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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 Assistant Editor: John Carlon T: +44(0)1244 680222 E: john.carlon@rapidnews.com
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duncan wood T: +44(0)1244 680222 E: duncan@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rate: UK, Europe and rest of the world £249 British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2017 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.
ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.
A manifesto for manufacturing
A
s I write this, the snap general election called by Theresa May is just three weeks away. Indeed, last night saw the first live televised leaders’ debate (albeit minus the Labour and Conservative candidates) and the past week has seen the publication of the major party manifestos. However, there is one manifesto that the EEF is urging all the candidates to focus on, and that is the one it has published urging all parties to put manufacturing at the front and centre of their plans. The organisation believes that by making manufacturing a priority, a new Government will install confidence in the industry in the wake of the complex process of leaving the EU. EEF, along with BPF, both outlined their hopes that the snap election will bring stability in an increasingly unstable world for Britain’s manufacturers. You can read more on page 8. Speaking of the world, delegates from 43 countries put Britain on the map at the end of April when they gathered in Brighton for the triennial ‘PVC’ conference. With a record 526 attendees, the three-day event attracted interest from the global PVC community, with visitors coming from as far afield as Japan, China, Brazil and Australia - and with good reason.
The conference is a flagship event that provides a comprehensive insight into the latest advances, developments, opportunities and challenges relating to PVC and, regardless of nationality, there was certainly a shared sense of achievement felt by all when it came to the latest figures highlighting how much progress has been made. You can read our full roundup on page 19.
EEF, along with BPF, both outlined their hopes that the snap election will bring stability in an increasingly unstable world for Britain’s manufacturers
Enjoy the issue.
Leanne Taylor, Group Editor
bp&r
THE BIG STORY Electric solutions with servo hydraulics:
HOW UK MOULDERS CAN HARVEST THE BENEFITS
H
aitian, the world’s largest moulding machine manufacturer, reported a “marked increase” in demand for all-electric technology in the UK in AS PRODUCTIVITY AND 2016. It’s KEEPING COSTS TO A ‘Venus II’ series MINIMUM REMAIN KEY and electric PRIORITIES FOR THE UK’S ‘Zeres’ series MANUFACTURERS, PREMIER accounted for over 40 percent MOULDING MACHINERY of sales from (PMM), DISTRIBUTOR customers in OF HAITIAN AND ZHAFIR the medical INJECTION MOULDING and automotive MACHINES, SAYS THAT THE sectors; both of which require BENEFITS OFFERED BY high precision INVESTING IN ELECTRIC and control. SOLUTIONS WITH SERVO So what is HYDRAULICS CAN PROVIDE driving this THE IDEAL SOLUTION. growth? Richard Hird, Sales Director at PMM, believes it is down to a combination of competitive pricing as well as targeted solutions for specific applications. “The Haitian philosophy is ‘Technology to the point’, which means we strive to provide highly engineered,
Haitian, the world’s largest moulding machine manufacturer, reported a “marked increase” in demand for all-electric technology in the UK in 2016
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It is 12 months since Haitian Germany opened its European Centre of Competence at its headquarters in Ebermannsdorf
energy efficient products for the right applications,” Hird told BP&R. “The Zeres Series machines provide electric solutions with fully integrated servo hydraulics, enabling complex moulding applications to be performed. This offers advantages in areas traditionally associated with hydraulic machines and covers a range of applications including an optical thin wall and precision parts.” The machines, which range from 40-1350t, are designed for high technical control and precision for electrical components or high end technical moulding. Available with high speed injection up to 350mm/s for high performance injection, the servo electric drives offer high precision and accuracy for a repeatable moulding process. The hydraulic system includes ejector and nozzle movements and core pulls mounted directly on the moving platen.
Harvesting the benefits
Continuing Haitian’s theme of naming its machines after planets, Zeres (Ceres) is named after a dwarf planet between Mars and Jupiter, which is turn is named after the Roman goddess of harvests. Hird believes investing in a Zeres Series machine can help moulders “harvest the rewards” from their investment, through not only lower capital investment, but through energy efficiency and running costs. “These machines can really help moulders gain maximum return on investment,” Hird explained. “The energy savings of a Zeres Series machine, of up to 70 percent is an obvious example of this, but also the added flexibility of the hydraulics, which enable a faster running machine to deliver lower cost parts is another. When you also factor in running cost reduction, as well as an improvement in uptime efficiency leading to reduced hourly rate, you can start to see why these machines are gaining popularity so quickly. These developments are allowing more and more customers to enter the all-electric
WWW.BRITISHPLASTICS.CO.UK
arena and gain the benefits of running these machines.”
European Investment
It is 12 months since Haitian Germany opened its European Centre of Competence at its headquarters in Ebermannsdorf. The new facility, which features a hall with 7,500 square metres of production area, enables full European product assembly, ex stock machines, product testing, after sales support and spare parts for the Haitian and Zhafir brands. Hird says service and support is a key aspect of its offering, with the investment in the new site in Germany an example of the dedication to its European customers. A team of 170 Sales and Service Engineers are supporting Haitian’s growing customer base throughout Europe. “We have ex-stock machines available in Europe; a third of which are all-electric Zeres machines,” said Hird. “In addition, we offer a highly competitive three year warranty on all our injection moulding machines and full UK service and spares support backed by Haitian international Germany where our UK engineers are trained.”
Invitation to Interplas
Following the success of the Haitian and Zhafir machines in the UK last year, PMM made the decision to double the size of its stand at the upcoming Interplas trade show, being held on 26th – 28th September at the NEC Birmingham, UK. This decision, says Hird, is to “showcase how Haitian International innovation in partnership can make money for its customers.” He added: “Our future projections show that given the price advantage of Zhafir electric machines, many of our customers are switching from standard hydraulic machines to the Zeres Series because of the increased productivity and reduction in the cost of ownership. We want to be able to demonstrate, explain and highlight this and Interplas offers the ideal environment. We look forward to welcoming visitors to our stand.” A Zeres Series injection moulding machine with a Sepro robot will be fully working on the stand (H60/Hall 4). WWW.HAITIAN.CO.UK
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bp&r BRITISH
contents
PLASTICS &RUBBER
MAY/JUNE 2017
on the cover ELECTRIC SOLUTIONS WITH SERVO HYDRAULICS: HOW UK MOULDERS CAN HARVEST THE BENEFITS As productivity and keeping costs to a minimum remain key priorities for the UK’s manufacturers, Premier Moulding Machinery (PMM), distributor of Haitian and Zhafir injection moulding machines, says that the benefits offered by investing in electric solutions with servo hydraulics can provide the ideal solution. SEE PAGE 4
Tony Bestall, Director of Silvergate Plastics, looks at how, by following strict quality controls and procedures, colour variation in a plastic product can be minimised, meaning a more efficient and cost effective manufacturing process can be achieved.
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Chris Lines, Managing Director of Dyne Technology, explains how developments in the capabilities of plasma surface treatment technology has seen it become the method of choice for bonding ‘non-stick’ polymers.
FEATURE PVC 2017: “No longer the black sheep of the plastics family” With recycling rates reaching a new high, industry initiatives commended by leaders from business and Government and patent applications showcasing new heights of innovation, PVC proved itself as no longer the “black sheep” of the wider plastics industry, but a trailblazer. BP&R reports from an actionpacked three days in Brighton.
REGULARS
INDUSTRY NEWS 08 13 interplas MACHINERY 21 SURFACE FINISH, ADHESION AND BONDING 30 3D PRINTING 33 MATERIALS 37 FILM AND SHEET 41 RECLaMATION AND RECYCLING 45 BUYERS’ GUIDE 47 SOFTWARE 49 NEWS FROM THE FRONTLINE 50
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FEATURE The Plasma Treatment Revolution
Editor’s Letter A manifesto for manufacturing
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FEATURE Understanding Colour Variation and How It Occurs
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FEATURE polymerman on prices As styrene-based polymers react to market fundamentals, what is likely to happen with other polymers? In this edition of our latest feature looking at the key issues that influence polymer prices, Mike Boswell assesses how the markets are reacting to a diverse range of factors, from oil prices and shale gas availability to the UK’s snap general election.
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General Election: Industry welcomes call for stability WORDS | Leanne Taylor
T
heresa May made the announcement during a speech outside 10 Downing Street on April 18, where she said that calling an election would bring unity in Westminster and THE DECISION BY THE end the “political PRIME MINISTER TO game playing” that could risk the CALL A SNAP GENERAL ability to make a ELECTION TO BE HELD success of Brexit ON JUNE 8 HAS BEEN during the upcoming WELCOMED BY THE period of difficult UK PLASTICS AND negotiations. Philip Law, MANUFACTURING Director-General of INDUSTRIES IN THE HOPE the British Plastics IT WILL BRING STABILITY Federation (BPF), TO BUSINESS. told British Plastics and Rubber: “Clearly this is motivated by Brexit. If the outcome of this election increases certainty for businesses in the UK, then it is to be welcomed. The worst scenario would be an equivocal result that muddies the waters.” Ms. May said that she had “recently and reluctantly” come to the conclusion that a general election was needed before 2020, adding that she felt it is “the only way to guarantee certainty and stability” for the years ahead. The decision by the Prime Minister to call a snap general election to be held on June 8 has been welcomed by the UK plastics and manufacturing industries in the hope it will bring stability to business.
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Terry Scuoler, Chief Executive of EEF, the manufacturers’ organisation, welcomed the decision by the Prime Minister to seek a clear mandate. “The last year has been one of considerable uncertainty which, if it had gone on unchecked, would have risked hampering future investment,” he commented. “We have significant negotiations to undertake with our partners in the rest of Europe and, doing this with a fresh and stable mandate from the country can only provide greater certainty about the future direction of travel for policy, and the potential to seek the best deal possible for the UK.” The EEF has urged political candidates from across all parties to focus on Britain’s Industrial Strategy in order to put manufacturing industry at the centre of any new Government’s vision. It recently released its own ‘manifesto’, entitled ‘Making the Future, making Britain Great’, within which it identifies ways for the new Government to make manufacturing more productive, including expanding tax credits for research and development, investment in teacher recruitment, and removing business rates tax on machinery. “Leaving the EU is an opportunity for a new Government to ensure the foundations of a comprehensive and ambitious industrial strategy are fully embedded. That means putting the delivery of that strategy at the very centre of Government and making [sure] all departments are accountable. This is not a revolutionary concept. Many successful economies have done this for decades and are reaping the benefits. The UK must do the same,” Scuoler added. The Prime Minister said that the General Election was an opportunity for opposition politicians that have so far objected to the Government’s plans for Brexit to “show [they] mean it” and that they are not doing it “for the sake of it”. She added that the upcoming vote was about leadership, and it was for the people to decide who they wanted to steer the UK through its exit from the European Union. Kevin Horne, Managing Director of Renmar Plastics Machinery, told BP&R: Some might say it is a brave move, other may say foolish, but I think the country has accepted the Brexit situation and I hope Ms. May will get the backing she deserves to push on through with it.” We will be covering the election result, and what it means for the UK plastics industry, in the next issue of BP&R.
“If the outcome of this election increases certainty for businesses in the UK, then it is to be welcomed. The worst scenario would be an equivocal result that muddies the waters,” – Philip Law
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INDUSTRY | NEWS THE SHORTLISTED PRODUCTS AND THEIR DESIGNERS ARE AS FOLLOWS:
TRAINS, PLANES AND AUTOMOBILES INSPIRE STUDENTS’ PLASTIC PRODUCT DESIGNS Six talented university students specialising in product and designrelated subjects have come up with new ways of making travel easier. Their products have been shortlisted as potential winners of this year’s 2017 Design Innovation in Plastics (DIP) competition, the longest-running student plastic design award in Europe. The competition brief, ‘Products for Independent Travel’, challenged students to design an innovative product, primarily in plastic, that will provide a more comfortable and less stressful travel experience. The six finalists were chosen from 166 entries by a panel of judges from across the plastics and design industries. The shortlisted products include an interactive sunshade for children; a face mask that counteracts the effects of jet lag; and a wristband designed to prevent sun burn by reminding the wearer to apply sun protection. “We were most impressed with both the inventiveness and creativity of the finalists as well as the approach they took. It made judging challenging but ultimately very satisfying,” commented Richard Brown, Chairman of the judging panel. The successful students were
Ellen Britton, Product Design Engineering, Glasgow School of Art: ‘Peek’ interactive travel
The judges in action
offered feedback as to how they could refine their original designs before being asked to present them at a final selection day on May 19. The overall winner was decided and the result will be announced at a ceremony in London on June 30. Mike Stuart, Deisgn Engineer at competition sponsor, Covestro, said: “The finalists have clearly thought through their designs and shown that they are familiar with their market. One or two ideas were clever in their simplicity, and just need developing a little further, and in one case where an idea was not in itself totally new, the student has found a new application which has made it novel, and helps satisfy the competition criteria.” Organised by the Institute of Materials, Minerals and Mining and the Worshipful Company of Horners, the awards are supported by several industry sponsors offering winning students placements, guidance and opportunities to further their potential within the plastics industry.
sunshade for entertaining bored and restless children. Kayleigh Dobson, Product Design, University of Central Lancashire: ‘AirBaby’ portable,
inflatable lap seat.
Russell Kilgour, Product Design Engineering, Glasgow School of Art: ‘Nomad’ travel camera bag.
