called DavisStandard Limited. The change is in name only, with Davis-Standard Limited continuing to supply screws and barrels associated with the DS Brookes brand, and will remain Davis-Standard’s key supplier of extrusion systems for the EMEA (Europe, Middle East, Africa) region. This includes support of aftermarket and spare parts activities across all product platforms and heritage brands under the DavisStandard umbrella. “The name change better aligns with Davis-Standard’s corporate uniformity in serving customers worldwide,” said Mark Woodgate, Managing Director of Davis-Standard Limited. “In addition to this development, we are pleased to announce that our facility is Davis-Standard’s European service centre for blown film, servicing the recently acquired Gloucester Engineering product range. As such, we have appointed Jon Bourne as our Service Centre Manager. He comes to us with more than 35 years’ experience with the Gloucester, Battenfeld/Gloucester and Gloenco brands.” WWW.DAVIS-STANDARD.COM
BODDINGTONS MAKES EXTENSIVE INVESTMENT IN MATERIALS HANDLING SOLUTION Injection moulder, Boddingtons Plastics, has installed a complete materials handling solution as part of an extensive investment in its new manufacturing facility. The Kent-based manufacturer, which suppliers to the medical and technical sectors, approached Motan Colortronic Limited to supply and install the system, which includes dryers and chillers. “The six figure investment with Motan Colortronic Limited includes an advanced fully automatic material handling system, complete with energy saving Luxor drying and Reglochill cooling systems,”
TWO NEW DRYERS BRING TWOYEAR REINVESTMENT PROJECT CLOSER TO COMPLETION Injection moulder, Pentagon Plastics, is one step nearer to completing a major reinvestment programme with the installation of two new materials dryers supplied by Summit Systems. The Horsham-based manufactuere placed the order for the new rotor wheel dryers following a year’s successful operation of two similar dryers acquired in January 2015. “The newly acquired dryers form the tail end of a major reinvestment programme which to date has seen investment in excess of £300k over the last two and a half years,” explained Paul Edwards, Managing Director at Pentagon. “We brought our original two Low
Paul Edwards, Managing Director of Pentagon Plastics
Energy Rotor Wheel Dryers because of their energy profile and have been delighted by their performance and the savings that they have provided.” Pentagon Plastics currently hosts nine injection moulding machines WWW.BRITISHPLASTICS.CO.UK
explained Andy Tibbs, Managing Director of Boddingtons Plastics Limited. Tibbs said the company had chosen Motan Colortronic Limited after “extensive market evaluation” for its “class leading products, system solutions and extensive backup and support.” Commenting, Karl Miller, Managing Director of Motan Colortronic Limited, said: “We are very pleased to have been chosen by Boddingtons Plastics Limited as the supplier of material handling equipment and look forward to a successful long term working relationship.” WWW.MOTAN-COLORTRONIC.CO.UK WWW.BODDINGTONS.CO.UK
ranging from 22 tonne to 280 tonne clamp force serving a wide range of industries from medical and aerospace to construction and security. “We are really pleased to support Pentagon with their expansion plans,” commented Simon Woods, Technical Sales Engineer at Summit Systems. “The Low Energy Rotor Wheel Dryers help them save energy as, when moulding stops, they do too. This, and some other energy saving features, save between 35 and 65 percent energy when compared to twin bed desiccant dryers, typically £10,000 per year.” WWW.SUMMITSYSTEMS.CO.UK WWW.PENTAGONPLASTICS.CO.UK
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Engineering Passion comment
The good guide to
injection moulding validation WHEN IT COMES TO PRODUCT QUALITY IN INJECTION MOULDING, MACHINE AND TOOL VALIDATION IS FUNDAMENTAL TO CREATING A STABLE MANUFACTURING PROCESS AND DE-RISKING THE PROJECT. YET, IT’S OFTEN BUREAUCRACY RATHER THAN METHODOLOGY THAT DRIVES COMPANIES TO VALIDATE. JAMES HINES, PROCESS AND TRAINING ENGINEER AT SUMITOMO (SHI) DEMAG GOES BACK TO THE BASICS OF WHY WE VALIDATE AND WHY THIS COMPLEX PROCESS SHOULDN’T BE JUST REGARDED AS A TICK-BOX EXERCISE TO GET THE FDA OR OTHER REGULATORY BODIES OFF YOUR BACK.
