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ISSN 0307-6164
Incorporating Polymer Age and Rubber and Plastics Age.
COMMENT
Wrapping up in style
Another year has come to a close –another year rife with innovation, partnerships and successes. 2024 also presented significant challenges, with energy prices increasing, the ongoing geopolitical conflicts and the US elections impacting exchange rates.
The issue of plastic recycling is as pressing as ever, but what’s important is the potential for the future and the steps we’re taking to excel at it together. Positive mindsets only, right? So, let’s take a journey down memory lane to look back at some of this year’s most memorable moments.
2024 brought us many anniversaries, and we celebrated them in style. Hasco reflected on its 100-year journey in the mould-making industry, while Hardie Polymers toasted to a century of milestones. Sumitomo (SHI) Demag enjoys 50 years of market presence in the UK and Ireland, paving the way for progress in injection moulding.
This year has seen AI and Industry 4.0 technologies advancing rapidly, which is the focus of our cover story this month. The British Plastics Federation’s thoughtprovoking Plastics & AI seminar touched upon the impact of AI in industrial manufacturing, the legislation for UK businesses and strategies to develop a corporate AI policy.
FANUC’s Open House also shed light on the matter, with a presentation by Airbus reinforcing the role of AI within the aviation industry. The message was clear. AI isn’t here to replace our job; it’s here to help us make it better, faster and safer.
2024 highlighted another pressing issue – the UK’s manufacturing skills gap, with 75% of manufacturers identifying skills shortages as their biggest barrier to growth. This reminded us of the importance of apprenticeships as a viable option to offer young people hands-on experience while earning a wage.
The Festival of Polymer Innovation (FOPI) by Plastribution took place in September, adding a twist to plastics events as we know them. The aim was to create a
“The issue of plastic recycling is still pressing, but what’s important is the potential for the future and the steps we’re taking to excel at it together.”
welcoming atmosphere for people at all levels of business, equally combining educational, networking and social aspects.
The BPF’s 91st Annual Dinner and the Plastics Industry Awards returned in full swing, acknowledging companies and innovators for their incredible efforts. It was a joy to see everyone get together to celebrate each other’s wins – teamwork makes the dream work after all! We’ve also continued to shape the world of Interplas 2026, knowing we’ll be there in the blink of an eye (physically, because we’re already there mentally!).
Thank you for your continued support and interest in our BP&R magazine – I am glad you’re on this journey with us, and I hope you’ll stay. I wish you a great Christmas break – I’ll be treating myself to an endless amount of Italian food, so I hope you’ll treat yourselves to something great, too!
See you in the new year.
GIULIA DANIELE
EDITOR
DYNACON CUSTOM CONVEYORS
YOU AND
“Since buying our first Yizumi D1, we have bought a further four.”
Yizumi D1 machines are playing a key role in Norham Plastics ISO 9001 accredited operations, providing the scope to produce products up to 20kg shot weight.
Operations Director Angela Clarke, said: “When we needed a machine to replace an older one, we looked around the market and Yizumi had the best combination of specification and value. Since then we have bought a further four Yizumis up to 2700 tonnes, and we are really happy with them and the service that STV provide. An unexpected bonus was the excellent energy saving of the servo hydraulics; we would definitely recommend Yizumi and STV.”
Norham Plastics puts its trust in Yizumi and STV. Will you? Give us a call today, to discuss your application or arrange a visit to our showroom and workshop.
MODEL SHOWN: YIZUMI D1 SERIES
PROCESS CONTROL SOFTWARE
Big data, smart manufacturing, vertical integration and crossplatform communication. Does anyone know how to do it? And is it even feasible? Sumitomo (SHI) Demag explores these questions as we enter a new age of connectivity and transparency.
Sumitomo (SHI) Demag UK has recently worked with a small consortium of premium machinery and automation partners to deliver a factorytested, CE-marked machine. This connected an IntElect injection moulding machine to the periphery moulding equipment, including four existing boxing and packing systems. The company used locally built software and hardware to make everything interact through a single NC5 controller.
GAINING VALUE FROM DATA
Data holds intrinsic value since it can optimise productivity and increase profitability.
ARE YOU CONNECTED?
Revolutionising plastics productivity and transparency
However, this is possible only if collected and handled correctly. Factories can now gather big data thanks to advancements in digital technology, from deep learning data analytics to cross-platform, open-source communication.
Industry 4.0 introduced Smart Manufacturing, whereby Industrial Control Systems (ICS) monitor the factory’s physical processes and make decentralised decisions. These become the ‘Internet of Things’, communicating with each other and with humans in real time.
As SDUK Director Nigel Flowers states, “The key to success is total integration and seamless interactive connectivity between all devices, from injection moulding machines and robotics to temperature controllers and mould flow digital devices.”
CAN MACHINES COMMUNICATE?
The move towards smart manufacturing and Open Platform Communications Unified Architecture (OPC-UA) interoperability continues.
The standard was created in 2006 by the OPC Foundation and proposed a standardisation of communications between ICS machines. It can be implemented on most current ICS devices, running a compatible operating system (e.g. Windows, Linux, IIOT).
OPC-UA allows equipment and machines to communicate but it doesn’t determine the topic. There needs to be a “conversation” layer – what the equipment talks to each other about and what data is collected – for real information to be exchanged. With the help of the OPC Foundation, Euromap has created this cross-platform, universal reporting language.
WHY DO WE NEED
THIS?
“90% of the machines we install at SDUK require some form of integration with existing equipment and technologies. Many of this existing equipment is not from the same company. Plus, few factories would ever have the luxury of replacing all their legacy equipment at the same time, or with the same brand,” states Nigel.
The MakeUK Industrial Strategy Report 2023 relays that the cost of upgrading capital equipment is often cited as the biggest barrier to decarbonising processes and sustainability efforts.
The overcomplexity and issues with enabling interoperability of ICS are only just being addressed. Few have been able to push the boundaries and mastered total integration, seamless communication, data collection and valuable analysis between devices.
To deliver the productivity, process and people improvements these new digital tools boast, companies need to be strategic in their approach, urges Nigel. He believes that even the best technologies are compromised by a lack of long-term planning and reactive piecemeal purchases. “Urgency very often takes precedence over strategy. Piecemeal investments may get you by today, but they rarely account for the future.”
When digital transformations are scaled across the entire value chain, the gains can transform a plastics processor’s competitive position. This ranges from an increased production capacity and a lower environmental impact to unparalleled OEE and higher employee satisfaction.
Fully leveraging the newest digital technologies can lead to a 50% reduction in machine downtime, a 30% increase in throughput and an 85% improvement in forecasting accuracy.
Generation 5 Technology
Taking energy efficiency and process optimization to the next level
Energy savings up to 40% versus Traditional Servo Hydraulic Machines
Energy savings up to 80% versus Fixed Pump Machines
THREE GENERATIONS of thermoforming excellence
LVF Packaging is a familyowned and run business, which prides itself on designing and manufacturing high-quality thermoformed packaging. Initially focused on retail, the company moved to food packaging, working closely with supermarkets across the UK.
It all started from a garden shed, where current Managing Director Nigel Coates built a small vacuumforming machine to keep his father, Harry, occupied after retirement. While the shed is long gone, Harry and Nigel’s legacy and commitment to innovation have lived on, leading to LVF Packaging still going strongly 37 years later.
Daniel Coates leads the business in its third generation, driving growth in all departments. He is highly passionate about the environment and keen to invest in renewable energy, having recently installed 670 solar panels.
Our conversation sheds light on LVF Packaging’s core values, mission and vision for the future.
[GD]. How was the state of the thermoforming market when you first started and how has it changed since then?
[DC] Today, it’s just a numbers game. Get the
Daniel Coates, Business Development Director, sits down for an interview with Editor Giulia Daniele at the Leeds facility. The conversation highlights current themes in the plastics processing industry, from the demonisation of plastic to the government’s lack of centralised approach to recycling.
material as cheap as possible and make it as thin and recyclable as possible. We need to push for recycled content; everybody knows it’s the right thing to do. We’re also seeing more requests for information on the CO2 profile, like where the energy comes from. This is why we’ve invested over £1 million in solar and battery storage.
We’ve also changed as a company from when I first started. We were doing a lot of gift trays and components, but we’ve been BRCaccredited since 2009, and now mainly do food
BP&R's editorial advisory board
Richard Brown, Chair of Judges Design Innovation in Plastics Awards
Dr
Sally Beken Knowledge
what people want and what materials companies should use, but we’ve never been busier. We’re still making trays and people still want them the way we make them. We’re trying to provide card packaging if our customers want it, but this doesn’t seem to have taken off yet.