Aidan Smith, Design for Industry, Northumbria University: ‘Pedlock’ bicycle pedal with integral lock. Monique Spoerri, Product & Furniture Design, De Montfort University: ‘Light therapy face
mask’ that counteracts the effects of jet lag. Dom Tindale, Design for Industry, Northumbria University: ‘Skin Watch’, a
wristband that reminds travellers to reapply sun cream to prevent sun burn. An exclusive interview with the winner will appear in the next edition of BP&R.
WWW.DESIGNINNOVATIONPLAS-
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SOLVAY RECEIVES MULTIMILLION POUND UK GRANT FOR AUTOMOTIVE COMPOSITES DEVELOPMENT The UK Government has awarded a multi-million pound grant to a consortium partnership involving Solvay, Bentley and Penso, that will enable the development of automotive composites. The Flexible Lightweight Architecture for Volume Applications (FLAVA) automotive project will be undertaken at the Advanced Propulsion Centre (APC) at the University of Warwick, based in Coventry. Here the partners will develop the composite design, material and manufacturing technologies required to implement a modular, multi-material Body-In-
White (BIW) structure suited for large production volume. The project, through the manufacture of composite intensive vehicle prototypes, will demonstrate the technical and commercial solutions required to meet emission legislation with design flexibility, structural integration, lightweighting, vehicle assembly and logistics simplification. This, says the partners, will demonstrate the capability of a composites supply chain to offer manufacturing processes that meet automotive OEM quality, serial production rate and total cost of ownership requirements in standard OEM production facilities. Alex Aucken, UK Automotive Director at Solvay Composite
Materials, said: “We are honoured to have been awarded this grant by the UK Government, and through this project we look forward to further develop our composite technologies portfolio to translate these technologies to the high-volume automotive market.” WWW.SOLVAY.COM
The UK Government has awarded a multi-million pound grant to a consortium partnership that will enable the development of automotive composites
IOM3 AND JL GOOR LAUNCH IRISH POLYMER ENGINEERING SCHOLARSHIPS A persistent shortage of polymer engineers in Ireland has prompted the launch of a new scholarship programme at the Athlone Institute of Technology (AIT), County Westmeath. The Institute of Materials, Minerals and Mining (Polymer Group South, Ireland) has joined with Dublin-based machinery and polymer materials supplier, JL Goor, to award two second-year students each year with a bursary of €3,000 (approx. £2,500 GBP) over the remaining years of their course. The first scholarships were awarded in April 2017 at the IOM3’s annual Seminar in Athlone to the successful students on the B.Eng (Hons) Mechanical and Polymer Engineering programme. Louis Goor, Director of JL Goor, said: “As JL Goor we are excited at this opportunity to recognise and support the polymer students at AIT. We know first-hand the value of this course as we have three past students employed. The growth of the Irish polymer industry is dependent 10
(From L-R) Louis Goor, Managing Director, JL Goor Ltd; Niall Gavin, Student; Bryan Slattery, Student; Gearoid Clarke, Managing Director, JL Goor Materials Ltd
on a continuous flow of able, ambitious polymer engineers and we hope to encourage this with these scholarships.” Joe Wall, Chairman, IOM3 Polymer Group South, Ireland, added: “The IOM3 Polymer Group is delighted to enable this sponsorship. The polymer processing industry is one of the few manufacturing sectors in Ireland that WWW.BRITISHPLASTICS.CO.UK
is thriving and it needs high calibre students coming through to fill the demand from processing companies. AIT has a long history of supplying well qualified polymer engineers to our industry and we want to continue to foster and recognise this excellence.” WWW.JLGOOR.IE
ELLEN MACARTHUR FOUNDATION LAUNCHES INNOVATION PRIZE FOR KEEPING PLASTICS OUT OF THE OCEANS The Ellen MacArther Foundation has launched its latest initiative to keep plastics out of the ocean environment with a prize fund available for innovators who come up with tangible new ways of designing packaging for recycling. In conjunction with the Prince of Wales’ International Sustainability Unit, the ‘New Plastics Economy Innovation Prize’ offers innovators grants of $2 million USD (approx. £1.5 million GBP) and visibility of their solutions to major businesses, the innovator community and the public. Winners will enter a 12-month accelerator programme offering exclusive access to industry experts, commercial guidance, feedback on user and scalability requirements, advice on performance expectations, and access to innovation labs for testing and development. The first winners will be announced later this year. The judging panel for the challenge consists of senior executives from major businesses, widely recognised scientists, designers and academics. Solutions The Ellen MacArther Foundation has launched its latest initiative to keep plastics out of the ocean environment. (Credit: Richard Carey_AdobeStock_1)
will be assessed against a broad range of criteria carefully crafted in collaboration with the challenge partners and participants of the New Plastics Economy initiative. Dame Ellen MacArthur explained: “After 40 years of effort, globally only 14 percent of plastic packaging is collected for recycling, with one third escaping collection and ending up in the environment. If we want to change this, we must fundamentally rethink the way we make and use plastics. “We need better materials, clever product designs and circular business models. That’s why we are launching the New Plastics Economy Innovation Prize, calling for innovators, designers, scientists and entrepreneurs to help create a plastics system that works.” To achieve the goal of eliminating plastic packaging waste, the Prize is composed of two parallel challenges worth $1million each; firstly a ‘Circular Design Challenge’, where applicants with a new idea for how to get products to people without using disposable packaging, or for how to design plastic packaging that is easier to recycle, are accepted. Secondly, the ‘Circular Materials Challenge’ seeks ways to make all plastics packaging recyclable, looking at alternative materials and end-oflife options. Wendy Schmidt, funding the New Plastics Economy Innovation Prize, said: “Working towards circularity in the way we make, use, and distribute plastic packaging will revolutionise the scale of the human footprint on our planet, hugely reducing plastic waste and its devastating impact on ocean health. The value of keeping materials in the economy is massive compared to the losses we suffer when plastic leaks into the very living systems we depend upon for our survival. The New Plastics Economy Prize is a call for creative design and technical innovation at a critical time.” WWW.ELLENMACARTHURFOUNDATION.ORG
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The BPF will host a seminar on Industry 4.0
BPF TO EXAMINE HOW THE ‘NEW INDUSTRIAL REVOLUTION’ WILL IMPACT THE PLASTICS INDUSTRY The British Plastics Federation (BPF) will host a seminar on Industry 4.0 to examine the opportunities and advantages the concept, and its related technologies, will have on the UK plastics industry. Industry 4.0 will result in what has come to be known as a ‘smart factory’, where new technology such as networked machines, data exchange and advanced communications in manufacturing will create efficient, interactive and flexible factories. During the seminar on June 6, Thorsten Kühmann, from VDMA, the German mechanical engineering industry association, will explain how Germany, the leading nation in Industry 4.0, is making a success of cutting-edge manufacturing practices. The seminar will also explore the help available to plastics firms from UK Government, with Claire Porter from the Department for Business, Energy and Industrial Strategy outlining the current perspective. Stephen Hunt, BPF Membership Services Director, said: “Industry 4.0 clearly has the potential to significantly change the plastics industry. The development of ‘smart factories’ will create amazing opportunities for manufacturers in the plastics industry and we will soon be able to optimise manufacturing processes in ways that it is currently hard to imagine. Standing still is rarely an option in business, and we feel that every manufacturer in our industry will benefit from coming to this seminar and learning what the future holds.” The seminar will be held at the BPF’s offices in London. WWW.BPF.CO.UK
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EXPORT DEMAND PUSHES MOTOR MANUFACTURING TO 17-YEAR HIGH British car makers produced 170,691 vehicles in March, up 7.3 percent, the most productive month in 17 years. One car was exported every 20 seconds in March with export demand up 10.6 percent on 2016. Overseas buyers, particularly those in continental Europe, also helped push overall production in Q1, to 471,695 units – an increase of 7.6
percent. This helped offset a decline at home, with demand down -4.3 percent in the quarter. Mike Hawes, SMMT Chief Executive, said: “UK car manufacturing is accelerating thanks to billions of pounds of investment committed over the past few years. Much of our output goes to Europe and it’s vital we maintain free trade between the UK and EU or we risk destroying this success story.” WWW.SMMT.CO.UK
DAVIS-STANDARD UK CELEBRATES 50-YEAR SERVICE OF DEDICATED EMPLOYEE
The UK’s car manufacturing industry has had another successful quarter
LANXESS BUYS CHEMTURA IN FIRM’S LARGEST EVER ACQUISITION Lanxess has completed its acquisition of Chemtura, one of the world’s leading suppliers of flame retardant and lubricant additives, after months of negotiations. American company, Chemtura, which has a total enterprise value of €2.4 billion (£2 billion), is Lanxess’ Lanxess is significantly strengthening its competitive position in the area of lubricant additives and synthetic lubricants for industrial applications.
(left) Dave Smith rtificate of ce a s receive g om Managin fr recognition is Dav Director of mited, Mark Standard Li ight). Woodgate (r
largest ever acquisition. The deal has been devised to expand its additives portfolio and position Lanxess as a leader in this growing field. Germany-based Lanxess has revealed that it will combine its entire additives business within a speciality additives unit, comprising both Chemtura and Rhein Chemie. In addition to additives, Chemtura’s urethanes and organometallics businesses will be integrated into the Lanxess portfolio, which will absorb some 2,500 Chemtura employees at 20 sites in 11 countries worldwide. The expected annual synergy effects from the Chemtura transaction amount to approximately €100 million (approx. £85million GBP) with realisation targeted until 2020. “The acquisition of Chemtura is another major step in our realignment process and a significant milestone in our course of growth,” said Matthias Zachert, Chairman of the Board of Management of Lanxess. WWW.LANXESS.COM
Davis-Standard Limited, the UK division of the US-headquartered extrusion and converting machinery manufacturer, Davis-Standard LLC, is celebrating the 50-year anniversary of one of its longest-serving employees. Dave Smith, who works at the company’s site in Brierley Hill, West Midlands, joined the company in 1967 when it was Brookes (Oldbury) Limited as an apprentice, working his way to a Maintenance Fitter’s position and then Foreman. In 2001, when the company was purchased by Davis-Standard LLC, Smith’s duties evolved, eventually seeing him become a Works Engineer, the position he holds today. “I’ve always enjoyed working with machinery because there are always new challenges and problems to solve. There has never been a day when I didn’t enjoy coming to work,” said Smith. The company says that owning to the length of time served, Smith’s extensive machinery knowledge has, and continues to be, an asset as the business evolves and adds new services and products to its range. “Dave’s knowledge of our business and his ability to provide expertise for the entire scope of his work has been instrumental to our success,” explained Mark Woodgate, Managing Director of Davis-Standard Limited. “We are grateful to him and for all he does on a daily basis to support customers.” WWW.DAVIS-STANDARD.COM
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PRE-SHOW NEWS
Women in Plastics to be championed at Interplas
T
he group made the announcement (WES) and Director at “We have had some Society on International Women’s Day, Eurovacuum Products Ltd, as well as fantastic feedback and Maryann Wilcox, President of the Society revealing that a networking event, featuring guest there is great support of Plastic Engineers’ (SPE) UK and Sales speakers, information Manager at Silvergate Plastics. WOMEN IN PLASTICS, on mentoring from the industry “We have had some fantastic THE UK-BASED opportunities and feedback and there is great support for the group. We NETWORKING advice on further from the industry for the group. We need to back this need to back this up with events GROUP FOR THE learning will take place up with events where members can meet face-toPLASTICS INDUSTRY, during Interplas 2017 on Wednesday 27th face and discuss the challenges and where members WILL RETURN TO September. opportunities facing women working in INTERPLAS IN 2017. can meet face-to“The Women in the modern plastics industry, as well Plastics Group aims as how to encourage more to choose a face and discuss to highlight the females in the industry career within it. The event at Interplas the challenges and that are doing great work, in every type will provide this and we look forward to opportunities facing encouraging as many people as possible of capacity,” commented Leanne Taylor, Group Founder. “It was a natural step, to join us.” women working in therefore, to announce the news of our Membership of the Women in Plastics the modern plastics Group is free. For more information on next event on International Women’s Day, which both celebrates achievement the Group, and to reserve your place industry, as well as and highlights the importance of gender at the event, please contact leanne@ how to encourage parity.” rapidnews.com The event, which is open to all more to choose a genders, will take place between 17:00WWW.WOMENINPLASTICS.CO.UK career within it.” 19:00 in Hall 4 of Birmingham’s NEC WWW.INTERPLASUK.COM Arena and is free to attend, regardless of whether delegates are exhibiting or visiting Interplas. VISITORS - REGISTER NOW FOR FREE ENTRY Speakers confirmed so far include Adrienne Houston, TO INTERPLAS 2017 PhD, Cluster Coordinator for the Woman’s Engineering Visitor registration for Interplas in September is now open. The show, which is free to attend, will run Women in Plastics at Interplas 2014 from 26-28 September 2017 and will provide three full days of exhibitions, demonstrations, conference seminars and unmissable networking opportunities. To get your badge, as well as receive all the latest news relating to the show, head to the Interplas website:
WWW.INTERPLASUK.COM/REGISTER.HTML
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BUILDING & CONSTRUCTION | NEWS 3M’S ETFE CHOSEN FOR ROOF REFIT AT LONDON’S TOTTENHAM HALE BUS STATION Highly transparent films made from ETFE have been used for a major construction project at one of London’s oldest stations. 3M, the laminates and films conglomerate, provided ‘Dyneon Fluoroplastic ETFE’ for the roof structure at Tottenham Hale station, as part of a construction project to ensure it is fit for purpose for decades to come. Opened in 1840, Tottenham Hale is one of the oldest railway stations in Europe. In 2014 Transport for London completed its £110 million transformation to a bus and rail interchange. The project saw 860 square metres of extruded Dyneon ETFE used for an umbrella-style roofing structure. This created a new space designed to both protect passengers from the elements and provide a bright, safe thoroughfare to replace a dark, ageing system of passageways. 3M assured Transport for London the ETFE will withstand Tottenham’s environmental impacts
mer eight poly The lightw PRO, is being R A material, othermal e new ge used in th ator ner energy ge
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The new passenger area at London’s Tottenham Hale bus and rail interchange
for 40 years. The surface of the film is so smooth that the rain rinses off virtually all dirt, keeping the roof transparent and reducing maintenance. ETFE films have high tensile strength, tear propagation resistance and puncture resistance. They also withstand impact from hail, and can bear high snow loads. Dyneon ETFE has 95 percent light
clarity, but weighs only five percent of a comparable glass build, allowing very slender support structures for the roof, increasing the brightness. Tensioning wires attached to the steel pillars support the film webs, which are welded to each other.
