BP&R October 2019

British Plastics

and Rubber

bp&r OCT 2019

A WORTHY SUBSTITUTE HEAT DISSIPATION BY LED LIGHT SOURCES: USE OF PLASTICS SAVES ENERGY AND PRODUCTION COSTS INSIDE THE CELL How robots are adding value for one UK plastics processor

COMING FULL CIRCLE Exhibitors at K 2019 talk about plastics in a changing world

SCORING WITH PACKAGING New grading tool helps users choose the most sustainable options

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editor’s letter

Future forward www.britishplastics.co.uk head of content: Leanne Taylor

T: +44 (0) 1244 952 371 E: leanne.taylor@rapidnews.com Assistant Editor: GRACE NOLAN

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Assistant Editor: Tom Walker

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W

alking around K 2019, visitors will see a glimpse into the future. From connected, multi-share vehicles using plastics for intelligent dashboards, lightweight components and new electrified powertrains, through to the products made using carbon dioxide, plants and recycled plastics as a feedstock, it will be a true showcase of innovation and the ways in which polymer materials will help meet global challenges and adapt to changing trends and lifestyles.

But it’s not just K where you can see a glimpse into how we might be using plastics in the future. In this issue of BP&R we have a special feature on pages 56-57 looking at a new era of how patients manage multiple drug prescriptions that could see medicines personalised to the patient and ‘made to order’, thanks to a combination of materials technology, 3D printing and injection moulding currently being trialled by researchers at the Athlone Institute of Technology in Ireland.

vast potential on page 60 – where we look at the ways in which Cheltenhambased Versarien is commercially developing large-scale industrial deployment of graphene-enhanced polymers for infrastructure projects.

These are just a selection of highlights from an issue brimming with innovation in plastics. As we fast approach a new decade, it’s fascinating to think of where these materials might take us in the next 10 years and beyond. I certainly look forward to finding out.

Enjoy the issue.

Leanne Taylor, head of content

On page 27 we look at the ways in which thermoplastic composites are changing the ways in which the automotive industry uses materials in series production, with an insight into how one component used to replace a metal application has brought positive results for premium car manufacturer, Porsche. And graphene, the oftencalled ‘wonder material’, showcases its

From connected, multi-share vehicles using plastics for intelligent dashboards, lightweight components and new electrified powertrains, through to the products made using carbon dioxide, plants and recycled plastics as a feedstock, it will be a true showcase of innovation and the ways in which polymer materials will help meet global challenges.

the big story

W HEN IT COMES TO HEAT DISSIPATION

BY LED LIGHT SOURCES, THERE IS A COMMON PRECONCEPTION THAT ALUMINIUM HEAT SINKS ARE SUPERIOR TO THERMALLY CONDUCTIVE PLASTICS. IN THIS ARTICLE, BP&R HIGHLIGHTS A RECENT DEVELOPMENT PROJECT UNDERTAKEN BY ALBIS PLASTIC THAT DISPELS THIS MYTH AND PROVES THAT PLASTICS WARRANT CONSIDERATION AS A NOT ONLY A WORTHY SUBSTITUTE, BUT ONE WITH ADDITIONAL BENEFITS.

A WORTHY SUBSTITUTE “Aluminium heat sinks are always superior to thermally conductive plastics.� This is a common preconception when it comes to the dissipation of heat by LED light sources. Well-established design practice, however, shows that because the heat sinks are generally in a closed plastic housing in still air, the high thermal conductivity of aluminium does not create any added value compared to thermally conductive plastics.

In a development project with Gessler GmbH, a leading manufacturer of safety light systems based in Rodgau, Germany, Albis Plastic was able to show, with the assistance of simulations, that there is a worthy substitute for aluminium heat sinks. The great potential of thermally conductive plastics is in the geometrical flexibility that the injection moulding process makes possible. At the same time, elimination of the aluminium component leads to considerable savings of energy and production costs during implementation of the production process. The lifetime and function of the light source are not affected in any way. This process can be used for a variety of applications in the E&E sector.

Contrary to popular opinion, LEDs generate heat, and depending on the version their efficiency is <40 per cent.

POWER OF THE LED Contrary to popular opinion, LEDs generate heat, and - depending on the version - their efficiency is <40 per cent. Each LED has a maximum permissible temperature that, if exceeded, greatly decreases the lifetime of the diode. In general, this is between 100 and 120 degrees Celsius. These days, LEDs are much more powerful than they were even just a few years ago, which correlates with increased cooling requirements. At the same time, they are used in a variety of applications in increasingly smaller spaces and are also being encapsulated (hermetically sealed off), for example in instrument clusters or lighting in and on vehicles.

A common approach to cooling them is to dissipate the created heat via an aluminium or zinc and magnesium heat sink. This is produced in a metal die-cast process and has a high thermal conduction coefficient (W/mK) of over 200 W/mK. At the same time, however, when compared to plastics, these materials are characterised by their heavy weight as well as expensive and energyintensive manufacture. As well as this, they cannot be manufactured in large quantities at the same speed as their plastic equivalents using injection moulding, and great effort is involved in removing burrs and sprues. Ultimately, the design freedom of injection-moulded plastic components remains unrivalled.

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Images of the aluminium temperatures on the top and bottom of the heat sinks

Images of the Alcom temperatures on the top and bottom of the heat sinks

TYPICAL CONSTRUCTION The standard construction of an LED unit is based on a printed circuit board (PCB). This is connected to the heat sink by a heat conducting material such as heat conducting pads, paste or glue. The boards carry the electrical conductors and are generally made of synthetic resin.