[GD] How does your view on the demonisation of plastic drive the company’s vision?
packaging. The accreditation opened a lot of new avenues, and we picked up from there.
[GD] What do you think are the biggest challenges in the industry?
[DC] Uncertainty. Many of our customers have moved to cardboard packaging, but many are moving back to plastic. There was also some uncertainty leading into the recent government budget, but we know where we stand now.
There’s just a lot of uncertainty around the issue of plastic. This includes
Robin Kent Managing Director Tangram
[DC] It’s all about trying to stay balanced. People believe we’re the problem because we make plastic trays, but we don’t want plastic in the ocean just as much as they do. We want to recycle it; the circular economy is the best way forward.
The demonisation of plastic starts with social media. They’re putting a lot of pressure on retailers and customers. We’re trying to ignore the loudest voices while being silently aware of them because we know everyone is listening.
All our trays are 100% recyclable, and we engrave this on the bottom. However, people still throw them in a non-recycling bin because they’ve read it on social
Dr
media. Products that were previously on plastic trays are now in cardboard, but can they all be recycled? Some of them can, some others can’t. If the cardboard gets contaminated with oil, fat or blood, it can’t be recycled. So, you’ll have replaced something perfectly recyclable with something that is not just because you’ve heard it on social media. We need to filter out some of the noise around us and keep doing what we do while educating our customers.
[GD] How do your process and products set the company apart from its competitors?
[DC] A food tray is a food tray, so our products aren’t different from other companies. What’s unique is our customer service. We can turn things around far quicker than a lot of our competitors. We have a small management team, which gives us great flexibility. Despite being small, we have the same machines and
relationships with suppliers as big companies, so we enjoy the best of both worlds. It also matters to people that we’re a family business because our name is above the door.
Our process is very straightforward. A customer will come to us with an idea, which we start drawing up. Most of the time, we make the sample before the drawing has been approved, because we know what the customer needs. Then, we make a prototype mould, make the samples and send them out. We manufacture our tooling in-house, which gives us and our clients great flexibility. We don’t make any profit from tooling; we make it at a cost price.
Everything we do is bespoke; we don’t have many off-theshelf items. Clients come to us with what they need, including the material. Our input involves making the product as thin and recyclable as possible.
[GD] What would you hope for the industry to achieve?
[DC] If I could wave a magic wand and get the industry to do one thing, it would be for everybody to move their packaging to clear rPET Mono. I know it would be an issue for microwavable and ovenable food, but regular packaging would benefit from it, increasing recycling nationwide.
It’s cheaper than rPET PE, but can be more difficult to seal. However, there’s been a lot of work done by the manufacturers of sealing film,
Dr Michael Junior Hopkins Managing Director Ross Polymer Services
Pravin S Mistry Global CEO PREA Ltd.
so I don’t see why we should keep using rPET PE. If all the tray packaging in the UK were made from clear rPET Mono, we wouldn’t have to worry about what bin it goes into.
Many companies are moving to clear rPET Mono, so the industry is going in the right direction. However, there doesn’t seem to be a nationwide approach to recycling. Everything is left down to the local councils, so how are people supposed to know what to do? The government needs to step in and take the matter out of the hands of the local authorities. There needs to be a conjoined approach to increase recycling across the board.
[GD] What’s next for the company?
[DC] What makes us successful is our customer service. It would be nice to expand, but we’ll lose our customer service. We do have plans to grow, but what we’re focusing on now and in the short-term future is becoming more efficient. This includes where we buy materials from, the energy we use and the process we adopt.
If you consider the customers we supply and the size of our company, many may think that we’re punching above our weight. I am proud of that. This shows a lot of trust in us, and we want to live up to that trust.
“If I could wave a magic wand and get the industry to do one thing, it would be for everybody to move their packaging to clear rPET Mono.”
Professor Edward Kosior CEO and Founder Nextek
Dr Thomas Bennett Research Fellow University of Manchester
COLOUR MASTERBATCH & ADDITIVES
PUSHING THE BOUNDARIES of material performance with GrapheneXcel
[GD] What is GrapheneXcel?
[JR] GrapheneXcel is the latest addition to Broadway’s +performance range of additive masterbatches. It brings the benefits of graphene to plastic manufacturing in the form of graphene-enhanced masterbatches (GEM). GrapheneXcel offers significant tensile and impact strength enhancements even at low addition rates. It also improves gas barrier properties, enhances electrical and thermal conductivity and offers better processability. Thanks to polymer-specific carrier systems, GrapheneXcel is compatible with various polymers, including PE, PP, PET, TPU and PA6, as well as several moulding processes like injection moulding, blow moulding film manufacturing.
[GD] Why did you feel it was necessary to bring this product to life?
[JR] Launching GrapheneXcel is a strategic response to the increasing demand for light-weighting and strength enhancements. It pushes the boundaries of material performance, enabling manufacturers in various industries to create stronger, better products. The potential it provides for material reductions and production efficiencies also reduces environmental impact.
[GD] How does GrapheneXcel benefit your products, your customers, and the environment?
[JR] GrapheneXcel helps widen the scope of plastics. Its enhanced barrier characteristics are highly beneficial in packaging applications like beer
Editor Giulia Daniele caught up with James Rous, Marketing Manager at Broadway, to discuss GrapheneXcel, the company’s latest addition to its Greener Solutions product portfolio. The conversation highlighted the benefits and the applications it caters to while exploring other sustainable options for a greener future.
bottles, where preventing gas exchange extends the shelf life of perishable goods. By creating a more effective gas and UV barrier within plastics, PET becomes a viable alternative to glass beer bottles (which are proven to have a greater carbon footprint), providing a gateway to improved sustainability for the brewing industry.
Substantial strength enhancements mean wall thickness can be reduced without compromising component strength. One customer reduced their TPU film thickness by 50% (halving the amount of polymer they need to process) whilst improving puncture resistance and increasing weld strength by 400%.
GrapheneXcel can also improve the flowability of the melt, leading to lower cycle times and energy consumption.
[GD] What are the other Greener Solutions from your product portfolio?
[JR] Broadway’s ‘Greener Solutions’ include the following:
• NIR detectable blacks – Improving the recycling compatibility of black plastics (without compromising on aesthetics) by formulating rich black colourants, which don’t rely on high levels of carbon black.
• UV protection – Customised protection packages which use multiple functional additives for a synergistic effect, prolonging the life of mouldings designed for outdoor use and reducing the volume of scrap material.
• PCR-based masterbatches and compounds – A masterbatch typically only forms a small percentage of the overall material used for moulding. However, brands that wish to legitimately claim ‘made from 100%
recycled plastic’ must use a PCR masterbatch carrier.
• Odour neutraliser –Reduces smells during processing and in end components. It’s useful when using smelly grades of PCR or other materials such as UBQ.
• MasterFoam – A new blowing agent which relies on a safe, environmentally friendly, endothermic reaction and is proven to reduce material usage and cycle times.
[GD] What’s next for the company in an effort to promote sustainable practices?
[JR] Broadway’s in-house technical team are currently exploring non-traditional chemistry pigments. We intend to disrupt the current polymer colouring market by giving customers sustainable colouring alternatives. In the past year, we’ve worked with material innovators to develop and manufacture compostable, bio-sourced plastic compounds. These offer an alternative to fossilfuel-derived polymers and are particularly beneficial in single-use or hard-to-recycle applications. If they end up in the environment they break down, avoiding the widely publicised end-of-life issues associated with traditional plastics.
CERAMICX L VES THE PRESSURE
Ceramicx has long been a co-exhibitor with the British Plastics Federation (BPF) at Chinaplas – a key market for the company’s infrared heating elements for thermoforming. The company exports IR components and platens for thermoforming to 61 countries, and UK-based highvolume customers like Linpac.
Ceramicx’s latest innovative investments in pressure casting systems and related technology have elevated it above international competitors for quantity and quality.
The change to pressure casting technology was triggered when a leading Tier 1 automotive lighting supplier asked for a new-design volume product – a low voltage IR DC heater to de-ice headlights with LED lighting.
Having used pressure casting methods to complete this project, Ceramicx realised that pressure casting technologies, which are normally deployed to manufacture ceramic tableware, could be expanded to make IR
Ceramicx, a leading manufacturer of infrared ceramic and quartz heating elements, has recently invested in pressure casting systems, gaining a competitive edge. It can now make IR heating products and systems bespoke for the thermoforming industry, assisting manufacturers from start to finish.
elements and systems for thermoformers.