ARPRO USED IN GEOTHERMAL GENERATOR CASING FOR ECOFRIENDLY HOMES
to 15 percent through a reduction of leakage and non-laminar air flow. ARPRO is the sole material used to house the generator, providing the partners with a shorter lead time, with fast assembly, easy handling and the transportation of readyto-fit units. With ARPRO’s thermal qualities, no additional insulation is required, eliminating the need for secondary operations and potential variability during installation, allowing an increase in customer satisfaction whilst reducing the overall costs. Ivars Gredzens, GHT Chairman, said: “The choice of materials is crucial when it comes to HVAC equipment, especially with the risk of air leakage. Manufacturers can rarely rely on one source to deliver the multiple requirements needed. However, ARPRO not only provides thermal insulation, but also structural strength and reduced weight, thereby allowing us to produce a more efficient and cost effective product.”
Engineering consultancy GHT, in collaboration with Latvian construction company, Artiva, is using JSP’s ARPRO material for heating and ventilation equipment casing in its latest energy efficient housing projects. Artiva’s buildings will use a geothermal energy generator, made with ARPRO, a lightweight expanded polypropylene bead foam material, as equipment casing. ARPRO delivers a combination of properties providing lightweight, durable and consistent thermal insulation. GHT’s geothermal energy generator is suited to all climates, heating the intake air in winter and cooling it in summer. The energy generator uses a geothermal heat collector which transfers heat from the ground to the air, streaming through a brine-defroster. The ARPRO enclosure channels the air efficiently through the heat exchanger increasing the energy transfer by up WWW.BRITISHPLASTICS.CO.UK
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MODULAR GFRP BRIDGE “70 PERCENT LIGHTER THAN STEEL” A railway footbridge built by a nature reserve in Oxfordshire is Britain’s first modular glass-fibre reinforced polymer (GFRP) bridge. The post-tensioned ‘Pedesta’ bridge, conceived by Civil Engineering firm, Arup, and launched by distribution partners, Mabey, is designed to be assembled in hard to reach sites where large cranes or heavy machinery cannot be used. Part-funded by the Rail Safety and Standards Board (RSSB), the modular bridge is expected to be of particular interest to the rail industry, providing a safer alternative to level crossings where traditional pedestrian bridges cannot be installed. Pre-engineered, modular, and fully customisable in its form, material, colour and finish, the Pedesta bridge features include identical modules, one metre in length, which are fixed together with bolted shear
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The new bridge in Oxfordshire
connectors and then post-tensioned. The system allows spans of up to 30 metres. The reinforced polymer is 70 percent lighter than steel, so modules only require forklift to move for more efficient delivery. The noncorrosive material is resistant to fire, graffiti, vandalism, and ultra-violet radiation. Michael Treacy, CEO, Mabey Bridge, said: “There is always room for innovation in bridging, and we pride ourselves on pushing boundaries with new materials so we can safely build longer-lasting structures even faster.” WWW.MABEY.COM
The new Beacon of Light stadium will feature a 4000m2 PVC tensile fabric roof
The centre will be used as a sports and education venue
PVC FABRIC ROOF TO BE THE ‘BEACON’ OF SUNDERLAND’S NEW SPORTING CENTRE A new education and sports facility in Sunderland will feature a PVC tensile fabric roof as part of a major community project that will host an expected 6,000 visitors per week.
The 4000m2 roof will cover the new facility, named ‘Beacon of Light’, which is to be built next to Sunderland Football Club’s ‘Stadium of Light’ on Wearside. With a £14.7 million budget, the Beacon, designed by Faulkner Brown Architects, will stand six storeys high and cover 12 acres, providing a vibrant place to encourage Sunderland’s community to gain skills and qualifications. Carrying on PVC’s legacy as a material of choice for sporting venues, the Beacon will house playing halls, football pitches, flexible informal learning spaces and education suites. The roof will be designed, manufactured and installed by J&J Carter, an engineering firm based in Andover. Sir Bob Murray, Chairman of the charity that will run the centre, said: “Our plans have been designed to complement and support plans to provide sustainable and vibrant learning, skills and health facilities to help achieve the City’s Economic Master plan and vision of an attractive and accessible Sunderland.” WWW.JJCARTER.COM
Covestro is using its polyurethane materials to help develop new, low-cost housing models as part of an initiative to provide sustainable and cost-effective homes across the globe. The company is supplying its polymer solutions as part of a sustainability concept designed to provide affordable homes in in low-income and economically underdeveloped regions, but also in places where housing is scarce or expensive, such as in densely populated areas or cities with a high influx of refugees. One current example is the ‘House of Nations’, a multipurpose building in Bergisch Gladbach, Germany, that was designed and built by the city administration, the French prefabricated building manufacturer, Logelis, and Covestro. The outer envelope of the model building is fully insulated with polyurethane. Self-supporting, prefabricated elements form the walls, which comprise a core of polyurethane foam encased in a thin layer of cement. The floors and drop ceiling are also insulated with polyurethane. The wall panels are super-insulating, with a thickness of 16 centimeters, meaning the annual heating energy requirement is designed to be less than 15 kilowatthours per square metre. The elements are simple to manufacture and very lightweight. Each of the large-sized, composite elements weighs just over 100 kilograms, meaning less fuel is required for transportation. The elements of the ‘House of Nations’ are said to be simple to install and create a single-story, multipurpose building that is significantly more affordable than conventionally-built structure. “This highly cost- and energyefficient building was completed in just four weeks,” said Dr. Markus Steilemann, Chief Commercial Officer at Covestro. “With this pilot project we want to show how we can work with partners to provide housing quickly and inexpensively. This is an increasing challenge in many cities.” In addition to the House of Nations, Covestro has worked on other housing models used for permanent housing for people in Asia that have become homeless as a result of natural disaster, as well as for residential units in Iraq for displaced victims of war. WWW.COVESTRO.COM
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PVC 2017: “No longer the black sheep of the plastics family” WORDS | Leanne Taylor
“P
VC has always been ahead of the game” - these were the opening sentiments from Stuart WITH RECYCLING RATES Patrick of REACHING A NEW HIGH, the IOM3 INDUSTRY INITIATIVES who pointed COMMENDED BY LEADERS to the sheer amount of FROM BUSINESS AND progress and GOVERNMENT AND innovation PATENT APPLICATIONS generated SHOWCASING NEW by a mature HEIGHTS OF INNOVATION, commodity polymer. PVC PROVED ITSELF AS Indeed, NO LONGER THE “BLACK PVC’s SHEEP” OF THE WIDER progress PLASTICS INDUSTRY, was mapped BUT A TRAILBLAZER. out by Dr. BP&R REPORTS FROM AN Brigitte Dero, General ACTION-PACKED THREE Manager of DAYS IN BRIGHTON. VinylPlus, who focused on how a united PVC industry, involving the entire value chain, is showing the way for the wider plastics industry. “Working together across the entire value chain was a new approach in the PVC industry. From resin manufacturers, stabilisers and plasticisers producers through to the converters, we are united. VinylPlus has seen almost 200 companies working together since 2007.” Dero explained how the achievements of the VinylPlus Voluntary Commitment to sustainable development over the past two decades had helped to turn PVC from “the black sheep in the plastic family” to a “pioneer” and “material of choice”.
Reaching a new high in PVC recycling
Dero chose Brighton as the place to reveal to the industry that PVC recycling has reached “a new high”, with 568,696 tonnes recycled in 2016 through VinylPlus. “Having recycled nearly 600,000 tonnes of PVC last year, we have demonstrated through the VinylPlus Voluntary Commitment that we can divert from landfill significant volumes of PVC waste, thereby contributing to resource efficiency,” Dero continued. Other recent achievements highlighted at the conference include
the development of an Additives Sustainability Framework (ASF) – a new, science-based system for assessing the sustainable use of additives in PVC products. The first ASF is almost complete for window profiles. Recycling aside, Dero explained how progress was also charted through the recognition of VinylPlus initiatives at the World Economic Forum (WEF) in Davos earlier this year, where the scheme was “highly commended” by business leaders for its notable contribution to the circular economy. She concluded by outlining yet more partner collaborations to come, both with EUROCITIES, as well as a major global sports products manufacturer keen to use PVC in its products. The outcomes of these collaborations, she hinted, would be unveiled at PVC 2020.
A rather different approach
Not afraid to balance the argument, PVC 2017 invited a “rather different” approach on the future for PVC, with a keynote paper delivered by Professor Michael Braungart of EPEA. He challenged delegates to think beyond current efforts towards a ‘cradle-to-cradle’ approach, where products and production processes are designed through principles that are healthy and beneficial to humans and nature. “Sometimes, what I am saying might be a little out of your comfort zone,” Braungart told delgates. “I am saying it here, however, as this is the best PVC conference in the world.” Within his address Braungart challenged the use of PVC for products where the material cannot be managed, however, said he fully supported using it for “service or technically responsible” products. “For example, I would support you to use PVC for all pipes,” he told delegates.
“Life in the old material still”
Taking to the stage later in the day, Chris Tane, CEO, Inovyn, attributed the European demand for PVC remaining well below peak levels to three elements. Slow demand from building and construction markets following the 2008 crash; the
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increase in use of recycled PVC; and the loss of competitiveness in the industry in terms of PVC producers since the advent of shale gas in the US were all contributing factors, he believes. “How do we overcome these issues? “I believe innovation is key – the solution to all of the above,” Tane told delegates. “People would argue that it is a bit “late in the day” for innovation in such a mature material and industry. However, there has been a huge amount of new ideas patented recently, particularly from Asia. This proves there is life in the old material still.”
What’s in a name?
The European Council for plasticisers and Intermediates (ECPI) chose PVC 2017 to announce news of its rebranding to ‘European Plasticisers’. The association said the new name “showed a clear move towards a more inclusive organisation which embraces the infinite opportunities of all plasticisers.” The association has seen a recent expansion of its membership which currently brings together eight major European plasticiser producers representing over 80 per cent of the market. The PVC conference was also used by the ECVM (European Council for Vinyl Manufacturers) to announce news of a new organisation established to support the PVC cables supply chain. ‘PVC4cables’ intends to act as a driver for environmentally responsible innovations in the PVC cables sector and as a focal point for dialogue and communications with all stakeholders: compounds and cable producers, regulators, specifiers, installers, electricians, media and the public.
A successful event
The conference attracted a record 526 delegates from over 43 countries and showcased almost 70 papers. Concluding, Stuart Patrick said: “We’ve always aimed to progress based on sound science. That’s what we’ll focus on so we can continue to keep ahead of the game.”
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MACHINERY | NEWS MOTAN ADDS MULTI-MATERIAL VOLUMETRIC DOSING UNIT TO RANGE Motan Colortronic has updated its product line with a new volumetric dosing unit with a flexible exchange system, that can handle powder, pellets, regrind, granulate, flakes or fibres. ‘Spectroflex V’ is a volumetric dosing unit for continuous processes, designed for a range of applications. Motan has used a unique exchange system to handle changes in material colour, flow properties or grain sizes, which swaps materials without tools in under a minute. Single and double screw exchange modules and an easy-clean supply hopper makes material changes faster and reduces production downtime. A further advantage, says Motan, is that the material loader mounted on the cover of the supply hopper does not have to be removed during the material change, resulting in higher efficiency and shorter downtimes during production.