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ast year the European Commission issued its first update since 2001, causing more confusion. The new version of Annex 15 now requires manufacturers to ensure that “critical aspects” of their operation are validated throughout the product lifecycle. This includes any changes that could impact a product’s quality. Effective 1st October 2015, the amendment to EurdraLex Volume 4, Annex 15: Qualification and Validation closely mirror the FDA’s (U.S. Food and Drug Administration) lifecycle approach. There’s also a greater emphasis on risk management to reflect today’s manufacturing and regulatory environment. So, how do these changes impact manufacturers? Like before, there are three key phases to process validation, only now the FDA categorises them as Process Design, Process Qualification and Continued Process Verification. These reflect the focus on the manufacturing lifecycle and the need to provide scientifically sound data to verify that your injection moulding processes start and continue to remain stable.
Why validate? Going back to the basics of why validation exists, it’s to ensure that injection moulders have a stable and dimensionally centred process that consistently produces high quality products. Validation is basically providing the scientific evidence that the machine and tool is repeatedly doing everything you expect it to do, every minute of every day. For any plastics manufacturer, zero defects remain the target. In the medical industry, for example, there’s no wiggle room. You can’t shift the parameters to suit. If you’re producing a medical device or a sterile implant, nothing less than 100 percent quality is acceptable. The validation process requires a step-by-step approach, working with each customer to break down each element of each injection moulding cycle and documenting every stage. Conducted by an engineer, the actual validation usually takes longer than actually building the tool itself. For this reason, the validation is often partially completed at the toolmakers’ facility by a
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For plastics manufacturers zero defects is the target
senior engineer from the company as this allows issues to be addressed there and then on site, rather than shipping the tool back and forth. Ultimately, the final phases of the validation will be completed in-house on the specified equipment.
Breaking down each validation phase At the Process Design stage you are looking to see if you have the proper sized machine - shot size and tonnage - and that the equipment is properly calibrated. During the Process Qualification phase, you will move on to establish the range of process parameters. This involves conducting a selection of statistical and dimensional studies, enabling you to identify and investigate any deviations in the process. A process is not considered as validated if the variations have negatively impacted the finished product in any way. The final validation phase - Continued Process Verification - focuses on demonstrating that your process is consistently stable. It involves simulating different production runs using the same production equipment and the processes that you will be routinely using, ensuring repeatability of the set-up conditions throughout the machine’s full lifecycle. In accordance with ISO 13485 standards, ongoing documentation of the injection moulding process needs to be maintained. This is a continuous process, which is a significant change under the new directive. From time to time, machine settings may have to be adjusted to compensate for changes in the environment or to address moulding issues, such as pulling, distortion, or aesthetic defects. The key areas that might impact
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a stable process include changes in pressure, temperature, flow rate and cooling rates, any of which may trigger a re-validation exercise. Major repairs, changes, or improvements to the mould tool may require changes in the set up, and this would mean re-validating the process. This is also true of the moulding machines. Significant repairs or machine exchanges, if not carefully managed and controlled, may trigger a full validation of the process, which takes time and costs the moulder more money.
Other considerations Before you start validating, it is vital to be clear on your expectations. If it’s to provide a documented source of evidence to satisfy a regulatory body, you need to do it. But that shouldn’t be your sole motivation. Validation is not purely about procedures and scrambling to put the correct documentation in place. The objective of having an efficient process and repeatable high product quality should never be overlooked, as this is ultimately how you can avoid costly product recalls and cosmetic product defects.
“Although not a prerequisite for the automotive and packaging sector, validation can be good business practice for a large number of mass manufacturers of injection-moulded components. Think of it as a long-term investment.”
From a business perspective, validation will also address profit-driven challenges and design out production weaknesses. Functional tests can help operatives better understand what drives the machine, how fast it goes and the consequences if manufacturing procedures are not correctly followed. In some instances, ramping up to a faster cycle time won’t always be the most optimised process. Although not a prerequisite for the automotive and packaging sector, validation can be good business practice for a large number of mass manufacturers of injection-moulded components. Think of it as a longterm investment. Essentially, it’s a risk assessment which, when executed professionally, can deliver efficiency gains and save your business time, money and resources by ensuring product integrity and reducing scrap volumes. UK.SUMITOMO-SHI-DEMAG.EU/
Conducted by an engineer, validation breaks down each element of the injection moulding process.