Five pressure casting machines were installed by moving the bulk of Ceramicx element production from manual bench casting to automated and semiautomated industrial production.
The net result of the production changes –accounting for an investment of some 2.4 million Euros in the past four years – has been revolutionary. The reliability of supply, design, consistency of parts and increased productivity have helped stabilise the supply side while producing a technically advanced, quality product at a competitive price.
Ceramicx can make IR heating products and systems bespoke for thermoformers at the start of any project and get retrofit thermoforming systems to order.
Thermoforming clients can discuss shapes and ideas for parts, elements and platens and get the tools designed, prototyped and built in-house. They can also get the products checked, environmentally tested and into full production in weeks.
Once the design phase is complete for the customer, the focus shifts to the tool room.
An expert tool-making team boasts high-precision DMG Mori machines and casts the resin-based mould.
“Every industrial innovation carries a disruption factor and a cost, but the benefits of pressure casting processes over traditional craft production have been clear throughout.”.
When the products first come off the pressure casting line, Ceramicx tests their fitness-for-purpose in the company’s purpose-built laboratory. This facility has a dedicated workforce and houses an automated test machine, an environmental test chamber and other devices that simulate all conditions in the field.
Every industrial innovation carries a disruption factor and a cost, but the benefits of pressure casting processes over traditional craft production have been clear throughout.
Having had the vision to make a unique pressure casting leap, Ceramicx is once more in pole position for thermoforming heat work supplies.
SMART AUTOMATION SYSTEMS
Centralized data & modular architecture to maximize performance
Designed around a best-in-class software architecture and based on years of experience with our customers in the plastics industry
PACKAGING
RECYCLED FOOD-GRADE PLASTICS A world of possibilities and developments
One of the major issues in the plastics industry is the use of recycled plastic in food contact packaging. This primarily concerns the safety of this material for use with food, meaning if it’s fit to come into direct or indirect contact with foods using functional barriers. Another concern is the large volume of plastic waste from the packaging industry, especially food packaging. Addressing this waste stream will promote recycling and sustainability.
Now that the Commission Regulation (EU) 2022/1616 on recycled plastic materials and other items that can come into contact with foods is in force, the volume of recycled food-grade plastics is expected to increase. One of the regulation’s key points is suitable recycling technologies and novel technologies. The former refers to postconsumer mechanical PET recycling and recycling from product loops in a closed and controlled chain. The aim is to increase and standardise the different technologies authorised in Commission Regulation (EU) 282/2008, facilitating new individual
Adrian
Morales, Lead Researcher in Mechanical Recycling at AIMPLAS Plastic Technology Centre, discusses the possibilities and developments of new technologies to manufacture plastics for safe contact with food. He focuses on the new Commission Regulation (EU) 2022/161 and explains how novel technologies can be authorised to comply with it.
“Today, recycled plastic can only be introduced in direct contact with products made of PET or through closed and controlled loops. Bottles, trays and other products with up to 100% recycled PET content are available on the market.”
authorisations based on what has already been authorised.
The industry’s biggest challenge is developing new technologies that can be used to manufacture plastics for safe contact with food. This can be anything that isn’t yet considered suitable, such as mechanical recycling of any material other than PET, chemical recycling of any polymer, physical recycling (using solvents) and
of recycled PET currently available is too low to cover all the industry’s needs. This is why this technology is suitable under the current regulations.
Recycled materials other than PET are often found in contact with food, such as polyolefins (mainly HDPE and PP) from closed and controlled loops. Products with recycled polyolefins include fruit and vegetable crates and food drums. These would require authorisation from the European Food Safety Authority (EFSA) under the previous regulation but are allowed under the current one.
functional barriers. The latter are no longer safe under the new regulation and require authorisation to be placed on the market.
Today, recycled plastic can only be introduced in direct contact with products made of PET or through closed and controlled loops. Bottles, trays and other products with up to 100% recycled PET content are available on the market. However, the volume
Several novel technologies have been submitted to EFSA. Some are functional barrier processes for PET and polystyrene (PS), where the effectiveness of the barrier layers must be ensured by migration tests and assessments of homogeneity over time and in the results. Polyolefin decontamination technologies have also been submitted to EFSA to validate an efficient decontamination technology for these materials, as well as physical recycling processes by dissolution of PS.
AIMPLAS works with different companies and its own developments in assorted studies to discover how to decontaminate these materials through challenge tests. It also provides advice to companies collaborating on the reports required to obtain EFSA authorisation for functional barrier structures in PET and decontamination of different polymers.
Discover all the classics: www.meusburger.com/60-years
Guiding systems for durable injection moulds
For our guiding systems, we rely on the in-house production of our products to ensure the best possible quality.
MOULD TOOLS
engelglobal.com/stockmachines
ZER WASTE? IT'S POSSIBLE WITH FYOUS
[GD] Can you tell me a bit more about the product?
[JS] It’s a shape-shifting tooling or moulding technology. We use thousands of densely packed pins that are automatically actuated to create geometries and shapes. These can be used in various manufacturing methods, from vacuum forming and casting to work holding and fixturing. We’ve recently tested it to make car packaging, so it can also be used as a forming tool. It’s a zero-waste manufacturing process.
[GD] Why did you feel it was necessary to bring such a product to life?
[JS] The idea came from affordable customised footwear. I worked in China for many years and realised that changing moulds is difficult and making moulds is expensive. What seemed to be missing was that they had the 3D scanning and software but didn’t have a manufacturing method to make the shoes custom-fit.
Fyous co-founders, Joshua Shires and Thomas Bloomfield, discuss their PolyMorphic Forming Machine in an interview with Editor Giulia Daniele ahead of the official launch. They touch upon the challenges they overcame to bring this technology to life and how it benefits the industry, customers and the environment.
“Our technology allows customers to make a mould in 20 minutes and generate zero waste. It reduces the storage costs, digitises the stock and decreases cycle times.”
About six months ago we understood there was a lot more value in it as a technology instead of trying to focus solely on footwear, so that’s where our journey began.
[GD] What was the biggest challenge you’ve met in developing the product?
[TB] Product market fit. Working in composites, vacuum forming and car packaging are potential markets that we’re working hard to validate. We don’t know which one makes the most sense, but we’ll likely end up with a cocktail of all because the technology is so versatile. It’s also very difficult to market the product when it can tackle many different industries.
[GD] Do you have any case studies of how the product has benefited manufacturers in the plastics processing industry?
[JS] Vacuum forming is the main area in the plastics processing industry. There’s a dental company that makes a million aligner
moulds a day – the mould being the 3D-printed teeth that are corrected. They vacuumform the medical grade, clear plastic over the top of the teeth. The mould is then discarded, generating a huge amount of waste.
What we have discovered with our technology is that we can use the pins as an in-fill material. Rather than the teeth being printed solid or slightly hollowed, we’ve recently decreased the resin usage by 65% while still being able to vacuum-form the plastic over the mould and not cause distortion.
Our technology allows customers to make a mould in 20 minutes and generate zero waste. It reduces the storage costs, digitises the stock and decreases cycle times.
[TB] For example, if you wanted to 3D print an RC car cover as a shape, it would take 7 hours on the current fastest printer. We create the same shape in 20 minutes, and its parts in 5 minutes. When you are in this low-volume space making the plastic part, you can quickly make your mould, modify your mould and manufacture as many products as you wish.
[JS] We’re all about decreasing the market time while also reducing waste.
[GD] What’s next for Fyous? [TB] For us, it’s about growing the technology and helping it make the impact we dreamed it could make while enjoying every day at work. We want to build a great team and make the journey fun and enjoyable for everyone.
ON THE COVER A GAME-CHANGER LIKE NO OTHER ENGEL embraces AI to drive long-term success
MARTIN STAUDINGER, Sales Manager for digital solutions at ENGEL, talked to BP&R about ENGEL’s view on AI, and how it can drive long-term success across all departments. He discussed labour shortage, digitalisation in the injection moulding industry and the future landscape of plastics processing.
[GD] What is your and ENGEL’s view on AI?
[MS] AI is a game changer. It addresses critical challenges, such as labour shortage and efficient knowledge collection, which customers are mainly struggling with.
I think AI, and digital tools in general, can help collect and store the data, making knowledge accessible across the board. This way, when people retire, new employees
can easily find the information they need.