The design of the unit’s massagerollers makes processing of nonfree flowing and fragile materials possible. Powered by an independent motor and designed for 48 different settings, Spectroflex V offers high dosing accuracy for a wide range of materials - even for small dosing quantities. The dosing unit is equipped with an intuitive touch screen, and can be integrated into an existing Motan CONTROLnet network through Ethernet interface.
dule – y nge mo Excha wapped easil s can be a minute r e d n in u an) e: mot (Imag
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the company’s VBD 150 model. While the VBD 150 is sized for the throughputs of many injection MAGUIRE’S DOUBLED moulding machines and of small THROUGHPUT MAKES extrusion lines like those for medical ADVANTAGES OF VACUUM RESIN tubing, the new VBD 300 model DRYING AVAILABLE TO opens the benefits of vacuum A WIDER RANGE OF resin drying to a broader range of APPLICATIONS applications. Maguire has launched In comparison with desiccant a new vacuum resin dryers, the VBD vacuum dryer dryer it says enables consumes 60 per cent less more moulding and energy, dries resin in one-sixth extrusion processors to of the time and substantially obtain the “substantial reduces the heat history to which advantages” of polymer is exposed. Maguire vacuum dryers says the speed with which over conventional the VBD system removes desiccant moisture makes properly systems, including dried polymer available for lower operating production only 35 minutes cost, increased after a cold start. efficiency and Like other VBD models, the greater control over VBD 300 dryer is a gravimetric the drying process. system that employs load The VBD 300 cells that precisely monitor has throughputs the weight of material at two of up to 136 kg critical points, making possible per hour, double precise control over material VBD 300 the capacity of Vacuum Dryer consumption and documentation WWW.BRITISHPLASTICS.CO.UK
of process conditions for certification to customers. Use of load cells also enhances control over the drying process, according to Frank Kavanagh, Maguire Vice-President of Sales and Marketing. “Load cell control makes it possible to precisely match the drying rate to the processing rate of the moulding machine or extruder, which is particularly important for proper drying of technical polymers like nylon,” he explained. “Because load cell control ensures that no material is left in the dryer when production stops, the next production run can start immediately.” VBD vacuum dryers use gravity to move material through three vertically arranged stages of the drying process, with the discharge of material from one stage to the next controlled by high-speed slide-gate valves with an accuracy per dispense of +/- 4 grams. Maguire drying systems are distributed in the UK through Summit Systems. WWW.MAGUIRE.COM 21
Engineering Passion
ENGEL E-FACTORY MES SYSTEMS REPLACED BY NEW SOFTWARE SUITE Manufacturing Execution Systems (MES) software from the ENGEL group will now be provided under a different interface. ENGEL will no longer operate its established ‘e-factory’ MES, but will utilise the ‘authentig’ software suite from T.I.G. to provide an independent interface solution. However, as e-factory is based on the authentig system, following a longstanding partnership between ENGEL and T.I.G., the companies say that existing users will only see a name change, with functionality and operating logic remaining the same as before. The decision to replace its system follows the integration of T.I.G. into the ENGEL group of companies in October 2016. T.I.G. will remain an independent company within the group, but will receive investment from ENGEL to develop its MES solutions, with the aim of becoming the market leader
QUALITY PLATED PLASTICS INSTALLS INTELICARE MATERIALS HANDLING EQUIPMENT Quality Plated Plastics, based in Birmingham, has added to its moulding facility with Intelicare material drying and loading equipment, mould heaters and a process water cooling system. The contract plating specialist has invested over £2m in new premises in Great Barr, Birmingham, with a plating plant, five Negri Bossi injection moulding machines from 55 - 500 tonne and ancillaries from a range of manufacturers supplied by Intelicare. The investment has increased the capacity for QPP to more than 60,000 parts per day and
as a MES provider for the plastic processing industry. By keeping the MES interface neutral, says T.I.G., means it can be utilised by manufacturers that do not use ENGEL injection moulding machines and systems. “ENGEL as an investor in the background provides stability and a long-term outlook. This gives an additional boost to the level of trust that processing companies place in us,” explained Wolfgang Frohner, Managing Director of T.I.G. T.I.G. says its systems are already used in over 8,000 networked injection moulding machines, boasting seven of the ten world’s largest automotive component suppliers as customers. “MES is a core component of ENGEL’s inject 4.0 programme”, emphasises Dr. Stefan Engleder, CEO of the ENGEL group of companies. “By bundling our expert knowledge we have significantly improved our expertise in the MES field.”
ENGEL will no longer operate its established ‘e-factory’ MES, but will utilise the ‘authentig’ software suite from T.I.G. to provide an independent interface solution.
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increases the size of mouldings that can be produced in house. It is now able to offer a complete package from tool design to finished product. The Intelicare system includes a cooling system, which comprises a 100kW cooling capacity dry cooler with twin pumps to provide cooling water to the mould shop for hydraulic cooling. The new closed loop system replaces the conventional cooling tower, preventing process water contacting ambient air, eliminating the risk of Legionnaire’s Disease or the need for a constant fresh supply of fresh water and chemical costs. The system also has dehumidifier dryers, including a honeycomb wheel dehumidifier dryer for drying efficiency; hopper loaders, for
optimum throughput with stainless steel receivers and latest generation controllers; and mould heaters, providing a no fuss, low maintenance unit for heating and cooling water for conditioning moulds. John Timmins, QPP Owner, said: “The Intelicare equipment has contributed to improved efficiency and quality from the plant, as well as lower energy costs, which ensure that QPP remains competitive and provides the opportunity to retain existing business and break into new markets. Intelicare provided us with first class equipment and continue to support us with an impressive after sales service.” WWW.INTELICARE.CO.UK
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TAKE-OFF AS SURFACE GENERATION DELIVERS LARGEST EVER PTFS SYSTEM TO AMERICA Surface Generation, a provider of advanced carbon fibre processing technologies, has announced that it has completed delivery of its largest ever Production to Functional Specifications’ (PtFS) system to California-based company Quatro Composites. Quatro Composites is using the PtFS system to produce thermoplastic components for a high volume US aircraft programme where quality of the parts is paramount. It is the first system from
Rutland-based Surface Generation that incorporates more than 200 individually heated and cooled areas within the tool faces, allowing thermal control to be applied even more precisely when forming highly complex components. Ben Halford, CEO of Surface Generation, said: “These monolithic composite components are subjected to high dynamic aerodynamic loads in a highly abrasive area of the aircraft. As such, this out-of-autoclave high volume production application needs to be incredibly precise to assure quality and maximise throughput. By using PtFS, Quatro Composites has achieved a step change in its manufacturing processes.” Rob Westberg, Vice President for Research and Development at Quatro Composites, said: “We’ve been working with Surface Generation to refine our production processes and prove the PtFS can form these complex components consistently, economically, and to a greater quality than previously possible. PtFS is a cutting-edge process that enhances our ability to produce structural components for state-of-the-art commercial and military aircraft.” WWW.SURFACEGENERATION.COM
MAAG/GALA LAUNCHES HIGH CAPACITY CENTRIFUGAL PELLET DRYER FOR POLYOLEFINS Gala Industries, a Maag company, has engineered a centrifugal dryer with the highest known capacity for drying polyolefins. The dryer was engineered for high capacity resin producers, engineering companies and parts makers who require a single dryer for virgin resins. David Bryan, President and CEO at Gala Industries, said: “After the
development of the Model 100 in 2008, based on our proven 48-inch rotor platform, with over 300 running applications, we have continued our [research] work to increase the drying capacity rates of the Model 100. “Through full scale testing and continual design adjustments, we have successfully increased the drying capacity of the Model 100 dryer to 150 t/h, processing HDPE with lentoid pellet geometry and melt flow index of 0.35, with moisture below 500 PPM. Future plans include a number of new concepts that will be evolving over the next 12 months.” The Maag/Gala full scale dryer demonstration facility allows customers to see their material being processed at actual rates. This eliminates the risks of small dryer upscaling for larger production rates. WWW.MAAG.COM WWW.GALA-INDUSTRIES.COM
SERVICE ENGINEERS BRING OLD INJECTION MOULDING MACHINERY BACK TO LIFE Engineers at STV Machinery have shown servicing and refurbishment of redundant injection moulding machinery could add 30,000 more running hours. The moulding machine servicers, based in Wellingborough, are highlighting the cost savings to manufacturers compared to replacing injection moulding machines with either new or used models. Richard Perry of STV Machinery said: “Most injection moulding facilities have an old war horse tucked away in the corner that can no longer be relied upon to give its best. Not only does it look like it’s entered a fight with a robot and lost, but it suffers from reliability and consistency issues.” Perry believes an injection moulding machine, after a complete reseal, pump overhaul and all major components repaired, should give a further 20,000 - 30,000 run hours without any serious problems. He said: “What could be better than a machine you already know inside out, back to its reliable, consistent state.” The engineers evaluate the condition of working parts, assessing elements such as plasticising and carriage units, clamping system, platen condition, ejector and core circuits, pistons, filters and seals. Parts which fail a set of stringent tests are either repaired or replaced. When the work is completed the machine is reassembled and tested under production conditions, and test-run for 2500 moulding cycles. Perry added: “We provide a completely transparent service. Every minute worked and every repair undertaken is logged on our internal system. In a few cases, an injection moulding machine will be economically beyond even our help. But generally, if a machine is working, it can be refurbished to an excellent standard.” WWW.STVCONNECT.CO.UK
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T
he meaning of ‘dew point’ has already been covered in previous editions of BP&R, however, owing to the many misconceptions associated with it, this month’s column will take a more Q: HOW IMPORTANT IS in-depth look. THE DEW POINT WHEN A short recap: Four parameters DRYING PLASTICS? are important when drying plastics: drying temperature, dry In this edition of Mo’s air flow, dew point temperature, and drying time. These four Corner – our regular parameters need to be feature that aims to coordinated with each other, as answer commonly each one influences the drying asked questions about process and the result. This the manufacture means that if one parameter is changed, then the rest also need and processing of to be adjusted in order to achieve plastics – we look the same degree of dryness. at the relationship Before we look at the dew point between dew point and in detail, we must be aware that (residual) moisture. firstly, the higher the temperature of the air, the more water (vapour) can be absorbed by it; secondly, the maximum water content of the air therefore depends on the temperature; and, finally, the relationship of actual water in the air (mH2O in g/m³) to maximum possible water content at this temperature (mmax (T)) is called relative moisture content:
rF =
mH 2 O mHmax 2 O (T )
If the air cools, it can hold less water. This means that with a decreasing mmax the relative moisture of the air increases (see above formula). If the relative moisture content reaches 100 percent due to further cooling, the air can no longer hold any water and water droplets condensate (dew, fog, rain). The temperature at which this occurs is called the dew point. At 100 percent air humidity, air temperature and dew point temperature have the same value. If you then reheat this air, its dew point – and therefore also the absolute moisture content – stays constant, the relative moisture content decreases. The dew point, or to be more precise the dew point temperature, is therefore a way to measure the absolute moisture content of the air (g of water vapour per m3 of air). The dew point temperature is specified in °C. It is important to bear in mind that the dew point temperature as a measure of air moisture content is not an actual temperature. Instead, it is the temperature at which the air would have a moisture saturation of 100 percent. Therefore, each dew point temperature also has a
corresponding specific water content. Everyone knows the phenomenon of cold glasses steaming up in warm rooms. We therefore also know, that the temperature of the glasses must in this case be equal to or below the dew point temperature of the air in the room. The water condensates on surfaces with temperatures which are below that of the dew point temperature (dew formation). In summary, the lower the water vapour content of the air, the lower its dew point temperature. Or, the dryer the air, the lower the dew point, or better the dew point temperature. The following two values help to better understand the maximum possible absorption of water by air: for air with a temperature of 100°C it is 600g/m3, at 0°C only 4.8g/m3. For hot air drying, the dew point varies depending on the current climate factors of the environment, whereas for dry air drying the dew point is maintained constantly within predefined boundaries independent of weather. However, it is important to remember that very low dew point temperatures require very large amounts of energy for air conditioning (drying of the air). For the drying of moist hygroscopic plastics, a dew point temperature of approx. -20°C is completely sufficient. At a constant drying temperature, different dew point temperatures have been proven to have only little impact on the drying time, whereas they determine together with the drying time the minimal possible residual moisture content (balance between granule moisture and dry air). These relationships will be explained in more detail in the next issue of Mo’s Corner. FURTHER QUESTIONS? EMAIL: ASKMO@MOSCORNER.DE
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Water content [g] in one m³ o fair at different dew points (graph: motancolortronic)
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COLOUR MANAGEMENT | NEWS A. SCHULMAN TO INCREASE EUROPEAN CAPACITY FOR COLOUR MASTERBATCHES A. Schulman has announced it is to increase its production capacity for colour masterbatches in Europe following growth in demand. The company, which has manufacturing plants across Europe as well as competence centres for the development of demanding applications, will invest in an additional three extruders at its sites in Poland, Hungary and Italy. “A. Schulman is committed to continue investments in our colour facilities,” explained Andrzej Rozalski, Vice President of Custom Concentrates and Services EMEA at A.Schulman. “We combine our technical expertise in colour masterbatches with increased capacity, which enables us to service our customers even faster and better.” Heinrich Lingnau, Senior VicePresident and European Manager, said: “Coloured masterbatches see increased demand across the European region and we want to be part of it.
some Ulf Trabert displays newest of Gabriel Chemie’s plastics colour effects for
A. Schulman has increased capacity for the production of colour masterbatch in Europe
“The expansion of our production lines in Poland, Italy and Hungary are the third significant investment that we are making in our masterbatch manufacturing sites in the last months.”
A. Schulman previously announced major investments new masterbatch plants in Changshu, China and Istanbul, Turkey.
GABRIEL-CHEMIE DEVELOPS NATURE-INSPIRED COLOUR EFFECTS FOR DIFFERENTIATION IN PLASTICS
just expect an impeccable product - they also want to be addressed personally and experience the product and its packaging with all their senses. “New technical ideas and solutions as well as the trend towards individualisation are taking on an increasingly important role in the world of plastics. New effects such as marble, onyx and oxidation impress the consumer and stand out at the point of sale.” The new effects are achieved through careful selection of polymers and the masterbatch recipe. It also involves the accurate adjustment of the processing machinery, essential for a perfect result. Gabriel Chemie says the effect polymers are showcased at their best when processed using injection moulding machinery.