Validation is the scientific evidence that the IM machine and tool is repeatedly doing what’s expected
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GREEN LIGHT FOR ENERGY SAVINGS – WITH ADVANCED TEMPERATURE CONTROL SOLUTIONS ICS COOL ENERGY’S COMPREHENSIVE TOTAL SOLUTIONS APPROACH IS UNSURPASSED, BRINGING BESPOKE SOLUTIONS FOR BUSINESSES TO DELIVER PRECISE TEMPERATURE CONTROL WITH ENERGY EFFICIENCY AND OPTIMUM PERFORMANCE FOR MANUFACTURERS IN A WIDE RANGE OF INDUSTRIES, WITH LONG ESTABLISHED EXPERTISE IN PLASTICS AND RUBBER PROCESSES.
We know we can trust ICS “Cool Energy and although
it’s difficult to get a precise handle on energy savings, £20,000 a year is realistic. They also helped us obtain a full interest-free loan from the Carbon Trust. It’s a fully rounded business solution, Eddie Rath, Managing Director, Primepac
“
NEW – ADVANCED TEMPERATURE CONTROLS Free cooling is the natural way to save money and energy by using the freely available cool air common in northern Europe to cool process water, without needing chiller power. It cuts electricity and energy costs which also lowers the business carbon emissions. • • •
Up to 70% lower energy costs Longer chiller life Short paybacks for systems, as little as one year
SOLUTIONS ON CALL ICS Cool Energy is a leading international temperature control specialist providing total equipment, service, hire and emergency support for all types of manufacturing businesses. With a heritage of nearly 30 years’, understanding and meeting the demands of consistent close temperature control for managers in plastics and rubber processing and manufacturing is a speciality.
A green light demonstrates when the free cooling is working at PrimePac.
ENERGY AND SAVINGS – WITH ADVANCED PERFORMANCE PrimePac is a busy and successful plastics manufacturer supplying packaging products for leading international household brands found in thousands of national retailers such as Sainsbury’s, Tesco, Boots and B&Q. The Northern Ireland-based manufacturer now has a new temperature control solution, with higher performance plus an estimated £20,000 a year in energy savings. The ‘A’ rated Aptus chiller together with a free cooling unit was installed as part of a 25% production capacity expansion for the production which operates 24/7 during the working week. “We’ve had a good working relationship with them for about 25 years and trust their expertise. The recommendation was a free cooling option as it offers us what we need,” said Eddie Rath, PrimePac’s Managing Director. The free cooling system starts operating when the ambient temperature reaches 12°C or lower and is especially hardworking and efficient in cooler climates. In the first full year it has operated for over 4,600 hours - 55% of the total cooling system’s working hours, giving energy savings and fewer compressor operating hours, extending the life of the chiller. There were extra financial benefits by identifying and assisting with the application for a full interest-free loan of £80,000 from the Carbon Trust Northern Ireland. Financial assistance: ask us about available funding schemes as these vary according to location.
CONTACT US NOW 0800 774 7415 or email us: info@icscoolenergy.com THE TEMPERATURE CONTROL SPECIALISTS. SALES. HI RE. SERVICE.
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RECLAMATION & RECYCLING | NEWS Waste PVC-U profiles (61,866 tonnes) comprised more than half of the UK’s recycling achievement in 2015, with pipes, rigid and flexible PVC films and cables making up the rest.