At ENGEL, we use AI internally to improve our operations as well as help our customers streamline their processes, including accessing their KPIs.
[GD] What emerging digital technologies or trends do you see impacting the injection moulding industry?
[MS] At ENGEL, one of our cloud solutions is shopfloor monitoring, which connects through an easily mounted Edge Device. This device extracts data from machines and sends it directly to the cloud, providing a simple and clear overview. While the basic explanation focuses on green tiles for running machines and red tiles for downtime, the system can do much more, like showing proper KPI’s (OEE) and offering deeper insights and functionality to optimise operations. Making data accessible to everyone is critical for saving time and resources.
For years, our very advanced MES system (Manufacturing Execution System) has been implemented directly in the plants, allowing in-house data management and much more. However, this is often very challenging for smaller companies because they do not have many resources in terms of people, such as IT, money and time. Digitalisation and
digital technologies are now available for everyone, not only for the big players. Everyone can do it.
[GD] Do you think there are more risks or benefits associated with AI?
[MS] The German saying ‘if you don’t try, you’ve already lost’ describes the situation very well. The risks exist, but at ENGEL, we prioritise safety and security in everything we do. We implement these changes gradually and know exactly what we’re doing, which minimises the risks significantly.
I am more concerned with how AI is being used globally, for example by companies in Silicon Valley. These are based on money and need investors to support them. However, investors are only interested in the financial aspect of digital tools and want advancements to happen quickly. This may make them forget about operating safely because they’re under constant pressure.
[GD] What can we take from AI to improve injection moulding?
[MS] We want to make AI bigger and better for our customers. We can offer them our intelligent software solution, the iQ process
“To say that AI won’t be useful is like travelling back to the 1990s and saying we won’t need computers. We do and use them all the time, and the same will happen with AI. We just need to get on board with this idea and understand the benefits associated with it.”
observer. It’s handled via an edge device and can observe over 500 parameters, informing every time they drift. This allows everyone to monitor changes in the machines and in the cloud and know why they occur. This is important for the future as we enter a labour shortage phase.
Less experienced workers will replace more experienced ones as they retire, and they’ll need to solve simple issues so that senior employees can focus on the more complex ones. AI allows for easy analysis of data, streamlining operations across all departments.
[GD] Do you think it’s more likely that AI will take away jobs or create new ones?
[MS] The job market will evolve rather than shrink, and AI will become a collaborative tool, enhancing how people work instead of replacing them. It’ll drive more efficiency, as humans will be able to focus on highervalue tasks over everyday operations.
We knew experienced workers were going to retire. At the time, it wasn’t an issue because we had so many of them, so it didn’t matter what task they were working on. But now that they’ve started leaving, we need to increase efficiency to make data-driven decisions. We need to know who can work on what and optimise resources.
[GD] How do you think AI will change the landscape of plastic processing?
[MS] The plastics processing industry needs to invest in digital tools and data collection to make data-driven decisions. They can help manufacturers produce a part for 60 or 70% of the cost of your competitor, bringing profits in the short and longterm future. In my opinion, we
will see the need for digital products increasing over the next 10 years.
In the injection moulding industry, companies will get to the point of wanting a more digitised environment with monitors and software to collect and analyse KPIs. For example, we had a digital event in Germany, where we held an AI workshop. Everyone agreed on how useful it was, except for this one customer, who claimed that AI wouldn’t improve his operations. I found out he was 63 years old. I am not against the older generations because they’ve brought us to where we are now, but perhaps they don’t see AI as a solution when they should. AI is not just a tool – it’s a game-changer for the whole industry.
[GD] Do you think there’s some stigma that comes with AI?
[MS] Yes. I think people need to be educated about it. Some are aware of it but don’t exactly understand its use or importance. Digitalisation is complex, and there’s a lot of confusion and misunderstanding around it. It’s about trust. You need to trust that this solution will help you and perform as well as you would.
[GD] Is there anything else you’d like to add?
[MS] I want to emphasise the critical importance of data collection and data-driven decision-making. It’s about education; people need to understand what AI can do for your business.
To say that AI won’t be useful is like travelling back to the 1990s and saying we won’t need computers. We do and use them all the time, and the same will happen with AI. We just need to get on board with this idea and understand the benefits associated with it.
ITHE MASTERBATCH REVOLUTION
Masterlink Solution’s eco-conscious approach
n a rapidly evolving world where environmental concerns and sustainability take precedence, the masterbatch industry is at a crossroads. It faces challenges to innovate and adapt to meet the rising demands of customers who seek competitive pricing, convenience and exceptional service.
The wider plastic industry has lost its authority in recruiting the best talent, giving way to more popular and less political fields of work. We have observed how procurement often suffers more than other departments when there is a personnel shortage, resulting in poor performance and unhealthy business habits. Buyers have less time to focus on masterbatch and compounded materials, robotically placing repeat orders. They don’t analyse their spending and suppliers properly to compare competitiveness and cost savings.
In 2006, the insurance industry was forever changed by sites like Compare the Market, which allows customers to compare their insurance policies against
Nick Barber, Director at Masterlink Solutions, a UK-based supplier of masterbatch products and services, explores how the masterbatch industry has changed over recent years. He also discusses Masterlink Solution’s innovative approach in providing commodity, additive and colour masterbatches.
“By enabling organisations to reclaim and repurpose unused plastics, we advocate for an eco-conscious approach to manufacturing and production.”
multiple service providers.
This helps them lower costs, optimise services and save time.
In 2024, Nick Barber and Chris Bird took the comparison business model to the next level by establishing Masterlink Solutions Ltd. The company has partnered with 6 UK-based masterbatch manufacturers, offering a complete range of commodity, additive and colour masterbatches.
As Nick recalls, “We have matched over 1,000
colours this year, achieving an average cost reduction of over 15%. The most significant undertaking involved rematching a collection of 112 colours for a customer, sourced from five different suppliers. Each presented varying lead times, quality standards and specifications for their masterbatch. The customer faced considerable frustration in managing these supplier relationships, which required interaction with multiple sales representatives.”
He adds, “We’ve initially addressed the customers’ concerns regarding managing numerous colours and multiple supplier relationships, which they found time-consuming. Once we understood this, we streamlined the colour selection to 81, as many were nearly identical. We collaborated with our most suitable supply partners to match them, considering batch sizes that varied from 25kg to 10,000kg per order. After receiving the matches, we evaluated them for strength, dispersion and colour accuracy using visual inspection and a spectrophotometer in a controlled light environment. We selected the optimal matches and compared pricing to identify the most significant savings. We presented the customer with annual cost savings of approximately £105K, representing a 22% reduction. The customer was delighted not only with the substantial savings but also with the simplification of their supply chain, as they only engage with Masterlink for all masterbatch and compound needs instead of managing five separate relationships.” In addition to its offerings, the company facilitates a UK plastics marketplace. This platform connects businesses with surplus plastic materials, promoting a culture of sustainability and reuse. Up to 18% of all plastic products purchased in Europe go unused due to changes in customer demand, specifications or simply lack of need. It advocates for an eco-conscious approach to manufacturing and production by enabling organisations to reclaim and repurpose unused plastics.
THE UK’S NO.1 PLASTICS SHOW
The event for us is a must in the plastics industry, and an opportunity to meet with both old and new clients. See you in 2026!
ANDY BARNARD, Solutions 4 Polymers Limited
FACE TO FACE NETWORKING
CO-LOCATED WITH: 12+000 ATTENDEES LIVE MUSIC, FOOD & DRINKS APP FOR LEAD GENERATION MARKETING SUPPORT WHO SHOULD EXHIBIT: SOFTWARE: CAD/CAM | DATA PROCESSSING | DIGITALISATION | INDUSTRY 4.0 | SMART FACTORY | PLM/PDM | MATERIALS: COATINGS | COMPOSITIES | FILAMENTS | MASTERBATCH & ADDITIVES | PACKAGING | POWDERS | POLYMERS & COMPOUNDS | SERVICES: CONSULTANTS | DESIGN | TRAINING | FINANCE | MEDIA | SUB-CONTRACT MANUFACTURING | R&D | MACHINERY: INJECTION MOULDING | EXTRUSION | AUTOMATION | ROBOTICS | RECYCLING | TESTING | SURFACE TREATMENT | THERMOFORMING 2-4 JUNE 2026
PEVERYTHING UNDER CONTROL... ...with GÜNTHER’s blueMaster controller series
recise, highperformance control technology maximises productivity and production quality in hot runner systems. What’s more, accurate temperature control produces a positive effect on processing and part quality.