Colourists at Gabriel-Chemie have developed colour effects in onyx, marble, oxidised metals and even concrete for differentiation in plastic products. The colourations are showcased in ‘Colour Vision 17’, the company’s annual swatch catalogue that gives an overview of colour trends. The technicians say the new effects have never previously been available in plastics and are designed to help brand owners offer individualisation, as well as helping products stand out at the point of sale. The effects can be achieved in both PP and HDPE. Ulf Trabert, Product Manager for Branded Goods at Gabriel-Chemie, explained: “Innovative product strategies are the basis for long-term market success. Consumers don’t 26
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Understanding Colour Variation and How It Occurs
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olour is subjective and has a huge impact on our physiology and psychology, so getting the right colour for a product is essential to widening its appeal, increasing perceived value and retaining the integrity of a TONY BESTALL, DIRECTOR brand. OF SILVERGATE PLASTICS, The human eye cannot be relied LOOKS AT HOW, BY upon to judge colour accuracy. FOLLOWING STRICT We all see colour differently, even QUALITY CONTROLS when we’re looking at the same AND PROCEDURES, object. When it comes to colouring plastics, it’s important to use a COLOUR VARIATION IN A variety of methods to manage PLASTIC PRODUCT CAN colour accuracy, especially when BE MINIMISED, MEANING matching physical samples. This A MORE EFFICIENT includes using highly effective AND COST EFFECTIVE systems for measuring colour MANUFACTURING PROCESS precisely, such as the use of a spectrophotometer and various CAN BE ACHIEVED. light environments. The spectrophotometer can measure the colour of a physical sample and also be used to check the accuracy of a colour match. Not only does it identify precise colour coordinates on a spectrum of over twenty million colours but it can store specific references and data, including industry standard RAL and Pantone references. More colour references can be added as they are created, thereby building a comprehensive library of accurate formulations or recipes from which to match a colour. When creating a colour formulation, it is imperative that the masterbatch technician knows the environment in which the end product will be used. If, for example, a product is to be used in direct sunlight, then the appropriate light fast pigments must be used to prevent discolouration. The use of a UV stabiliser will not protect pigments and subsequently they can change colour. There is a common misconception that if a stable, robust manufacturing process is utilised in colourant manufacture, using the same raw materials in the same ratios, the same colour will be produced every time. Practically, this is not true. The pigments used to manufacture masterbatches are all bought to a specification regarding colour. That specification is commonly the same used for masterbatches. The colour difference between each batch of pigment and the ‘standard’ is described as ‘Delta E’. This is a single number used to communicate colour difference. The industry standard ‘pass or fail’ criteria is a Delta E of one, and visually this difference is usually accepted as a good match to the human eye. When producing a specific colour masterbatch,
each pigment will be purchased to an agreed colour difference and will potentially vary up to a maximum of one. If a colour is comprised of several pigments, the resulting masterbatch produced can be different from the masterbatch standard, as the small variances in each pigment can be cumulative. Consequently, masterbatch producers commonly tweak off-shade materials by adjusting the colour back into specification. Of course, there are processing errors that can occur along the way once a masterbatch has been supplied. When the masterbatch is approved for sale, post quality control, it will be within specification and supplied at a recommended ‘use at percentage’ that will exhibit a colour that is very close to the original standard. If the use at percentage (by weight) is different from that recommended, for any reason, the colour of the moulded component will be wrong. If the processor has dosed the masterbatch according to the agreed ‘Let Down Rate’ and the colour is variable, the likely root cause will be poor distribution. The term distribution describes the homogenisation or mixing process between the masterbatch and host polymer. If the two are not mixed sufficiently, colour variation and streaking will inevitably occur. This is also true if there is a static build up within the processing equipment, as the masterbatch sticks to the side of the machine hopper rather than flowing consistently into the host polymer. By following strict quality controls, including such practices as retaining a master plaque, colour variation can be minimised. Once the colour has been verified, it is up to the processor to ensure the masterbatch is dosed accurately and mixed sufficiently to achieve the desired colour strength. Good quality masterbatch manufacturers ought to be able to discuss such colour variation challenges with plastics processors so unnecessary complications and delays within their manufacturing processes can be avoided. WWW.SILVERGATE.CO.UK
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Getting the right colour for a product is essential to widening its appeal, increasing perceived value and retaining the integrity of a brand
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How automation of thermochromism compensation enables 100 percent inline inspection in plastics production
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t is generally understood that the effect of temperature will change the observed colour of a product. Even with a temperature difference of just 20°C, colour deviations of more than 2 ΔE units can occur CHRIS JONES, MANAGING for certain colours, this effect is DIRECTOR AT MICRO- known as ‘thermochromism’. Therefore, it is usually necessary EPSILON UK, EXPLAINS to allow the product to cool before HOW, ALONGSIDE a precise colour measurement GERMANY’S SKZ, can be taken. In a drive for 100 THE COMPANY HAS percent inline inspection and DEVELOPED A SYSTEM reduction of product wastage THAT COMBINES to zero, a method THERMOCHROMIC has to be developed to compensate for COLOUR MANAGEMENT thermochromism WITH AUTOMATION TO effects. Micro-Epsilon PROVIDE A SOLUTION has worked with SKZ, THAT REDUCES WASTAGE (Süddeutsche KunststoffAND INCREASES YIELD. Zentrum) to develop a working solution.
Tackling thermochromism with colour and temperature sensors
In injection moulding processes, products are usually moulded with colour pellets supplied in batches and even supplied from different manufacturers. Therefore, it is essential to continually monitor precise colour values of these products to ensure they are exact. In order to provide 100 percent inline control of the product colour during injection moulding of plastic parts, the SKZ institute has developed and tested a method to correlate the difference in colour of an object at different temperatures - thermochromism behaviour - using colour spectrophotometers and infrared temperature sensors from Micro-Epsilon. Colour measurements carried out with a colorCONTROL ACS7000 spectrophotometer and temperature measurements using the CT series infrared temperature sensors generate a master curve at several different temperature levels that describes the thermochromic behaviour of each specific colour or shade. This allows colour values measured on a warm product to be converted to the actual room temperature colour values. The pre-calculated ‘cooling curves’ are stored in the system software and allow the colour values determined during the de-moulding process, which is typically 6080°C to be converted into a reference temperature, for example, 20°C. This enables the colour to now be automatically checked earlier in the process, which reduces cycle time, optimises productivity and increases yield, compared to conventional sample checks.
Inline quality control and colour inspection in injection moulding
Different inspection techniques can be skilfully combined, enabling easy, flawless in-process monitoring. In injection moulding, for example, the new moldCONTROL inline thermography system and the colorCONTROL ACS7000 inline colour measurement system, can be combined to measure and inspect during production. Here, a moulded component is conveyed directly in front of an infrared camera during the
The new moldCONTROL inline thermography system
The colorCONTROL ACS7000 inline colour measurement system
production process. Modern injection moulding systems are normally equipped with an automatic handling system for removal and storage of components. The positioning of the component in front of the camera enables a precise time window to be met when recording thermographic images. This ensures that the thermographic images from one video image to another can be compared. During automatic removal of the components, a “good/bad” component decision must be made within a short time frame. The aim here is to prevent problems that may disrupt further processing and to take any corrective measures as quickly as possible, to avoid any unnecessary additional costs.
Defect detection using thermal imaging
The inline thermography system, moldCONTROL, detects variations in quality by using a high speed and high resolution infrared thermal imaging camera. It records the entire component in up to six different views and examines it. The principle is simple: a thermoIMAGER TIM thermal imaging camera records the infrared radiation emanating from the mould and visualises it. The temperature distribution provides a quality statement about incorrect temperature control of the mould, malfunction of the tool temperature, visible geometry errors and hidden defects. The software displays the reference image, the IR image of the component and the difference between the two images. The identified temperature differences provide the basis for a Pass/Fail decision. Temperature alarm limits can be freely specified using the operating SKZ software. Defective components can be sorted and removed depending on these settings.
100 percent inline quality control for plastic products
By combining the colorCONTROL ACS7000 inline colour measurement system with correction for thermoschomism and MoldCONTROL thermaI imaging camera system for geometrical defect detection, 100 percent inline quality control of moulded parts is now possible. WWW.MICRO-EPSILON.CO.UK
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SURFACE FINISH, CLEANING & ADHESION | NEWS OXFORD ADVANCED SURFACES LAUNCH NEW UV-CURABLE ADHESION PROMOTION SYSTEM Oxford Advanced Surfaces, a specialist surface modification company, has launched a revolutionary new adhesion promotion surface treatment that can be cured using Ultra-Violet light. OAS has developed a range of versatile and reliable ‘Onto’-branded surface preparation treatments that improve the adhesion of epoxy and polyurethane
coatings to difficult-to-bond substrates. While using heat is a common and effective way of curing surface treatment solutions, the Oxfordshire-based company has acknowledged that some material applications cannot be cured in this way. This can be for several reasons, such as some customers not having the equipment to heat their component up to 110°C, or that the material has a glass transition temperature that is too close to the curing temperature. Oxford Advanced Surfaces has launched a new adhesion promotion surface treatment that can be cured using Ultra-Violet light.
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OAS started a lengthy product development programme to create its Onto solution that can be cured either using a drying step, followed by UV light treatment, or by using a traditional heating method. The product can then be easily applied using a spray gun. Jon-Paul Griffiths, OAS Technical Manager, said: “As the demand for lighter and higher performing materials increases across various applications, so does the need for creative products that make them easier to process and able to perform to a high standard. “We have used our surface chemistry expertise to develop the first solution of its type that can be completely cured using only UV light after a drying step. This will give customers more flexibility during the materials processing stage and will also increase the scope of the materials that can be surface treated for painting or lacquering.” The new UV-curable product removes the need for sanding, abrasion and plasma treatments, it can modify a wide range of substrates with a single product (e.g CFRP and polyamide), it works with virtually all epoxy and polyurethane-based coatings, it is a simple wet chemistry sprayable system that contains no harmful aromatic hydrocarbons, and is clean and dust free. Philip Spinks, Chief Executive Officer, said: “Our brand-new, UV-curable system is suitable for use in a wide range of industries from automotive and aerospace, through to sports and leisure. The product has successfully come through a period of stringent testing and, because it can be applied to the substrate both quickly and easily using a spray gun, we expect there to be considerable interest from customers who are facing adhesion and coating challenges and therefore searching for a solution that is effective, scalable and easy to process.” WWW.OXFORDSURFACES.COM
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The Plasma Treatment Revolution
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he landscape of manufacturing ultimately changed in 1957 with the start of large scale production of polypropylene. Over the years, polypropylene has become one of the most popular plastics in the world and is well known for the CHRIS LINES, MANAGING headaches it causes engineers DIRECTOR OF DYNE when attempting to achieve TECHNOLOGY, EXPLAINS good adhesion. When the use of these new HOW DEVELOPMENTS IN THE ‘non-stick’ polymers began CAPABILITIES OF PLASMA taking off in the 1980s, SURFACE TREATMENT engineers were introduced to TECHNOLOGY HAS SEEN IT the growing need for surface BECOME THE METHOD OF modification. Popular methods at that time included high CHOICE FOR BONDING ‘NON- temperature flame torch STICK’ POLYMERS. treatment and environmentally damaging solvent-based primers and pre-treatments. Although flame treatment methods provide a fairly good option for treating surface areas with simple geometries, such as two-dimensional web materials, it is not so well suited for parts with more complex geometries, wide surface areas and materials easily damaged by the high temperature output of the flame torch. Manufacturers and engineers ultimately picked up on the shortfalls of flame treatment and harsh solvent based primers and pre-treatments. Alongside the high running costs of gas and compressed air, there are often high insurance costs and associated health and safety concerns due to the naked flame in a production environment of a plastics factory.
Why is surface treatment necessary?
Achieving any level of adhesion to low surface energy materials, such as PP, PE, PEEK etc. is difficult at the best of times, but more often than not, impossible. The low surface energy of these materials effectively renders them non-stick, gaskets and seals won’t bond and adhesives, paints, inks and coatings will not adhere. Due to their low surface energy, no matter how much you attempt to abrade or clean the material’s surface, they remain difficult to paint, coat, print or bond to without resorting to flame torch treatment or environmentally damaging solvents. With the ever increasing drive towards the use of UV curing or water-based adhesives, paints, inks and coatings, materials that have traditionally given acceptable adhesion results, such as ABS, nylon, glass filled nylon and composites to name a few, can also become difficult to bond to.
Plasma Treatment Explained
The last 10 years has seen a real shift towards the use of viable alternatives to the aforementioned surface treatments, particularly plasma treatment. This is mainly due to its ability to improve adhesion to ‘non-stick’ plastics but with low running costs, low temperature and,
most importantly, the flexibility provided. During plasma surface activation the component undergoes an environmentally friendly process which does not alter the bulk properties of the treated part. The relatively low temperature of the plasma discharge does not mark, discolour or damage the component in any way, eliminating problems experienced with flame treatment, where the high temperature causes surface damage or shrink back of composite materials exposing glass fibre reinforcing. During the plasma treatment process, a gas, usually air, is excited by a strong electrical field; this strong electrical field ionises the air or other gas creating a plasma. When exposing the material to plasma for a predetermined amount of time, the polarity of the material is increased as the free radicals and other active particles that exist within the highly active plasma discharge attach to the material’s surface, which forms additional polar groups. Polarity is key to adhesion as it enhances the chemical attraction to paints, adhesives, inks, etc., which therefore increases the strength of adhesion that can be achieved.