UK’S RECYCLING RATES FOR PVC HIT RECORD-BREAKING NEW LEVELS The UK contributed 21 percent - or 107,593 tonnes – to the total recycled through Recovinyl, the PVC industry’s recycling scheme, in 2015. This represents an increase of 13 percent compared to the previous year (2014: 95,525) and represents the equivalent of nearly 4.3 million PVC-U windows or 426,662 houses (assuming each house has 10 windows). A total of 508,154 tonnes of waste PVC was recycled through Recovinyl last year across its 16 European member countries. The Recovinyl network currently comprises 163 companies. Recovinyl is an operational arm of VinylPlus, the European PVC industry sustainable development programme, which is tackling the sustainability challenges for PVC and delivery of current recycling targets to 2020. Waste PVC-U profiles (61,866 tonnes) comprised more than half of the UK’s recycling achievement in 2015, with pipes, rigid and flexible PVC films and cables making up the rest. “The recycling of PVC continues to grow in line with continued
investment in recycling infrastructure throughout the country and robust commitment from the sector. It’s a remarkable achievement that demonstrates the sustainability of this readily-recyclable material,” explained Project Manager Jane Gardner of Axion Consulting, Recovinyl’s UK agents. Growing demand from manufacturers for good quality recycled material is a key factor behind the recycling success, says Recovinyl. PVC can be recycled up to seven times without any loss of performance and can be reused in many diverse new products, from construction products such as windows, to flooring and electrical
components – or even goalposts. Having already established significant volumes of PVC recycling with Vinyl 2010, Recovinyl’s strategy continues with consolidating and increasing the steady supply of PVC waste being recycled in Europe by creating demand – a ‘pull-market’ for recycled PVC material - from the converting industry. One of the objectives of the VinylPlus Voluntary Commitment is to recycle 800,000 tonnes of PVC waste per year by 2020, including 100,000 tonnes of difficult-to-recycle PVC through innovative recycling technologies. WWW.RECOVINYL.COM
The Gloucestershire-based company supplies a broad range of commodity and engineering polymers for all primary manufacturing processes and applications across a number of industries. “I have known Philip Tyler Polymers for many years and am thrilled to be joining such a well established and respected company,” said Porter upon his appointment. “I look forward to playing a key role in its future growth and development.”
PHILIP TYLER POLYMERS LTD APPOINTS NEW ASSOCIATE DIRECTOR Plastics recycling industry specialist, Philip Tyler Polymers Ltd., has announced the appointment of Ian Porter to its commercial team as an Associate Director. The company says this represents a key element of a strategic plan to deliver growth and to enhance its position in the plastics recycling sector. “Whilst Ian clearly has considerable commercial plastic recycling experience, it is his integrity and strong reputation which made him the stand-out candidate,” explained Philip Tyler Polymers’ MD, Roger Baynham.
WWW.PHILIPTYLERPOLYMERS. CO.UK ciate er, Asso yler T Ian Port ip r at Phil Directo . d t L Polymers WWW.BRITISHPLASTICS.CO.UK
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28 SEPT - 29 SEPT 2016
REGISTER NOW
BPI has been awarded Zero Waste to Landfill’ certification
BPI RECYCLED PRODUCTS’ SITES ACHIEVE ZERO WASTE TO LANDFILL BPI Recycled Products, the UK’s largest producer of refuse sacks and the largest polythene recycler in Europe, has achieved ‘Zero Waste to Landfill’ certification at three of its manufacturing sites across the UK. The sites that were awarded the Valpak certification following an independent assessment and audit were Heanor, Rhymney and Stroud. BPI Recycled Products’ manufacturing sites gained ISO 14001:2004 accreditation for environmental management, with each site putting controls in place to reduce the amount of waste they were generating. This was done via three methods: staff training, raising the profile of waste management on site, and increasing the segregation of waste. “We are delighted to have now achieved Zero Waste to Landfill certification from Valpak at three of our manufacturing sites and this achievement recognises our ongoing commitment to waste
management whilst demonstrating our environmental credentials to our customers,” said Daryl Winder, IMS Compliance Manager of BPI Recycled Products. “We believe that we can now claim to be one of a very small few, if not the only company in the UK that produces a finished product from recycled material with zero waste to landfill from the process.” A company can be awarded Zero Waste to Landfill certification when it sends zero waste to landfill (including production, hazardous and
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packaging waste); sends a limited amount of waste to energy from waste (EfW); and shows commitment to continual improvement – waste reduction and diversion. BPI Recycled Products supplies over 270,000 tonnes of material each year for a wide variety of everyday applications. The company also receives 50,000 tonnes of scrap polythene per year and recycles it into finished goods. WWW.BPIPOLY.COM
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MEDICAL PVC TAKE-BACK SCHEME NOW OPERATIONAL IN SEVEN UK HOSPITALS A take-back scheme for the recycling of non-infectious PVC medical items is now operational in seven hospitals across the UK. The ReocMed scheme, which has been running since early 2014, has recycled over 830 kg of PVC waste as of March this year. RecoMed was established when VinylPlus, the voluntary sustainable development programme of the European PVC industry, commissioned UK-based resource efficiency specialists, Axion Consulting, and the British Plastics Federation (BPF), to develop a collection scheme to capture some of the estimated 2,250 tonnes of PVC waste from the UK’s hospitals each year. Items collected include IV solution bags; nasal cannulas; oxygen tubes; anaesthetic masks and oxygen masks. By collecting these items, the scheme helps avoid certain medical devices unnecessarily ending up in clinical waste, which would otherwise be sent for incineration. Instead these items are recycled into products for the horticultural industry, such as tree ties, promoting a circular economy and reducing waste in the medical sector.