The primary goals during the development of the new GÜNTHER control technology comprised optimum control characteristics, extensive connectivity and smart operation. The technology also needed to be compact in dimension and form the basis for future upgrades while being price-sensitive. These goals have been attained with the new blueMaster controller series.
new blueMaster control technology to maximise productivity and production quality. It’s tailored as a control unit for small applications and in servicing, and it can be monitored via an easy-touse app to enhance resource efficiency.
reliable control of complex hot runner systems available. These units are suitable for 6 to 24 control circuits. They can be operated directly on the unit or in a browser.
Conventional tabletop controllers with a built-in display have a comprehensive range of functions and can also be operated in a browser on a tablet and a seven-inch display. No built-in display is required, and control via a control panel is possible.
The temperature control units in the blueMaster series are being launched on the market in their blueMaster compact and blueMaster pro versions first.
The blueMaster compact 3 (three control circuits) and blueMaster compact 6 (six control circuits) are designed as control units for smaller applications or use in servicing. Both units feature adaptive control optimisation, meaning the unit adjusts its control behaviour to the connected load with no need for the user to intervene. PID parameters no longer require adjustment. Control remains stable, even under tiny loads. Four operating modes are available per zone: adjust, control, master mode and monitor.
Intuitive operation of control units from any location using an app can increase resource efficiency in the industry.
GÜNTHER developed an easy-to-use app that can be operated in complex situations. It’s intuitive thanks to a user-oriented intro with comprehensive explanations, assistance functions and a temperature indicator that is straightforward for the user to interpret.
“We already have modern interfaces in our pockets or under our arms. We are able to use smartphones or tablets with ease. So why not simply use your phone to operate the controller?” asks Christoph Münch, Project Manager for Control Technology at GÜNTHER Hot Runner Technology. “All measurement data can also be uploaded to a cloud swiftly and securely and then used for documentation or a more detailed evaluation.”
For higher cavitation tools, GÜNTHER has 4 new blueMaster pro variants for
“Both units feature adaptive control optimisation, meaning the unit adjusts its control behaviour to the connected load with no need for the user to intervene.”
The system is connected to the network via Ethernet or wireless LAN. An assistance wizard not only helps to set up new moulds but also provides group management of systems with multicomponent applications or several drops.
One key to networking temperature control is data interface standardisation. The new blueMaster pro hot runner regulator series fully supports Euromap 82.2. This standard defines the interface for data exchange between injection moulding machines and hot runner regulators. It is based on the OPC Unified Architecture interface (OPC UA), a communication standard for secure, reliable data exchange in industrial automation.
• Print high-resolution on plastic pipes
• UV curing for solvent resistant printing
• Plasma treatment for scratch resistant printing
• Affordable, reliable, user-friendly printers
• Cartridge ink system means no mess
RECYCLING
In the dynamic landscape of polymer innovation, the journey from laboratory breakthrough to industrial application is critical. This transition is known as “scale-up” and transforms small-scale successes into commercially viable processes that meet global demand. It is not a technical hurdle but a strategic necessity to ensure that promising new materials can be produced consistently and economically.
AIMPLAS, the Valenciabased Plastic Technology Centre, has positioned itself at the forefront of this transformation process. With its advanced facilities and expertise in polymer synthesis, AIMPLAS bridges the crucial gap between research and real-world application, enabling companies to confidently bring innovative, sustainable materials to market.
THE IMPORTANCE OF SCALE-UP IN POLYMER SYNTHESIS
Polymer synthesis forms the backbone of many advances in the plastics industry and drives the development of enhanced-performance, sustainable materials. However, scaling up these processes from laboratory conditions to industrial production presents unique challenges. In a controlled lab environment, processes can be meticulously managed, but maintaining the same level of control and consistency becomes far more complex at larger scales. Factors such as reaction kinetics, heat transfer and material properties can behave unpredictably when scaled up and potentially compromise the quality and economic feasibility of the final product.
CHALLENGE THE
FROM LABORATORY TO INDUSTRY
“Polymer synthesis forms the backbone of many advances in the plastics industry and drives the development of enhanced-performance, sustainable materials.”
Plastic
Technology focuses on breaking down plastic waste into smarter polymers, while a circular approach to
AIMPLAS’ pilot plants are equipped with high-pressure reactors and sophisticated monitoring systems, allowing researchers to replicate industrial conditions, optimise processes and ensure material consistency. This meticulous approach not only refines the technical aspects of polymer synthesis but also addresses sustainability considerations from the outset in alignment with circular economy principles.
UPLIFT AND REPURPOSE PROJECTS
Two standout projects, UPLIFT and REPURPOSE, exemplify AIMPLAS’ scale-up and commitment to sustainability.
The UPLIFT Project: Transforming Plastic Waste into Renewable Polymers
One of AIMPLAS’ most ambitious initiatives, the UPLIFT Project, exemplifies the centre’s leadership in polymer synthesis scale-up. Funded by the European Union’s Horizon 2020 programme, UPLIFT aims to revolutionise the plastic packaging value chain by developing biochemical processes that upcycle bio and fossil-based plastic waste. At its core, the project focuses on breaking down plastic waste into fundamental building blocks using enzymatic depolymerisation. These building blocks are repurposed to create new, smarter polymers that are renewable and easier to recycle.
AIMPLAS plays a pivotal role in scaling up polymers and additives. By
testing and refining them at an operational scale close to industrial conditions (TRL 6), the centre ensures that the innovations developed in the UPLIFT Project can be seamlessly integrated into existing production lines. It also works to align the project’s outcomes with emerging regulatory standards and market demands to ensure that the new materials can compete commercially while delivering significant environmental benefits. UPLIFT’s goal is to address the plastic packaging sector, which represents over 60% of the market, by offering a sustainable alternative that could redefine industry standards.
The REPURPOSE Project: Advancing Circular Polymer Systems
The REPURPOSE Project focuses on transforming postconsumer and bio-based waste into valuable materials. Central to this initiative is the development of a new class of polymers — REP — that are designed to integrate seamlessly into existing recycling systems and facilitate a circular approach to plastic use.
The heart of the project, Bio Base Europe Pilot Plant (BBEPP), takes on the crucial task of scaling up the enzymatic processes used to break down different types of waste, including plastics, paper and cardboard. This involves converting these waste streams into fundamental polymer building blocks through optimised fermentation and enzymatic treatments. BBEPP’s expertise ensures that these biochemical processes can be validated at an industrial scale, thus laying the foundation for real-world applications.
RECYCLING
“Effective scale-up is the key to unlocking the full potential of new materials, ensuring they can be produced consistently, economically and sustainably.”
Once these building blocks are ready, AIMPLAS develops the final polymer structures. Drawing on its capabilities in polymer synthesis and processing, AIMPLAS transforms the REP building blocks into functional polymers tailored for specific industrial applications. The centre’s work focuses on refining the properties of these polymers and ensuring they meet the stringent requirements of recyclability and performance. AIMPLAS also oversees regulatory compliance by aligning the new materials with REACH and CLP standards to facilitate market entry.
These efforts ensure that REPURPOSE not only advances the technical feasibility of circular polymers but also paves the way for their practical implementation and contributes to a more sustainable and efficient recycling ecosystem.
SCALING UP FOR A SUSTAINABLE FUTURE
The journey from lab-scale innovation to industrial production is fraught with challenges, but it is also a journey of immense opportunity. Effective scale-up is the key to unlocking the full potential of new materials, ensuring they can be produced consistently, economically and sustainably.
AIMPLAS’ leadership in polymer synthesis scale-up, exemplified by its contributions to the UPLIFT and REPURPOSE Projects, highlights the transformative impact of this process. By providing the infrastructure, expertise and strategic vision needed to bridge the gap between research and reality, AIMPLAS is helping to shape the future of the plastics industry—one innovative polymer at a time.
The World’s Leading Injection Moulding Machine Manufacturers
Borche’s UK facility, based in the West Midlands offers a wide range of Servo Technology Machines up to 6800ton clamping force which bring substantial energy savings. We have stock machines available for immediate delivery and an experienced team of UK service engineers, with spare parts ready for prompt delivery.
Expert of Intelligent Two-Platen IMM
SUSTAINABILITY IS THE WAY TO GO Spectra’s collaborative approach
In a world where sustainability and environmental consciousness have never been more crucial, Spectra Packaging continues to develop solutions that reflect its customers’ values. It prioritises collaboration, innovation and environmental responsibility by working closely with its customers to bring packaging ideas to life. Successful collaborations begin with a comprehensive consultation, which helps the team evaluate the customer’s vision and understand product specifics, including the item’s ingredients.