Unlocking a world of new materials development
As part of the growing acceptance of plasma treatment as a method of surface activation, the capabilities of the process have advanced incredibly. For example, plasma is now widely accepted as the industry standard for the surface activation of ‘nonstick’ components throughout large-scale production. To best serve those with these large production processes, ‘vacuum plasma’ has been developed to become bigger and more powerful than ever before. A decade ago, a large chamber was considered to be one with a 200- litre capacity, now chambers with a 2,000-litre capacity are commonplace. Not only chamber size but functionality of these units has dramatically increased, rotating vacuum plasma is now commonplace, which is excellent for the treatment of small size, high volume parts such as powders and granular materials. Atmospheric plasma is ideal for targeted treatment and integration with automation and cannot be forgotten; the early systems of this cutting-edge technology offered little or no control, limited power, air operation only and had a large footprint. The latest atmospheric plasma units are only one third of the size of traditional units yet offer more power than ever before. The introduction of ‘rotating atmospheric plasma’, which utilises two plasma nozzles on a spinning head, reduces the already relatively low heat exposure to the material being treated; Now, thin and heat sensitive materials, e.g. thin films and sheet materials can now undergo treatment, something that would have seemed impossible a decade ago. WWW.DYNETECHNOLOGY.CO.UK
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3D PRINTING | NEWS Dr.-Ing. Fee Zentis
DYNEON INVESTS IN A 3D LABORATORY PRINTER TO PRINT FULLY FLUORINATED POLYMERS The 3M Company, Dyneon, is investing in research on additive manufacturing of fluoropolymer components with the purchase of a new 3D laboratory printer at its Burgkirchen site in Germany. The material specialist is using a new patent-pending technology with which fully fluorinated polymers such as polytetrafluoroethylene
3M’s new laboratory printer
MOLDEX3D AND STRATASYS PRODUCE NEW WHITE PAPER ON VALIDATING 3D-PRINTED INJECTION MOULDS Moldex3D and Stratasys have collaborated on a new white to provide manufacturers with a way of validating injection mould prototypes produced using 3D printing. The companies say that the growing adoption of 3D printing technology offers new alternatives for creating injection mould prototypes cost-effectively and quickly using 3D technology, however, without a dedicated validation tool, part designers and mould builders might not reap the full benefits. In the new white paper, entitled “Demonstration of an Effective Design Validation Tool for 3D Printed Injection Moulds (3DPIM)”, the companies present the advantages of using upfront simulation to assess and improve the mouldability of 3D printed injection moulds. It also discusses opportunities and
(PTFE) can be processed by means of 3D printing. The objective is to bring the new additive process to the production stage. “With our new laboratory printer we can manufacture PTFE parts directly from digital information without any tooling,” explained Dr.Ing. Fee Zentis, who is responsible for the development of the new 3D printing technology with PTFE at the Burgkirchen site. The new process enables the manufacture even of complex components and the integration of several functions in one part. On the new 3D laboratory printer, Dyneon manufactures parts with dimensions of about 35 x 30 x 55 mm. “This new additive manufacturing technology is of particular importance for PTFE, which is usually machined by subtractive manufacturing methods,” continued Zentis. Fully fluorinated polymers, such as PTFE, exhibit virtually universal chemical resistance. They are frequently used where aggressive media have to be controlled at high temperatures. Apart from large series applications in the powertrain of cars, these high-performance materials are also used in the aerospace
challenges of generating injection mould prototypes with 3D printing methods, and how Moldex3D injection moulding simulation software is a viable solution for 3DPIM design validation and optimisation. By applying simulation analyses, product designers and moulders can accurately predict mould performance, validate design decisions and take corrective actions to avoid costly mistakes that might occur in final production. The solution will enable high-quality and highperformance prototypes to create better final production parts. “Moldex3D is a powerful simulation tool to help evaluate the performance of 3D printed injection moulds. Combining Stratasys 3D printing with Moldex3D simulation software, customers have an enhanced solution for validating and testing thermoplastic parts and moulds for fast and inexpensive production,” explained Gil Robinson, Head of Moulding Use Case at WWW.BRITISHPLASTICS.CO.UK
and chemical industry, in medical equipment and in semiconductor factories. The process developed by 3M Advanced Materials, which is based on stereolithography, enables the printing of fully fluorinated polymers such as PTFE with the aid of a binding agent and, if necessary, with additives such as fillers used in conventional manufacture to initially form a so-called hydro-gel. The binding agent is photosensitive and cures under UV radiation. It is thermally removed at the end of the process. “Additive manufacturing allows for completely new design flexibility and the manufacture of complex internal structures” Zentis concluded. WWW.DYNEON.EU/3D-PRINTING
Stratasys. “Simulation has increasingly permeated many aspects of product development process, from initial concept design, prototyping to production,” said Venny Yang, President at Moldex3D. “For part designers and mould builders looking to take advantage of rapid prototyping with 3D printed injection moulds, we believe Moldex3D’s upfront simulation capabilities can not only to help them better understand the complex nature of injection moulding process, but also to bridge the gap between prototyping and final production.” The white paper also includes a case study which provides valuable examples of how Moldex3D’s simulation technology can be used to predict, validate and optimise the design of 3D printed injection moulds. WWW.MOLDEX3D.COM
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NEW 3D PRINT MATERIAL FROM IPF EXTENDS POSSIBILITIES FOR MEDICAL TECHNOLOGY APPLICATIONS North London-based 3D printing and plastic CNC machining specialist, Industrial Plastics Fabrication Limited (IPF), has added a new polymer to its portfolio of advanced 3D print materials. One of the latest generations of materials from Stratasys, Agilus30 can be used to create 3D printed parts that offer realistic rubber-like qualities of flexibility and durability. The new material has numerous applications in medical technology, either for prototyping or in component production. Available in black and translucent, IPF says the new material family is ideal for modelling parts for design verification and testing, or to create flexible components of production quality. Due to a tear resistance of up to 7kg per cm and elongation of up to 270 percent, components created in Agilus30 are reportedly able to withstand repeated flexing and bending. Agilus30 can be used to simulate rubber over-moulding or a huge variety of functional parts such as living hinges, hoses, seals and
SOLVAY’S ADDITIVE MANUFACTURING MATERIALS KEEP SPACE PROJECT IN ORBIT High performance additive manufacturing (AM) materials from Solvay are being used in the development and manufacture of an ambitious low-Earth orbit aerospace project. The lightweight materials are being used by US-based Oxford Performance Materials (OPM), the key supplier of 3D printed components for use in the production of the Boeing CST-100 Starliner. OXFAB Complex structural component additively manufactured by OPM for the Boeing CST-100 Starliner
gaskets, knobs, grips, pulls, and handles. It has excellent heat resistance and can be combined with other materials to achieve specific Shore A hardness values, colours and textures for maximum versatility.
The new material has numerous applications in medical technology, either for prototyping or in component production.
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The CST-100 Starliner is designed to take up to seven passengers to low-Earth orbit destinations, such as the International Space Station. Solvay’s supply of durable materials has enabled OPM to begin shipping parts to Boeing already. “Solvay has positioned itself as the material science leader for AM technologies and processes for very challenging advanced transportation applications,” said Armin Klesing, Global Business Development Manager for Aerospace at Solvay’s Speciality Polymers Global Business Unit. “Consistent product quality and robust supply chain security are essential factors to manufacture very high standard parts on time in this fast-growing market.” Boeing selected OPM to provide its ‘OXFAB’-branded 3D-printed components as a result of their substantial cost and weight reductions, as well as reduced lead times. Solvay’s high performance materials will play a crucial role in meeting the high standards set by Boeing for the parts. Bernard Plishtin, Chief Business WWW.BRITISHPLASTICS.CO.UK
Development Officer, Oxford Performance Materials, explained: “From the project’s inception, we needed to provide not only significant weight and cost savings but also a drastic cut in lead-times. This was made possible by Solvay’s reliable supply of high performance materials for our specific additive manufacturing processes for 3D-printed aerospace structures.” Solvay is a leader in speciality polymers with cutting-edge AM material solutions for Fused Filament Fabrication (FFF) and Selective Laser Sintering (SLS) and is a strategic supplier to the aerospace industry. The company’s AM platform comprises facilities in Alpharetta, Georgia (USA), Lyon (France) and in Brussels (Belgium) with products such as AvaSpire polyaryletherketone (PAEK), KetaSpire polyetheretherketone (PEEK), and Radel polyphenylsulfone (PPSU) for FFF, and polyetherketoneketone (PEKK) and Sinterline Technyl PA6 powders for SLS processes. WWW.SOLVAY.COM 35
Biesterfeld Petroplas Ltd Biesterfeld Petroplas Ltd Biesterfeld Petroplas Ltd 6F Park Square, Milton Park 6F Park Abingdon, Square, Milton Park 6F Park Square, Milton Park Oxfordshire Biesterfeld Petroplas Ltd Oxfordshire Abingdon, Oxfordshire OX14 4RR 6F Abingdon, Park Square, Milton Park OX14 4RR OX14 4RR Abingdon, Oxfordshire T: 01235 822 040 F: 01235 833 155 OX14 4RR
E: sales@biesterfeld-petroplas.com T: 01235 822 040 T:F:01235 01235822 833040 155 F: 01235 833 155 T:W: 01235 822 040 F: 01235 833 155 www.biesterfeld-petroplas.com E: sales@biesterfeld-petroplas.com E: sales@biesterfeld-petroplas.com E: sales@biesterfeld-petroplas.com W: www.biesterfeld-petroplas.com W: www.biesterfeld-petroplas.com W: www.biesterfeld-petroplas.com
Design & Development Engineer Plastic & Rubber Extrusions A Product Design and Development Engineer is required to join the Technical Team of Reddiplex Group, a major trade extruder producing a wide variety of Plastic, Rubber and Graphite Profiles. www.reddiplexgroup.com The experience and ability to design and develop extruded products are essential. A wide-ranging knowledge of raw materials would also be required with a desire to grow further in this area. CMYK COLOR INFORMATION:
CMYK COLOR INFORMATION:
INDORAMA DARK BLUE: C100 | M80 | Y6 | K30 {PANTONE 288C) INDORAMA GREEN:INDORAMA C97 | M2 | Y98 | K12BLUE: (PANTONE DARK C100348C) | M80 | Y6 | K30 {PANTONE 288C) INDORAMA LIGHT RED: C2 | M100 | Y82 |C97 K6 (PANTONE INDORAMA GREEN: | M2 | Y98186C) | K12 (PANTONE 348C)
The position would involve working closely with customers on their individual projects and designing product for inclusion in the Group’s branded range. This includes supporting Field Sales Personnel in Technical visits to customers.
INDORAMA LIGHT RED: C2 | M100 | Y82 | K6 (PANTONE 186C)
CMYK COLOR INFORMATION:
INDORAMA DARK BLUE: C100 | M80 | Y6 | K30 {PANTONE 288C) INDORAMA GREEN: C97 | M2 | Y98 | K12 (PANTONE 348C) INDORAMA LIGHT RED: C2 | M100 | Y82 | K6 (PANTONE 186C)
CMYK COLOR INFORMATION:
INDORAMA DARK BLUE: C100 | M80 | Y6 | K30 {PANTONE 288C) INDORAMA GREEN: C97 | M2 | Y98 | K12 (PANTONE 348C) INDORAMA LIGHT RED: C2 | M100 | Y82 | K6 (PANTONE 186C)
The successful candidate could expect a suitable package and an exciting future within the Reddiplex Group.
Polymer distribution across Polymer distribution across the UK and Ireland the UK and Ireland
Full details of qualifications and experience should be submitted to: Madeline Senatore. Group H R Director. maddy@reddiplexgroup.com
www.biesterfeld-petroplas.com Polymer distribution acrossacross www.biesterfeld-petroplas.com Polymer distribution the UKthe and Ireland UK and Ireland Biesterfeld 1-4 advert.indd 1
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04/05/2017 13:10
MATERIALS | NEWS SABIC LAUNCHES NEW PHTHALATE-FREE PP IMPACT COPOLYMERS FOR THINWALL PACKAGING SABIC has added to its polypropylene portfolio for packaging with the introduction of two new high flow, injection-moulding grades. New SABIC PP 513MK46 and 512MK46 are impact copolymers based on a phthalate-free catalyst. The grades will provide packaging manufacturers with production efficiency through shorter cycle times and weight savings for thin-wall manufacturing. SABIC has developed the grades to comply with industry’s organoleptic requirements for taste and odour, with excellent stiffness and higher top-load strength for high stack-ability that helps manufacturers achieve faster production cycle times, along with lower transport and storage costs. “The need for the industry has never been greater to find efficient solutions to the challenges - especially in food packaging - that the world faces today,” explained Lada Kurelec, Director of Polypropylene Business.
BRITISH-MADE BIOPLASTICS COULD HOLD THE KEY TO COFFEE CUP WASTE A UK-based producer of bioplastics says its “world first” range of plantbased materials could hold the key to tackling the high-profile issue of coffee cup waste. Southampton-based Biome Bioplastics says it has developed a range of materials over the past five years specifically for coffee cups, lids and coffee pods based on natural and renewable resources including plant starches and tree by-products such as cellulose. Biome says its “world first” range of plantbased materials could hold the key to tackling the high-profile issue of coffee cup waste.