The RecoMed scheme is now operational in seven hospitals and has recycled over 830kg of PVC waste
“RecoMed is growing and we’re expecting more hospitals to join the scheme in 2016. It is estimated that up to 2,250 tonnes of PVC could be recycled by collecting these items alone from 150 hospitals in the UK, enabling them to save money on their waste disposal costs and increase recycling rates,” explained Jane Gardner of Axion Consulting.
The scheme has now produced a promotional video explaining what it involves and how it is implemented, which can be viewed by accessing the web address below.
CELEBRITIES DRESSED IN RECYCLED PLASTIC TURN HEADS ON RED CARPET
It was designed and manufactured by Calvin Klein along with Eco Age, a sustainability brand. Every element of Watson’s look was reportedly considered from an ethical and aesthetic perspective, including smaller details such as the zips, also manufactured from recycled plastic. Watson said that she was “proud to say” her clothes were “truly sustainable.” Other famous faces championing the same cause were Lupita Nyong’o and Margot Robbie.
Dresses made from recycled plastic bottles and fabrics have put sustainability in the spotlight at a high-profile event in New York. Actress Emma Watson, star of the Harry Potter films, wore a dress made from ‘Newlife’ fabric, a unique yarn engineered from used plastic bottles sourced, processed and spun into yarns in Italy. The actress wore the dress to the MetGala, an annual fundraising event which took place on May 2nd. outfit son in an Emma Wat plastic d le yc g rec made usin a m mage: Em bottles. I k o o eb ac Watson/F
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WWW.BPF.CO.UK/RECOMED
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BUYER’S GUIDE
PL Machinery BG 2015_Layout 1 2
MATERIALS
DEHUMIDIFIERS
Whatever your ancillary needs – we have the solution
MASTERBATCH
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
HEATING EQUIPMENT
BLACK & WHITE MASTERBATCH Compounding
Recycling
Moulding
Film
Pipe
Conduit
Whitelands Mill, Whitelands Road Ashton-under-Lyne, OL6 6UG, UK Tel: +44 (0)161 308 2550 Fax: +44 (0)161 343 2026 E-mail: aml@abbeymb.com Web: www.abbeymb.com
Telephone: 01582 883666 Email: sales@plmachinery.com Web: www.plmachinery.com
MOULD RELEASE
ASSEMBLY hot plate welding Branson Ultrasonics
158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu
induction heating for platens and tools
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
Accurate colour systems for the PVC and additives industries t: +44(0)1942 254006 e: sales@astropol.uk.com www.astropol.uk.com
ultrasonic welding
MF Induction Heating
CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd
T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.
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
HOT RUNNER SYSTEMS hot runner controllers
DRYERS Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
MACHINERY & EQUIPMENT colour masterbatch
ANCILLARIES
InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)
New and used Granulators, Shredders, Pulverisers, Wash Plants Blades and Screens Blade Sharpening Ancillary Items Service – Repair - Spares UK & Ireland Agents for
Call: 0161 624 2114
Tel: 01827 838840
Email: sales@colourmaster.co.uk Eclipse Buyers Guide_Layout 1 07 Email: info@granulators.org www.granulators.org www.colourmaster.co.uk
BG Advert buyers guide.indd 1 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.
PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk
MATERIALS HANDLING AND STORAGE gravimetric/volumetric blending Motan Colortronic Ltd
Telsonic UK 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
12a - 15 Birch Copse Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: info.uk@telsonic.com W: www.telsonic.co.uk Blog: telsonicuk.wordpress.com
for sale
vibration welding Branson Ultrasonics
158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 21/01/2015 16:42 E: bucuk.sales@emerson.com W: www.bransoneurope.eu
DRYER HIRE Hire from one month Monthly rolling contract Opportunity to purchase
CHILLERS/TEMPERATURE CONTROLLERS Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
Range of models Preventative Maintenance Visits
We buy/sell
prime, reprocessed, regranulated PVC compounds, dry blends, pulverised, scrap flexible PVC, PVC resin and associated raw materials. Please send us your offers/enquiries.
vinyl_ltd@mail.com vinyl_ltd
We can offer prime PVC compounding facilities to cover your specific requirements, bespoke compounds, breakdowns, holiday cover etc. Please telephone to discuss.
Vinyl Ltd Tel: 01625 500912 Mobile: 07860371294
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BUYER’S GUIDE SCREWS & BARRELS
MACHINERY & EQUIPMENT LABORATORY MACHINES
Magnetics Separators Metal Detectors Eddy Current Separators
Bunting Magnetics Europe Ltd European Design & Manufacturing Facility
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
TRAINING
Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co
/magnetic_separation_and_metal_detection/
Contact: Carlton Hicks
NOZZLES & NOZZLE TIPS Engineers to the Plastics & Rubber industries, specialising in the following: Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd
MATERIALS HANDLING AND STORAGE hopper loaders
PRINTING MACHINES pad
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
thermocouples
SECONDHAND AND RECONDITIONED
3D PRINTING
3D Printing FOR SALE
in Plastic & Rubber
BILL CARRINGTON
Regular quantity of Nylon/Polyester mixed fibre based in bales of 300400 kilos per bale. Contact 01253 736963
Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
STATIC CONTROL
Tel: 01420 88645
www.projet3d.co.uk
SERVICES MOULDFLOW ANALYSIS
Arrowquint Ltd
Unit 2 Sanders Close, Finedon Road Industrial Estate, Wellingborough, Northamptonshire NN8 4HQ T: 08450 655455 F: 08450 655456 E: sales@arrowquint.co.uk W: www.arrowquint.co.uk Static control solutions, equipment sales and rental, repairs and on-site servicing. UK/Eire agent for Eltex – market leaders in static control systems.
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
RECYCLING SYSTEMS EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
MIXING, FEEDING & DOSING Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
METAL DETECTION & SEPARATION EQUIPMENT Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
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Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at
CHOOSE THE NUMBER ONE.
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.
SCREEN CHANGERS Industrial Plastics Ltd
DM Machinery Ltd
Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk
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
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
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
WWW.BRITISHPLASTICS.CO.UK
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
BUYER’S GUIDE
SERVICES SOFTWARE
PRINTERS
Gammadot Rheology Testing & Consultancy Services
printers of plastic mouldings Total Print Ltd
Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry
PARTS & SERVICE
TESTINg/CONSULTANCY
Component PRINTERS
Unit 5C, Leaton Industrial Estate, Bomere Heath, Shrewsbury, Shropshire, SY4 3AP T: 01939 291677 E: enquiries@gammadot.com W: www.gammadot.com Providing independant testing solutions to all your quality control, failure analysis & flow simulation data needs
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
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
SOFTWARE DIRECTORY A listing in the Software Directory costs £160 per programme per year. Call Lisa on 01244 680222 for details. real time production monitoring, scheduling and process monitoring Epicor Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Modules: Production Monitoring, Process Monitoring, “Drag and Drop” Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts’ Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/Public Address System Alerts, Stand-alone “Drag and Drop” Scheduler, Stand-alone SPC “Machine Analyzer”, Machine Energy Monitoring, KPI Dashboards, Visual Manufacturing (Large LED Displays), Automatic Data Import/Export Functions (For Integration with Epicor ERP & Other Manufacturing Systems/Software Packages). PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/ SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy
Monitoring, Bar Coding, Pager Alerts. Easy to use systems from a €600m company with over 30 years experience. intouch T: 01604 646144 E: enquiries@ intouchmonitoring.com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages. ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/ Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages). SYSCON – PlantStar Tel: +44 (0)7747 014545 E: ianh@syscon-intl.com W: www.mtec-services.co.uk W: www.plantstar.org
PlantStar systems provide customised, scalable applications that deliver real-time plant floor data from any machine, shift, and plant anywhere in your business. Affordable systems available for all size of processor. Browserbased software and hardware, and wireless Ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include realtime alarms, downtime & reject analysis, capacity scheduling , ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Materials traceability, barcoding. New QuickShot entry level system, provides real-time data collection & reporting, plus drag & drop scheduling and much more for less than £500 per machine!
enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Epicor ERP software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, warehousing and distribution. Available on-site, hosted & SaaS it seamlessly integrates with Epicor Mattec Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.
WWW.BRITISHPLASTICS.CO.UK
Process Optimisation Software RJG Technologies UK Ltd t/a G&A Moulding Technology T: +44 (0)1733 232211 E info@gamt.co.uk Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.
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NEWS FROM THE FRONTLINE
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bp&r BRITISH PLASTICS &RUBBER 50
days. The feedback from exhibitors was exceptionally positive, with companies praising the quality of the visitors to their stands as well as the location of the British Pavilion, which was in Hall W1, right by the main entrance to the show. UK exhibitors saw people from India, Chile, Indonesia, Thailand, Iran, Malaysia, South Africa, Venezuela and Japan amongst others in attendance, and commented on a “a distinct improvement” in the quality of visitors, specifically in the last two years. Morgan Jones, of MSA Engineering told me that having exhibited at Chinaplas since the early 2000s, this year’s edition was “definitely busier” than the last and that there are “clear signs” that the Chinese market is picking up. He also said that there was a “high chance” that the company will get an order as a result of the show. The fair was bursting with energy and UK companies there said they were working with many successful companies in China. Whilst the headline figures for the economic performance of the whole Chinese economy have met with disappointment by financial specialists, it is clearly the case that some customer subsectors are performing well. WWW.BPF.CO.UK
ASSOCIATED ORGANISATIONS
ate April saw the BPF exhibiting at Chinaplas in Shanghai. We’ve had pretty much an unbroken record of attending Chinaplas since the 1990’s when Beijing was included in the IN THIS MONTH’S EDITION cycle alongside Guangzhou OF HIS REGULAR COLUMN, and Shanghai. Back then, Chinese trade PHILIP LAW, DIRECTORfair centres were crude GENERAL OF THE BRITISH and facilities rudimentary. PLASTICS FEDERATION Potential Chinese customers (BPF), GIVES HIS OWN TAKE were as keen to acquire ON CHINAPLAS FROM BOTH any form of coloured print AN EXHIBITOR’S AND A – magazines, pictures – as BUSINESS PERSPECTIVE. they were the equipment and materials on offer. But now the show grounds have been upgraded and their setting – certainly in Shanghai – illustrates the growing interest of the Shanghai urban planners in environmental improvements. Trees abound, as do electric motorcycles, but you only hear them coming when it’s almost too late! UK Trade and Investment once again supported the BPF co-ordinated British pavilion, with most companies claiming a £2,500 Trade Access Programme (TAP) Grant. TAP funding is increasingly hard to obtain and we are constantly fighting a rearguard action to keep the funds flowing. Our stand was made up of some fine veteran exporting companies many of whom already had a strong Chinese presence. Demand on space at Chinaplas is typically huge and normally sells out around six months prior to the event taking place. This year there was a massive waiting list. Consequently, the BPF stand is constantly growing. In 2012 it occupied 170 square metres but this year it had expanded to 221 square metres. This was in a show which, overall, broke records, both in terms of visitor numbers and exhibitors. As mentioned in the Chinaplas review in this issue of BP&R, there was over 3,300 exhibitors (up five percent from the previous year) and they were spread over 240,000 square metres. In total the show attracted nearly 150,000 visitors over the four
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