Spectra conducts a thorough needs assessment following the initial consultations, considering sustainability, functionality, aesthetics and suitability. At the heart of this process lies a commitment to using sustainable materials, prioritising post-consumer recycled (PCR) content and bioplastic solutions to ensure every product minimises environmental impact while promoting a circular economy. With an in-house design and tooling facility, Spectra can craft custom moulds for extrusion blow moulding, injection stretch blow moulding and injection moulding, providing control
Mark Kingston, Marketing Manager at Spectra Packaging, caught up with Editor Giulia Daniele to reflect on the company’s collaborative approach to sustainability. He highlights Spectra’s commitment towards the circular economy through initiatives like the Prevented Ocean Plastic and the PCR35 project.
levels that shorten project timelines and maintain highquality outcomes.
Customers can access over 250 standard bottle and closure designs, facilitating quick and efficient development. Available in both HDPE and PET, Spectra’s off-the-shelf designs come in capacity sizes ranging from 30ml to 500ml. The company also has a dedicated decoration capability, offering techniques like silk screen printing, hot foil blocking, high-build braille, anti-counterfeiting UV and circumference bottle printing.
Sustainability is embedded in every aspect of the company’s operations. One example is Spectra’s
Prevented Ocean Plastic (POP) commitment, which aims to combat ocean plastic pollution by sourcing all recycled materials from ocean-bound sources. To date, Spectra’s endeavours have helped divert over 50 million plastic bottles from entering oceans in at-risk regions while providing significant societal benefits. The POP program contributes to cleaner oceans and supports communities by creating jobs in recycling and waste management, fostering economic development in areas particularly affected by plastic waste.
Spectra leads various environmental initiatives, including the PCR35 project, which mandates 35% PCR
content in new projects. Similarly, their zero-tolandfill policy reflects a strong intent to recycle all manufacturing waste, demonstrating authentic leadership in addressing packaging waste. Challenges in sustainable packaging are opportunities for innovation and growth.
The company fosters a culture that encourages creativity and collaboration among its employees, believing that a sustainable future starts with today’s decisions.
Spectra’s collaborative approach is matched by understanding customer needs, driving the development of high-quality, sustainable packaging solutions. It focuses on continuous improvement and responsible practices, crafting a future where sustainability isn’t just a goal but a core value of the packaging industry.
New Cooling Tornado Z9665/...
With the new Cooling Tornado Z9665/…, HASCO offers innovative possibilities for saving energy directly in the mould.
▪ Improved cooling through turbulent flow
▪ Efficient cooling enables shorter cycle times
▪ Avoidance of hot spots
▪ Up to 10°C temperature difference attainable compared with conventional cooling bores
▪ Energy saving through turbulence between 20 and 40 %
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Couldexchangerates triggerpriceincreases?
Since the US elections, the USD has strengthened against the GBP and other major currencies. Although the outcome was di cult to predict in the lead-up to the US Presidential election on November 5th, the currency markets indicated that a Democrat victory would result in a slightly weaker USD and a Republican victory would result in a strengthening of the greenback. The outcome was decisive in terms of President-Elect Trump’s majority and the control that the Republicans now have across US politics.
The GBP: USD rate has fallen from a pre-election high of 1.34 to values at the start of December of 1.27, with further pressure coming from the economic woes in Western Europe.
HOW DOES THE USD: GBP EXCHANGE RATE AFFECT UK POLYMER PRICES?
Materials supplied directly from the USA and most non-European countries tend to be priced in USD. This means this exchange rate impacts either buyer, seller or the economics of both. In the case of polyethylene, the UK has an increased reliance upon US-origin products resulting in a more direct impact from exchange rates.
HOW SIGNIFICANT HAVE RECENT EXCHANGE RATE VARIATIONS BEEN?
This depends upon the points of reference. As illustrated in the graph below, the many scenarios cover a di erence between 2.78 and 8.84 cents. The smaller range is taken from the average rate over the 18 days before
Who is ‘Polymerman’?
the US presidential election on November 5th. This is compared with the following 18 days, which shows that the Republican win has strengthened the USD by almost 10%. As illustrated in the table, even this modest variation has a direct impact on polymer prices of almost £50 per tonne, excluding the e ect of factors like duty and other USD-related costs like logistics.
WHY DIDN’T POLYMER PRICES INCREASE IMMEDIATELY?
This is due to weak market fundamentals. Supply was plentiful in the latter part of 2024 and longer supply chains can exhibit lag as enroute materials Cents $ per Tonne
have probably benefited from more favourable exchange rates. In the case of PE, many US states apply a year-end inventory tax which results in price discounts being applied to shift inventory and avoid the tax liabilities.
WHAT ABOUT THE FUTURE?
In the short term, the yearend promotions will soon be absorbed, and sellers will face the prospect of increased input prices, which they will try to push through. In the mid-term, the USD is likely to strengthen as the Trump presidency gets underway. With this will likely come further inflationary pressure on polymer prices.
per Tonne
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 its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution.co.uk | www.pieweb.com @POLYMERMAN ON PRICES
Tonne
Your technical experts for plastic injection moulding
Make Pentagon your UK supplier of choice for Mould Tool manufacture and Plastic Injection Moulding. Whether you need a supplier for a new injection moulding project or sourcing a new manufacturing partner for existing production, Pentagon will support you at every stage.
Plastics are used daily, from medical devices to household products, offering unmatched versatility. As demands for enhanced functionality grow, incorporating antimicrobial additives into plastics has become popular. However, questions about maintaining the integrity of the original material often arise; will the durability, strength or appearance be compromised?
At BioCote, we ensure the answer is a confident no, backed by our team’s knowledge and expertise and rigorous processes.
Understanding Antimicrobial Additives in Plastics
Antimicrobial additives are substances integrated into plastics during manufacturing to inhibit the growth of microorganisms on the product surface. These provide a long-lasting enhancement to products without altering their original properties. Achieving this balance requires a precise understanding of the additives and the plastics.
As David Hall, Managing Director at BioCote, explains, “Not all plastics are created equal. Different types – such as polyamide, polypropylene, polycarbonate, and PVC – have unique chemical compositions, thermal tolerances and mechanical properties. Our technical team assesses each type to determine the most suitable additive and application method. Whether the plastic is injection-moulded, extruded or thermoformed, the integration process is carefully tailored to ensure optimal results.”
He continues by explaining
Biocote, a leading antimicrobial additive supplier, strives to incorporate antimicrobial additives into plastics without compromising the original material’s durability, strength and appearance. The company’s process includes assessing each type of plastic, finding a suitable additive and compounding it into the plastic. quality control.”
“From sterile environments like hospitals to regular household items, antimicrobial-treated plastics have diverse applications. These solutions offer added value beyond functionality, enhancing product longevity and setting them apart in competitive markets.”
that “The process starts with selecting an antimicrobial additive that complements the plastic’s specific properties. This step is crucial to prevent any negative interactions between the additive and the polymer. Next, the additive is compounded into the plastic, ensuring even distribution. Uneven dispersion can lead to inconsistent performance or visible defects, which we mitigate through meticulous
Temperature is also critical. Many plastics are processed at high temperatures, which could degrade some additives. Our team ensures the selected additive withstands the required heat without losing efficacy. As Dr Conner Hodgkiss, Regulatory Chemist, adds “This technical expertise enables plastics treated with BioCote to maintain their antimicrobial performance throughout the product’s lifecycle.”
Broad Applications with Real Results
From sterile environments like hospitals to regular household items, antimicrobial-treated plastics have diverse applications. These solutions offer added value beyond functionality, enhancing product longevity and setting them apart in competitive markets.
In healthcare, antimicrobial plastics contribute to cleaner surfaces on medical devices, while in consumer goods, they help create fresher items like kitchen utensils and storage containers. BioCote technology seamlessly integrates into the manufacturing process, empowering businesses to innovate without compromise.
At BioCote, we combine scientific precision with industry insight, ensuring antimicrobial additives elevate plastics without affecting their core qualities. By protecting products against microbes that cause staining, odors and material degradation, BioCote helps create longer-lasting products, reducing the need for premature replacement and contributing to a more sustainable approach to consumption.
Screws, Barrels and Precision Components for the Plastics and Rubber Industry
Single, Twin Parallel or Conical, Multi -start and mixing, we offer a wide choice in Nitride and hardened alloy screws.