SABIC’s new phthalate-free PP impact copolymers enable downgauging and faster processing for thinwall packaging
“SABIC understands the need for its packaging customers to not only stay ahead of industry trends and regulations but also meet the demand for lowering weight and cost by reducing packaging thickness with down gauging, faster production cycle times, and minimising waste and the environmental impact. SABIC’s new impact polypropylene 513MK46 and 512MK46 grades are created to help our customers remain at the forefront of industry where consumer safety and sustainability are all critical.” SABIC says the new 513MK46
(MFR 70) and 512MK46 (MFR 50) products provide a great balance between high stiffness and impact strength than standard impact copolymers. The grades are typically used in rigid packaging such as packaging for frozen/chilled/ ambient food, dairy products, housewares and appliances, as well as toys, caps and closures. These new products are produced in SABIC’s Saudi Kayan facility in Jubail and will be available for customers around the world.
The company says it is the first time such bioplastic materials for disposable cups and lids have been made that are fully compostable and recyclable, while still performing like petroleum-based plastic under heat and stress. “For such a simple product, disposing of a single coffee cup is a very complex problem. Coffee drinkers are acting in good faith when they see recycling logos on their takeaway coffees but most cups are lined with oil-based plastic and the lids made of polystyrene making recycling impossible, even when placed in the right bin,” commented Paul Mines, CEO of Biome. “Our solution is making biopolymers that can be made into fully biodegradable coffee cup and lid combinations. The result being a bio-based takeaway cup disposable either in a paper recycling stream or food waste stream. “In appropriate composting conditions our cups and lids will disappear to carbon dioxide and water within three months.”
The British manufacturer says the bioplastics it has developed for cups and lids will enable retailers and packaging manufacturers to offer consumers a more sustainable option, after its market research showed growing concern amongst the public following reports of the issues surrounding difficulties recycling conventional coffee cups. “There are high-tech biopolymer materials being produced here in Britain that are ready to be deployed at scale for the market. Bioplastics can now perform almost exactly like petroleum-based plastics under mechanical stress and at boiling temperatures,” Mines continued. “The shocking amount of landfill waste shows the urgent need for big brands to accelerate work in new, sustainable materials such as bioplastics. High street retailers can now give consumers what they want: a sustainable takeaway cup option that can either be properly recycled or composted.”
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@POLYMERMAN ON PRICES As styrene-based polymers react to market fundamentals, what is likely to happen with other polymers? IN THIS EDITION OF OUR LATEST FEATURE LOOKING AT THE KEY ISSUES THAT INFLUENCE POLYMER PRICES, MIKE BOSWELL ASSESSES HOW THE MARKETS ARE REACTING TO A DIVERSE RANGE OF FACTORS, FROM OIL PRICES AND SHALE GAS AVAILABILITY TO THE UK’S SNAP GENERAL ELECTION.
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hat now appears to have been a spike in styrene-based polymer pricing based upon short supply of styrene monomer now over, and given that styrene-based polymers are generally in a state of good supply, prices are now falling away, giving welcome relief to hard-pressed processors. From the graph to the right it is clear that the spot price for Benzene and Styrene Monomers have acted as lead indicators. So, as oil prices start to soften what is now in store for other polymers?
market also contains an interesting combination of some feedstock-based deflationary pressure and also at a polymer type level significant differences in terms of supply/demand balance. The polymers that are in plentiful supply, and therefore likely to succumb to feedstock pressure, include PC and POM. Whereas PMMA, PA6 and PA66 are in a situation of extremely tight supply and are likely to remain so throughout 2017, which is likely leave buyers having to contend with both difficulty in securing supply and the likelihood of further sharp price increases. Given that for the UK polymer pricing is typically USD or Euro denominated the recent increase in value of the GBP following the snap General Election to take place on June 8th will relieve some of the effects of devaluation following the BREXIT decision at the end of June last year. What remains to be seen is what further impact the election result will have, although given the likely outcome the financial markets will have already factored this in. It certainly looks like an interesting time ahead in terms of polymer pricing, with influence from a diverse range of factors.
“It certainly looks like an interesting time ahead in terms of polymer pricing, with influence from a diverse range of factors.” The combined graph (below right) also appears to indicate that other spot markets for feedstock have started to move downwards. However, it is important not only to consider the supply/ demand fundamentals for the feedstocks, but also for the polymers they themselves create. Interestingly, these market forces can act not only on broad polymer categories, but also at even a polymer type, grade or application level. To some extent this is visible in the polyolefins market with increasing evidence that PP will become increasingly detached from PE as the availability of C3 changes with the advent of shale gas-based PE. Furthermore, markets can act quite differently depending upon grade, with often significant variance in fundamentals between the relative niche injection moulding and the high-volume grades for extrusion processes including film, sheet and blow moulding. On this basis it is possible that polyolefin pricing, at least in the short-term, may have a diversified reaction to the reduced input prices. The engineering polymers
Who is @polymerman
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, and, most recently, its ‘BREXIT Committee’. 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.
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FILM & SHEET | NEWS SENSORY EXPERIENCE IS AS IMPORTANT AS FUNCTIONALITY FOR FLEXIBLE PACKAGING, SAYS AMPACET Masterbatch manufacturer, Ampacet, says that the right sensory experience is as important to the consumer as functionality when it comes to flexible packaging. As a result, the company is focusing its portfolio of masterbatches for film applications on those that combine both aesthetics and haptics to create packaging that is both visually attractive and pleasant to touch and feel. “Besides packaging functionality, such as food shelf-life extension, easy-opening etc., consumers sensory experience strongly matters. Indeed, it influences their buying decisions, which, in a crowded retail
The Paperlook range
and its to exp A films is ik Evon PMM y for capacit ulti-million m with a vestment in pound
environment takes a few seconds, sometimes less,” explained François Thibeau Ampacet’s European Strategic Business Manager for Films & BOPP business units. “Ampacet has a large range of masterbatches for film applications that allow brand owners to enhance both aesthetics and haptics by providing an attractive and unique aspect to their flexible packaging. This not only provides increasing brand shelf-appeal, but provides the consumer with a sensory experience.” Examples of Ampacet’s more unusual effect finishes include ‘ReptyleFX’ technology, where a spiderweb-like or snakeskin-like effect is possible for multi-layer coextruded film structures, allowing designers to create flexible packaging products that replicate snake skin’s tactile and visual appeal. The technology is based on the unique combination of colours and special effect masterbatches added in the different layers of coextruded films. The company also offers masterbatches to mimic traditional materials, whilst offering the benefits of polymeric films. Its ‘Paperlook’ and ‘Kraft Paperlook’ masterbatches for example provide the look of white or brown kraft paper and retain some of the characteristics of paper, including high stiffness, easy diecuttability, good dead-fold properties for easy converting, hand-writability
MAJOR INVESTMENT FROM EVONIK IN NEW MULTI-LAYER FILMS FACTORY Evonik is to expand its capacity for the production of polymethyl methacrylate (PMMA) films with a multi-million pound investment in a new production plant in Weiterstadt, Germany. The new plant will enable production of extremely wide and high quality flat films with a “previously unachieved” number of layers. Martin Krämer, Head of the Acrylic Products Business Line, said: “With the investment we have now approved, we are strengthening our role as innovation leader for acrylicbased technologies and products.” “This is an example of how we are putting our vision ‘Evolution in acrylics is our passion’ into daily WWW.BRITISHPLASTICS.CO.UK
ReptyleFX ide effects prov an unusual finish
and matte soft surface finish, whilst presenting advantages over woodpulp paper such as low tearability, low permeability and high moisture and grease resistance. Ampacet recently announced the addition of a new range of matte compounds for Bi-Orientated Polypropylene (BOPP) film producers that it says complements the growing trend for a more low-gloss appearance in plastic packaging. The ‘Matif’ range has been developed and designed for the BOPP process, but is also suitable for use in multi-layer polyethylene blown film applications. When used in the outer layer of polyethylene film applications, Ampacet says the Matif range will provide “outstanding matte properties”, as well as an easy view of graphic details due to a very low light reflection and excellent contact transparency. In addition it can provide a silky, smooth, softtouch finish that Ampacet says can contribute to giving a luxury and quality image to a brand. WWW.AMPACET.COM
business.” Evonik’s multi-layered PMMA films are used in medical technology, building windows and façades, as well as the graphics industry. It hopes the new Weiterstadt facility will be producing PMMA film by the end of 2018. Michael Enders, Head of Film Activities, said the new plant will also allow new film compositions: “We’re expanding our offerings of custom-designed specialty films that offer not only our customers but also the consumers genuine added value. “Wider multi-layer PMMA films allow particularly long-lasting and sustainable products and offer our customers new design and processing possibilities.” WWW.EVONIK.COM 41
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KLÖCKNER PENTAPLAST TO ACQUIRE LINPAC GROUP The Klöckner Pentaplast Group (KP), a leader in rigid plastic film and packaging solutions, has announced it is to acquire the LINPAC Group and subsidiaries for an undisclosed sum. The transaction will create a global leader in the rigid and flexible film market, with combined annual revenues exceeding $2 billion (approx. £1.6 billion GBP). The combination of Klöckner Pentaplast’s film production with LINPAC’s film production and conversion capabilities will create a ‘one-stop-shop’ that they say will provide “complete packaging solutions” to customers. Wayne M. Hewett, CEO of Klöckner Pentaplast, said: “This is a highly complementary acquisition that will help Klöckner Pentaplast expand our technological capabilities and presence into the food industry and the rigid and flexible film market, as well as further develop our offerings in end markets such as pharmaceuticals, food and beverage, and consumer and industrial products.” Daniel Dayan, CEO of LINPAC, added: “We are excited to join forces with KP and believe this transaction will significantly accelerate LINPAC’s geographic expansion.” The combined company will have an extended reach and portfolio breadth, as well as a broader customer base. Together, KP and LINPAC will have 32 locations across 16 countries with about 6,300 employees. KP’s existing global footprint with operations on six continents will greatly accelerate LINPAC’s geographic expansion ambitions, particularly in the Americas. The consolidated group will be led by Wayne M. Hewett. Daniel Dayan will lead the Food portfolio.
The new ASTM Standard for thickness and variability: What it means for the plastic film industry
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ilm thickness – and thickness variability – is a key parameter for film, but as films get thinner and thinner they get harder to measure and FILM VARIABILITY HAS define. For example, REAL IMPLICATIONS many producers FOR PERFORMANCE, use micrometers INCLUDING STRENGTH, that are precise to +/- 1 micron, but PERMEABILITY, PRINT this is +/-8 percent SPEED, CONSISTENCY of the thickness IN THE CONVERTING of a 12 micron PROCESSES AND MORE. film. Additionally, THE INTRODUCTION OF micrometers are slow, A NEW STANDARD WILL prone to operator error, deform the film HELP DRIVE THE MARKET while measuring it and TOWARDS BEING QUALITY are subject to errors ORIENTED, IMPROVE due to contamination RELATIONSHIPS from dust and dirt. Since it is not BETWEEN SUPPLIERS practical to measure AND CUSTOMERS AND every spot on a film HELP THE INDUSTRY sample, most decide MOVE FORWARD INTO to measure several THE FUTURE, SAYS points and call that ROB LAWRENCE OF their variability; SOLVETECH INC. this is obviously incomplete, and it is not standardised in any way. So when someone says they have a material that is +/-5 percent in variability, what does that mean? Many try to turn to their on-line gauges for the answer, but under examination, this again comes up short. With dozens of different suppliers using different techniques, measurement footprints, scanning speeds and averaging functions in their software, there is no way to standardise variability coming off of all of these systems. ‘Two-sigma’ can mean something different on every different gauging system used. PR2000 Precision Profiler
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A solution the industry can use
A new ASTM standard coupled with innovative technology seeks to change the status quo and is currently going to vote in subcommittee. This standard, entitled ‘Standard Test Method for Determining Plastic Film Thickness and Thickness Variability using a Non-Contact Capacitance Thickness Gauge’ defines film thickness using a NIST traceable calibration and a device with a precision of +/- 0.1 micrometres. In practice, SolveTech’s PR2000 Precision Profiler can exceed this performance level. In addition, the new approach eliminates the problems of film deformation, dust and dirt affecting the reading and it takes readings fast. Users are able to profile a strip characterising the entire extrusion in 30 to 60 seconds, measuring every area along the strip. If a 3mm wide measurement area is used, the film will be measured every 3mm, providing complete coverage. This will enable producers to claim “my pattern of variability has a sigma of +/- 4.5 percent according to an ASTM standard.”
Why this “changes the game”
The film industry trades tens of billions of Euros in film every year and without a standard in place, it can be difficult to distinguish between suppliers. Many buyers are therefore forced into making price-based decisions. Now, there will be an “apples to apples” way to compare the variability of film coming from two suppliers. Before film is shipped to a converter, the film can be checked using this new standard to verify that it will perform in its intended conversion process. In addition, hundreds of millions of Euros in extrusion equipment is purchased every year, with each supplier claiming to produce the best film. Now there is a standard way to compare them and make fact-based decisions. In the UK and Europe, SolveTech Inc. is distributed by Quantum Ops Business Solutions Limited. WWW.QOBUSINESSSOLUTIONS.CO.UK
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RECLAMATION & RECYCLING | NEWS HALIFAX-BASED EXTRUDER REDUCES COSTS WITH PLASMAC RECYCLING TECHNOLOGY Bond A Band, a plastics extrusion company based in Halifax, is saving both production and materials costs following investment in a new recovery and recycling system from Plasmac. The company, which manufactures extruded aromatic/aliphatic polyurethane sheet, film and profiles, chose a system from UK-based Plasmac’s ‘Alpha’ range. The Alpha system was supplied by UK Extrusions Ltd, announced as Plasmac’s sales agent early this year. It allows Bond A Band to utilise its production waste by enabling the company to reclaim and pelletise its start-up waste, including flake product and coiled films. These are then fed directly into the system to avoid granulation prior, before they are fed proportionally back into the company’s extruders as a formed pellet to maintain bulk density. Commenting, Bond A Band’s Managing Director, Jonathan Heaton, said: “Having researched the market,
FLEX PACKAGERS START CEFLEX PROJECT A group of European flexible packaging companies have set up ‘CEFLEX’, a new project to advance the use of flexible packaging within the context of the circular economy. The scheme continues the work of the recently concluded ‘FIACE’ CEFLEX is a new project to advocate the use of flexible packaging in the circular economy
I came to the conclusion that the Plasmac Alpha range fulfilled my criteria in terms of capability in handling a very difficult material, running costs and quick return on investment. “The way this system is designed means that we will not require any prior size reduction for most products, in terms of a granulator or shredder, which will contribute towards reducing our production costs. Additionally, this was one of the smallest footprint units available to us and will therefore release valuable space for other applications.” Before purchasing the system, Bond A Band sent samples of its start-up waste to Plasmac’s UK facility for trials. After initial tests staff were able to visit, view the proposed system and see their material being processed. UK Extrusion Director, Steve Trainor, said: “The Alpha system that Jonathan has chosen features Plasmac’s patented Short Screw Technology. This provides minimal power consumption and highest output, giving overall lower running costs. “The low shear, minimal dwell
time and absolute minimal material degradation means that Bond A Band will be able to recycle all their waste into high quality pellets. This will immediately reduce their raw material costs. Put this together with the energy savings and the great return on investment becomes apparent.”
project, which helped to quantify the added value and identify opportunities to increase recycling of flexible packaging; and REFLEX, an Innovate UK-funded technical project focused on recycling flexible packaging in the UK. The consortium currently has 34 stakeholders including Tomra, Suez, Dow, Borealis and Siegwerk. The entire value chain is represented, from raw materials suppliers, packaging converters, brand owners and retailers to producer responsibility organisations, collectors, sorters and recyclers, as well as other technology suppliers and end users of the secondary raw materials. Graham Houlder, Project Coordinator, said: “The earlier studies clearly identified technical solutions for successfully sorting and recycling more than 50 percent of flexible packaging, using state of the art
technologies. We are moving forward from this excellent work. “We expect more flexible packaging to be collected and recycled in an increasing number of European countries. There will be recognition of the significant value this packaging format adds to the circular economy through measurable resource efficiency, waste prevention and recycling benefits.” CEFLEX will work towards the development of a collection, sorting and reprocessing infrastructure for post-consumer flexible packaging across Europe by 2025. This will be enabled by the development and application of robust Design Guidelines for both flexible packaging and the End of Cycle infrastructure to collect, sort and recycle it, due for completion by 2020.
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Unilever has unveiled a new recycling technology for sachets that it says could divert billions of tonnes of plastic from littering, landfill and the oceans
UNILEVER DEVELOPS PLASTIC SACHET RECYCLING METHOD TO TACKLE WASTE PROBLEM IN DEVELOPING WORLD Unilever has unveiled a new recycling technology for sachets that it says could divert billions of tonnes of plastic from littering, landfill and the oceans. Developed in conjunction with the Fraunhofer Institute for Process Engineering and Packaging IVV in Germany, the new ‘CreaSolv Process’ is described as “the circular economy in action” and is part of Unilever’s pledge to ensure all of its plastic packaging is fully reusable, recyclable or compostable by 2025. The technology is designed for developing and emerging markets, where billions of single-use sachets are sold every year, allowing lowincome households access to otherwise unaffordable products. However, without a viable recylig system, the sachets end up as litter or landfill. The CreaSolve Process has been adapted from a method used to separate brominated flame retardants from waste electrical and electronic equipment polymers. During the process, the plastic is recovered from the sachet, and the plastic then used to create new sachets for Unilever products - creating a full circular economy approach. David Blanchard, Chief R&D Officer at Unilever, said the company intends to make the technology “open source”, meaning
These containers are produced using 25 percent post-consumer recycled polypropylene and so contribute to reducing polyolefins going to landfill (Credit: PCEP)
others – including its competitors – can use it. “There is a clear economic case for delivering this. We know that globally $80-120bn (approx. £60-90bn GBP) is lost to the economy through failing to properly recycle plastics each year. Finding a solution represents a huge opportunity. We believe that our commitment to making 100 percent of our packaging recyclable, reusable or compostable will support the longterm growth of our business.” Unilever will open a pilot plant in Indonesia later this year to test the long-term commercial viability of the technology. Indonesia is a critical country in which to tackle waste, as it produces 64m tonnes every year, with 1.3m tonnes ending up in the ocean. To tackle the wider sachet waste
issue across the industry, Unilever is looking to create a sustainable system change by setting up waste collection schemes to channel the sachets to be recycled. Dr. Andreas Mäurer, Department Head of Plastic Recycling at the Fraunhofer IVV, said: “With this innovative pilot plant we can, for the first time ever, recycle high-value polymers from dirty, post-consumer, multi-layer sachets. Our aim is to prove the economic profitability and environmental benefits of the CreaSolv Process. Our calculations indicate that we are able to recover six kilos of pure polymers with the same energy effort as the production of one kilo of virgin polymer.”
POLYOLEFIN CIRCULAR ECONOMY PLATFORM ANNOUNCES KEY STRATEGY TO INCLUDE POLYOLEFINS AS RECYCLATE
with circular economy focus, as well as enhanced collection and sorting systems. Eugenio Longo, Chairman of PCEP, said: “This is just the beginning of an exciting journey. Six working groups have been created to deliver on the mission. Each of those groups are refining their objectives. “To mark this starting point, we have launched a website where visitors can learn about the different activities that will be undertaken to reach these goals.” Along the website, the platform also launched its visual identity with the creation of its logo.
Following its creation in October 2016, the Polyolefin Circular Economy Platform’s founding partners, European Plastics Converters, PlasticsEurope and Plastics Recyclers Europe, have agreed on a joint mission to advance the circular economy by increasing the recycling of polyolefin-based products and the use of recyclates as raw material. Starting with polyolefin packaging, the value chain platform has set two strategic goals, covering innovation 46
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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
www.hte.ie TO ADVERTISE in this space CONTACT LISA MONTGOMERY 01244 680222
WWW.BRITISHPLASTICS.CO.UK
TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222 47
BUYER’S GUIDE
MACHINERY & EQUIPMENT
PRINTING MACHINES
SCREWS & BARRELS
pad
MIXING, FEEDING & DOSING
www.magog.co.uk Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries.
Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
• Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks Contact us to find out how we can help you Magog Industries Ltd, 10 Crane Mead, Ware, Hertfordshire, SG12 9PY T: +44(0)1920 465201 E: enquiries@magog.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
TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222 Magnetics Separators Metal Detectors Eddy Current Separators
Bunting Magnetics Europe Ltd European Design & Manufacturing Facility
Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co
/magnetic_separation_and_metal_detection/
DTL Machinery UK
- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com
TESTING EQUIPMENT 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
TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222
EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H. Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at
TransXL International Ltd
CHOOSE THE NUMBER ONE.
I’VE GOT A BUMPER LOAD OF RECYCLED PLASTIC IN ME, THANKS TO VANDEN
50mm high and 35mm
Mould change
We buy and sell high quality plastics
028 9266 8009
www.vandenrecycling.com supply@vandenrecycling.com
Engineers to the Plastics & Rubber industries, specialising in the following:
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
thermocouples
SECONDHAND AND RECONDITIONED 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
Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com
www.quick-mould-change.com COMPOUNDS
FOR SALE 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
Cooper Plastics Machinery
SCREEN CHANGERS 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
TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222
for
ulders injection mo
We buy/sell Prime, reprocessed, regranulated flexible PVC compounds, dry blends, pulverised PVC, scrap PVC, PVC resin and associated raw materials. Please send us your offers/enquiries vinyl_ltd@mail.com We can offer prime and reprocessed flexible PVC compounding facilities to cover your specific requirements, bespoke compounds, breakdowns, holiday cover etc.
WWW.BRITISHPLASTICS.CO.UK
Vinyl Ltd
Tel: 01625 500912 Mobile: 07860 371294 Web: www.vinyl-ltd.com
c.co.uk www.rjgin
vekacompounds.com +44(0)1322 387 219
8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 719850 E: Cooperplastics@gmail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, fly knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.
TRAINING
11 )1733 2322 P. +44 (0
QUALITY PVC PELLETS FOR EXTRUSION
Industrial Plastics Ltd
Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk
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
ANGLO PLASTICS LTD
48
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
RECYCLING SYSTEMS
Contact: Carlton Hicks
NOZZLES & NOZZLE TIPS
DM Machinery Ltd
TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222
BUYER’S GUIDE TO ADVERTISE IN THis SPACE CONTACT lisa montgomery 01244 680222
MOULDFLOW ANALYSIS
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
3D PRINTING
3D Printing
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
in Plastic & Rubber
PRINTERS printers of plastic mouldings Tel: 01420 88645
www.projet3d.co.uk
TESTINg/CONSULTANCY
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
Component PRINTERS TAMPO.SCREEN.FOIL
Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com
Gammadot Rheology Testing & Consultancy Services
SERVICES BUSINESS FOR SALE
Selling the Business? Kingswood Business Sales are your industry experts with a proven track record of successfully selling companies like yours. Avoid the pitfalls - contact Paul Holohan in complete confidence on 07798 530684
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
kingswoodbusinesssales.com
MOULDFLOW ANALYSIS Injection
SOFTWARE DIRECTORY
SOFTWARE
Moulding
Trainingancy Consultow fl & Mold
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, Standalone “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. Realtime 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.
c.co.uk www.rjgin
211 )1733 232 P. +44 (0
c.co.uk www.rjgin
211 )1733 232 P. +44 (0
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’ WWW.BRITISHPLASTICS.CO.UK
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).
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 Realtime MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.
Process Optimisation Software RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E ingo@rjginc.co.uk Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors. 49
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NEWS FROM THE FRONTLINE
A
bp&r BRITISH PLASTICS &RUBBER 50
must be working together with one aim. We have had plastics recyclers in the UK for many decades and indeed some of the current members of the BPF’s Recyclers Group date back to the 1940s. The Recycling Group itself has been active since the 1980s and today embraces some 40 highly responsible recyclers. As an industry we have had award systems which have embraced recycling. Additionally, for two years the BPF has been coordinating an organisation called PIRAP, the Plastics Industry Recycling Action Programme, which bring together a large number of plastics industry players, brand owners and retailers. It has been endorsed by Defra. Its single objective is to increase the recycling rate for plastics packaging and it has working groups already in existence focusing on bottle recycling and the issue of black trays. The Ellen MacArthur initiative is certainly well received but we all have to be clear that no single project is likely to produce a silver bullet to resolve the whole issue. Only full and transparent cooperation is likely to get anywhere near the Holy Grail. The political environment has been nothing less than a hair- raising roller coaster in recent weeks. A surprise General Election was announced in the UK, indiscretions about a dinner with Mrs May released by high level Commission officials and a President, pretty much behind ‘the European project’, was elected in France. How do we react? Well, the old wartime adage springs to mind, ”Keep calm and carry on”, focusing on the search for business opportunities. The BPF is presenting one such opportunity to the industry and that is participation in the Plastimagen trade fair in Mexico City in on November 7-10 2017. There will be 14 international pavilions spread over for halls and over 30,000 visitors are expected. Contact Justyna Elliott at the BPF on jelliott@bpf.co.uk for more information. www.bpf.co.uk
ASSOCIATED ORGANISATIONS
s you may have already read at the beginning of this issue, the Ellen MacArthur Foundation has launched an award to the IN THIS MONTH’S EDITION value of $2M OF HIS EXCLUSIVE COLUMN, (approx. £1.54m GBP) for Innovation PHILIP LAW, DIRECTOR- in plastics recycling GENERAL OF THE BRITISH to address what PLASTICS FEDERATION, they described as “the 30 DISCUSSES WHY THE ELLEN percent of plastics that can’t MACARTHUR FOUNDATION’S be recycled”. Whilst this is NEWEST INITIATIVE CANNOT certainly to be welcomed and, as an industry, we are eager BE SEEN AS A ‘SILVER to absorb genuine advances in BULLET’ FOR THE ISSUES technology, we have to place SURROUNDING PLASTICS this initiative in context. In our view, all plastic is RECYCLING, AS WELL AS recyclable and its lightweight WHY THE INDUSTRY SHOULD and resource efficiency saves “KEEP CALM AND CARRY energy and significantly ON” IN THE CHANGEABLE reduces CO2 emissions. POLITICAL ENVIRONMENT. Plastics recycling has grown fast in recent years with some 57 percent of plastic bottles now being collected for recycling and well over one million PVC window frames being recycled. Of course, there are significant challenges impeding progress, including logistical difficulties such as inconsistent collection between local authorities and global market factors. But an assumption which lays behind the Ellen MacArthur initiative is that, as one journalist put it to me, that the industry itself has been doing very little about this. “How”, she said, “is so much plastic still not being recycled in this day and age?” I told her that the issue is by no means as simple as she thinks and that “recycling” is a combination, currently, of industry effort, consumer engagement and Government intervention at both local and central level and by “industry” I mean all the parties along the supply chain who are involved in the presentation of a product to the consumer. For recycling to move forward all parties
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