Single or Twin Barrels for extrusion and barrels for injection and blow moulding Nitride and Bimetallic that meet and exceed OEM standard Fast Track Services for refurbishment, on site wear check surveys and technical support, full in -house design facilities...and much more.
To discover more about our products and service, please contact us: Tel 01920 465201 E.mail enquiries@magog.co.uk www.magog.co.uk
Process Experience Manufacturing Expertise Engineering Excellence
10, Crane Mead, Ware, Hertfordshire SG12 9PY
INJECTION MOULDING
BETTER DURABILITY with rubber injection moulding
Organic rubber injection moulding uses traditional organic rubbers and synthetic organic rubbers, like SBR and EPDM. These undergo a curing process called ‘vulcanisation’, which gives them a resilient structure for high-durability applications. The rubber is heated and mixed with vulcanising agents before being injected into a preheated mould where the product is cured and formed.
Natural and synthetic rubber injection moulding can create parts with excellent mechanical properties, such as increased resilience, elasticity and abrasion resistance. These properties are often required in heavyduty applications, including tyres, hoses and industrial seals. The process has longer cycle times because of the vulcanisation process, but it provides enhanced durability.
Seals Direct used injection moulding to manufacture rubber bumpers for a customer within the railway industry. The customer was looking for a product they could fit over the end of an RSJ steel beam for safety edge protection. We developed a product that fitted over the 20mm thick steel corner. Since it was used within railway stations, it was manufactured from a commercial grade of EPDM as it did not need to conform to the EN45545 certification required within transport systems.
The most common restricting factor with bespoke moulded rubber products is the mould tool’s initial set-up cost. As the shape required by this project was unique, we had to create a new tool to mould
Adam Howard, Director at Seals Direct, explains the benefits of organic rubber injection moulding, including resilience, elasticity and abrasion resistance. He also discusses the challenges of manufacturing rubber bumpers for a client in the railway industry and the techniques they used to overcome them.
a corner piece specific to the customer’s requirements. The costs often exceed £2,000, which can be prohibitive for a client that only requires a small number of items. As this moulded corner piece was required by our customer for hundred buildings, they were happy to absorb the cost.
Due to the initial high set-up tooling costs, we ensured that the profile shape could fit over an RSJ made from 20mm thick steel. Failure to choose the correct profile shape may have required subsequent rounds of prototyping and
tooling, leading to longer set-up and development costs. We sent our customer an existing product so they could test suitability with their specific RSJ. Once approved, we developed our cornershaped tool on this existing product knowing that it would correctly fit over the 20mm thick steel.
This rubber bumper was developed for edge protection on steel beams. They previously experienced issues with damage to other equipment that unintentionally knocked into the end of
“Accelerating the timeline is important for quickly refining designs and developing multiple sealing solutions suitable for the final application.”
these RSJs. By protecting the edge with a rubber-based product, anything that hit the end of the RSJ touched softer rubber rather than hard metal.
Developments in 3D printing technology have allowed us to quickly prototype rubber profiles using flexible rubberlike filaments. This enables us to print a short sample of their chosen profile for testing and evaluation before proceeding with further prototyping or bulk production. Accelerating the timeline is important for quickly refining designs and developing multiple sealing solutions suitable for the final application.
To prototype rubber sections, we use a TPU-95A filament – a Thermoplastic Polyurethane with a 95 Shore hardness. It is a blend of rubber and PVC with a hardness that is roughly comparable to the rubber on a car tyre. It offers the necessary flexibility to create rubber-like seals that can stretch and return to their original shape without deformation. It provides all the benefits of TPU with a high elasticity that is easy to print. It also offers excellent layer-to-layer bonding.
POLYURETHANES
POLYURETHANE PRODUCTION
CONTROLLING THE HEALTH RISKS
Polyurethane products, such as foams, elastomers, adhesives and paints, use isocyanates as a raw material. Isocyanates can severely impact the health of those who work with them, as they are classified as potential human carcinogens and are one of the leading causes of occupational asthma in the UK.
Health effects related to isocyanate exposure can include lung problems and irritation to the eyes, nose, throat and skin. Symptoms can include chest tightness, difficulty breathing and inflammation of mucous membranes and skin.
People can become sensitised to isocyanates, which can trigger an asthma attack even with low-level exposure. This can be via inhalation and skin contact.
Exposure in the workplace can occur from a variety of processes. Routine tasks, such as painting, varnishing, foam-blowing, the manufacturing of insulation materials (e.g. car seats, furniture, mattresses) and adhesive application, can lead to isocyanate exposure.
The UK and many other countries have set Workplace Exposure Limits (WEL) for isocyanates. In the UK, airborne concentrations should be kept below the WEL and to a level that is as low as reasonably practicable.
We recommend the following steps for any substance deemed hazardous to health:
Polyurethane products use hazardous substances, such as isocyanates, as a raw material. Pragma and Associates, a leading health and safety consultancy, recommends some essential steps to prevent health risks in the workplace, from maintaining control measures to providing training across the board.
• Assess the risks and inform the appropriate people.
• Prevent, or where this is not reasonably practicable, adequately control exposure.
• Maintain and check control measures.
• Check the efficacy of control measures through air monitoring and health surveillance.
• Provide information, instruction and training.
• Make plans for accidents and emergencies.
Your risk assessments for processes involving isocyanates should be completed by a competent person, include comments on the following and, where appropriate, outline reasons why further control measures cannot be implemented:
• Can the isocyanates be eliminated from the process?
• Can the isocyanates be substituted for an alternative substance that is less hazardous?
• Can further engineering controls be used? These can include total or partial enclosure of the process with local exhaust ventilation.
• Can further administrative controls be used? These can include reducing the exposure duration (time limits or rotating staff) and improving the training provided to appropriate people on the health effects and control measures.
• Does personal protective equipment (PPE) or respiratory protective equipment (RPE) need to be used?
Having a competent person undertake an industrial hygiene assessment, including air monitoring, can help you ascertain the level of control of isocyanates in your workplace. Air monitoring results should be included in your risk assessment.
You should also keep maintenance and service records, and consider biological monitoring and health surveillance.
Pragma and Associates has decades of experience in controlling exposure to isocyanates and has helped many workplaces prevent occupational ill-health and comply with the relevant legislation.
“Having a competent person undertake an industrial hygiene assessment, including air monitoring, can help you ascertain the level of control of isocyanates.”
MOULD TOOLS
5-AXIS LASER
AND ITS ENDLESS DESIGNS
5-Axis laser texturing is a specialised manufacturing process that employs a high-powered laser to manipulate material surfaces precisely.
“5-axis” refers to the multi-directional movement capabilities of the laser system, which can move the laser head in five directions. This enables it to access complex three-dimensional surfaces from multiple angles, from curved to contoured.
It’s particularly popular with toolmakers because it can texture moulds, dies, inserts and other tooling components with intricate patterns and textures. This enhances their grip, wear resistance and functionality. In the plastic moulding industry, textured moulds ensure better part ejection, reduced friction and improved surface finish of moulded parts. For stamping and forming dies, laser texturing helps lower material adhesion, minimises tool wear and prolongs tool life.
Laser texturing facilitates better mould tool release by creating surface textures that reduce material adhesion. Rubber parts can be released cleanly from mould tools, preventing tearing and surface defects. The process ensures the texture is consistent and repeatable, with no variations between batches or over time.
Manufacturers benefit from increased productivity, quicker turnaround times and a lower overall cost of production. This eco-friendly solution also eliminates the need for chemical processes. An example of this is when the team at Fimark helped a toolmaking and plastic injection moulding company
Advanced surface texturing should be on everyone’s wishlist, and Fimark, a UK-based supplier of laser marking and laser etching, knows this well. 5-Axis laser texturing uses lasers to create complex patterns on three-dimensional objects’ surfaces, helping reduce material adhesion and tool wear while prolonging tool life.
“Whether it’s producing fine features on moulds or applying intricate textures for improved release, this technology provides flexibility to meet diverse requirements and ease of replication.”
facing challenges in its rubber moulding release by applying a 12VDi surface. Traditional techniques were proving limited, prompting them to explore laser texturing options. Our team devised a solution in which the tool’s surface underwent laser etching to create a Vdi equivalent surface. This resulted in an improved texture conducive to optimal rubber moulding release. Another example concerns a manufacturer of doubleglazed windows. The company wanted to enhance
its window surrounds’ look to achieve a natural, lifelike wood grain texture. We began by scanning a real wood grain sample to capture its intricate details digitally. We used the 5-axis laser texturing technology to precisely replicate this pattern onto one of their existing mould tools, ensuring the texture seamlessly transferred onto the moulding. This approach provided a durable, wear-resistant solution that eliminated the need for overlays or printed films and offered the client an authentic
wood grain finish. Whether it’s producing fine features on moulds or applying intricate textures for improved release, this technology provides flexibility to meet diverse requirements and ease of replication. This leads to a streamlined manufacturing process, lower lead times and enhanced production efficiency. Since it is a digital process design, it can be easily rescaled or faded out at the tools’ edges to reduce scuffing during mould release.
“Manufacturers
benefit from increased productivity, quicker turnaround times and a lower overall cost of production. This eco-friendly solution also eliminates the need for chemical processes.”
A remarkably efficient 2024 FOR WIBA UK
At the start of 2024, Wittmann Battenfeld UK (WIBA UK) could have been forgiven for thinking that the coming twelve months might provide a period of consolidation and relative calm in the injection moulding sector.
However, 2024 saw the company introduce radical options for sustainable moulding users. These include deploying Direct Current (DC) powered methods and facilitating battery and solar power use to drive the effective production of cells. The company designed these technologies to save energy, supporting storage and overnight battery charging at lower cost.
Wittmann Battenfeld UK looks back at a remarkably efficient 2024 and how it has kept its promise to develop sustainable solutions for the circular economy. These include the Direct Current (DC) powered methods and the HiQ processing systems.
of bids when competing IMM machines fail to get through the door or clear the ceiling.
For example, Wittmann’s current EcoPower IMMs drive most of the machine axis electrically and the injection unit carriage. It uses a small servohydraulic system with the possibility to “store/ keep” the energy in the actuator (hydraulic cylinder) while switching off the drive completely.
The DC version of the company’s EcoPower injection moulding machine further reduces energy loss, supplying the current to the user directly. The company is also confident in its forecast that DC grids will soon be part of sustainable global infrastructure, helping prevent largescale energy losses.
As environmental criteria and product traceability factors take an increasing hold of
“As environmental criteria and product traceability factors take an increasing hold of manufacturing methods, injection moulders need to account for the environmental cost of their production.”
manufacturing methods, injection moulders need to account for the environmental cost of their production, typically expressed as Product Carbon Footprint.
Wittmann’s HiQ processing systems help users save all available energy-per-part, enabling the use of regrinds, recycled materials and other materials like paper-based systems. Wittmann is also developing technology to aid the integration of Post Consumer Recyclate (PCR) into the moulding process. The Combimould, Sandwich and Cellmould packages perform energy and costsaving roles in this regard.
WIBA UK notes that three technical considerations have increasingly stood out in terms of company sales this year. The first is the compact size of Wittmann-made IMMs – length, height and depth. The company counts an increasing number
The second factor is the large mould tool area. Although the Wittmann IMM machine footprint may be compact, the mould tool area has typically been larger throughout the range, giving moulders greater value for money and scope for locking force and shot size.
The third factor concerns Wittmann IMM machines’ energy efficiency. WIBA UK sales managers offer comparable machine energy audits at customer sites, proving the large cost savings.
2024 has seen Wittmann’s strategy further embrace the upcoming demands of the circular economy while WIBA UK has continued to thrive on the excellence of Wittmann IMM machine design and running costs.
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Dave Raine
Onto greater heights
Dave Raine reflects on what has been a challenging yet positive 2024, praising the industry for showing great resilience and collaboration to achieve a sustainable future.
As we come to the close of a difficult year, I want to take a moment to reflect on the achievements we have made together in the UK plastics industry. The recent PIA award ceremony was a testament to the hard work, innovation, and dedication everyone in our sector has contributed throughout the year. Congratulations to all the winners and nominees — your achievements inspire us all.
The journey towards a more sustainable, innovative and resilient industry continues, and the passion and commitment demonstrated by the entire sector have been nothing short of remarkable. Whether through new product developments, cutting-edge technologies or our collective efforts towards reducing environmental impact, we have made substantial progress in shaping the future of plastics.
While there is significant potential in automation, digitisation and AI, many manufacturers find it difficult to invest in the latest technologies due to high costs and financial uncertainty. Transitioning to
more advanced manufacturing processes is vital to staying competitive but requires careful planning and investment. Additionally, factors such as geopolitical tensions, inflationary pressures and a consistently slow recovery continue to create economic uncertainty, making it harder for manufacturers to plan long-term investments and navigate shifting demand in domestic and international markets.
Looking ahead to the new year, it would be too bullish to say I’m excited about the opportunities we have to continue collaborating, innovating and driving positive change within the industry. However, I’m equally adamant that the resilience shown this year will persist in
2025, and that together, we can build on the momentum of these successes to achieve even greater heights.
Finally, I would like to finish with two messages. Firstly, a huge thanks to friends and colleagues in the industry, including the PMMDA committee and membership – your support and enthusiasm are infectious and keep me coming back for more. My final wish is that everyone enjoys a healthy and happy Christmas and New Year – for those of you going through tough times commercially, physically or mentally, I hope 2025 brings you some good news and good times.
Dave Raine Chairman, PMMDA
“Whether through new product developments, cutting-edge technologies or our collective efforts towards reducing environmental impact, we have made substantial progress in shaping the future of plastics.”
sales@plmachinery.com www.plmachinery.com
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Philip Law
BPF’s Director-General Philip Law talks about the BPF participation in the University of Birmingham’s UK REACH legislation workshop.
The BPF at work
An excellent example of the ‘BPF at work’ manifested itself through our November workshop at the University of Birmingham on the current status of the REACH legislation and how to comply. The legislation is complex and requires time and effort to understand properly.
UK REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) is a regulatory framework that came into force on the 1st of January 2021, following the UK’s departure from the EU. The legislation manages the use of chemicals and substances on the UK market and aims to protect human health and the environment by ensuring chemicals are safely managed and evaluated. Most of the legislative text replicates the EU REACH version, with minor amendments and additions to ensure the framework remains relevant to the UK industry.
Under EU REACH, GB companies that imported chemicals and substances from EU countries were considered downstream users. However, they’re considered importers under UK REACH and have additional responsibilities.
To continue to use or import a substance in the UK, companies are legally required to ensure it is registered by the following deadlines:
• Registration for substances > 1000 tonnes per year; CMRs etc. 27th October 2026
• Registration for substances > 100 tonnes: 27th October 2028
• Registration for substances > 1 tonne: 27th October 2030
The British Plastics Federation (BPF)’s Product Safety Committee comprises regulatory experts from the various BPF groups and is chaired by Chris Howick, Inovyn. The committee meets at least twice a year to discuss the latest about UK and EU REACH, PFAS, microplastics, CLP and drinking water regulations.
Guest speakers included Professor Andrew Dove (Birmingham Plastics Network), Professor Neil Champness (Head of Chemistry, University of Birmingham), Dr Chris Howick (Inovyn) and Dr Neil Hunt (Yordas), a consultant who worked with DEFRA on the Alternative Transitional Registration Model (ATRm). The presentation from Yordas (new BPF member), was useful as it provided a comprehensive breakdown from the background of UK REACH to practical steps companies can take to ensure compliance. There was strong engagement from attendees. Members asked insightful questions, shared answers and offered feedback from their experiences. Many commented that hearing real-world examples was particularly helpful. The combination of expert insights and peer-driven discussions made for a highly informative and valuable session.
During the workshop, members were split into smaller groups and asked to discuss pre-determined questions, such as ‘What use and exposure data should you be collecting now and how can you source the required information?’ and ‘What are the biggest financial concerns when it comes to UK REACH?’
During the feedback session, clear themes appeared. These include guidance documents from the UK government, concerns about the final impact of UK REACH, recycling-specific challenges, the difficulty in meeting the UK REACH registration deadlines and the challenge of sourcing exposure data which may go above and beyond what is required by EU REACH.
A laboratory tour of the University of Birmingham Chemistry Department’s facilities was also arranged for BPF Product Safety Committee members. Whilst polymers are currently UK REACH exempt, importers and users of the polymer must ensure the monomer is registered. Getting characterisation data can be complex, so it was useful to have an overview of the analytical capabilities at the University of Birmingham for those responsible for regulatory compliance.
Overall, the event was a great success. The BPF would like to thank the University of Birmingham’s Plastics Network, Yordas and the Chair of the Product Safety Committee, Chris Howick, for making this event possible.