Their typical thermal conductivity is 1 to 6 W/mK. The heat conducting material between the printed circuit board and the heat sink should mechanically connect the two, conduct heat and also generally electrically insulate the board against the heat sink. The materials used have thermal conductivity in the range of 0.3 to 5 W/mK.

low thermal conduction coefficient, meaning that in this case the high thermal conductivity of a metal heat sink creates no advantages when compared to the use of thermally conductive plastics. It is much more important in these assemblies to prevent thermal ‘hot spots’ around the heat source, and to efficiently distribute the heat energy around the whole heat sink to maximise the surface area and thus the contact area to the surroundings.

REDUCED COSTS, INCREASED RELIABILITY

On the basis of these considerations, Gessler and Albis decided to reduce component costs for the LED assemblies and at the same time fulfil the This frequently used construction, with a moderately thermally conductive material, requirement for exceptional reliability.

The safety lighting systems and inhibits heat dissipation of the LED heat associated light fittings by Gessler are source in the heat sink because the use of metal means that it cannot utilise its full essential in large buildings and guarantee safe operations. Because these systems potential due to the barrier mentioned. are safety-relevant components, their Added to this is the installation situation functionality also needs to be guaranteed of many LED assemblies in sealed over a period of 20 years or more, so housings without forced air flow (for that they can reliably fulfil their alarm example by a fan). This means that and guidance functions in the case of an heat dissipation by the heat sink to the emergency. surroundings occurs exclusively through A step like this is associated with thermal radiation and the release of high investment costs, including the thermal energy to the surrounding air. construction of the required injection However, transfer of heat from the heat moulding tools, so it needed to be sink to the air is characterised by a very verified in advance using simulation.

By using a transient thermal structural mechanical simulation (FEM) it was confirmed that temperatures in the LED are only different by 1.5 °C under continuous load when compared to the previously used aluminium.

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By using a transient thermal structural mechanical simulation (FEM) it was confirmed that temperatures in the LED are only different by 1.5 °C under continuous load when compared to the previously used aluminium. ALCOM TCD, a plastic that features particularly high thermal conductivity, was used. With a maximum temperature in the core of the LED of 68.5 °C instead of 67 °C, the values were in the safe zone, and the intended lifespan of the LED could be guaranteed.

If you only compare the performance of the heat sinks, it can be seen that the hot spot of the aluminium is also easily visible in the rib base. Surrounded by static (not moving air) air, however, this area is the most ineffective, as its own heat dissipation is impeded by the heat emission of the surrounding cooling cylinders of the heat sink. On average, temperatures at the surface of the cooling cylinders are almost identical, since transition to heat flow air non streaming air is once again reduced to the known level of around 4 to 6 W/mK. CONCLUSIONS “Quod erat demonstrandum: The ALCOM TCD plastic can be used for this application and leads to increased energy efficiency for the application, despite the nominally much lower performance,” explained Jonah Kock, Albis’ Application Technician working on the project. “To further validate the results, additional simulations of experimental setups based on our own TCD test heat sink were carried out. Here we also managed to sufficiently prove the measured temperature ranges with the set parameters.”

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£ OCT 2019

on the cover

A WORTHY SUBSTITUTE When it comes to heat dissipation by LED light sources, there is a common preconception that aluminium heat sinks are superior to thermally conductive plastics. In this article, BP&R highlights a recent development project undertaken by Albis Plastic that dispels this myth and proves that plastics warrant consideration as a not only a worthy substitute, but one with additional benefits.

SEE PAGE 4

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Editor’s Letter FUTURE FORWARD

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Feature

INSIDE THE CELL: ROBOTS ADD VALUE FOR UK PLASTICS PROCESSOR The introduction of robotics and automation is now seen as essential if plastics processors are to remain competitive, capture new markets, and increasingly add value to the products that they manufacture. In this article, Craig Forrester, General Manager of Stäubli UK Limited, shares with BP&R an example of how one UK injection moulder is using the technology to its advantage.

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IN THIS ISSUE

K2019: THE PLASTICS INDUSTRY HEADS TO DÜSSELDORF In the second part of our special focus on K Show, we preview exhibitor highlights, as well as a special feature about the central theme of this year’s show – circular economy – covering topics ranging from how the view of plastics has changed since 2016, and where the future could lead.

08 INDUSTRY NEWS

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29 K PREVIEW

SCORING WITH PACKAGING DESIGN In this exclusive interview for British Plastics and Rubber, Brian Lodge, Design Manager at Berry Global and working with the BPF as a Sustainable Design Consultant, gives readers get an insight into the work he has done on PackScore, a newly-launched, simplified online grading system that helps users choose the most sustainable and recyclable packaging designs.

41 RECYCLING MACHINERY

Special Preview

Feature

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Feature MADE TO ORDER As a new decade draws ever near, researchers at the Athlone Institute of Technology (AIT) in Ireland are working on futuristic ‘made to order’ personalised healthcare technology that would enable the mass-customisation of medicines using a combination of 3D printing and injection moulding. BP&R looks at how the technology could have the potential to change lives.

17 AUTOMATION AND ROBOTICS 23 Composites

44 RECLAMATION AND RECYCLING 51 PROCESSING AGENTS 56 MACHINERY 59 MATERIALS 61 POLYMERMAN 62 SOFTWARE GUIDE 63 BUYERS’ GUIDE 66 NEWS FROM THE FRONTLINE

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INDUSTRY | NEWS BPF calls for better public understanding of plastic materials The British Plastics Federation is calling for better understanding of materials to help people make more environmentally friendly choices, after commissioning a recent YouGov poll.

The poll found that only two per cent of people thought that plastic is the packaging material that is least damaging to the environment in terms of helping to keep down greenhouse gas emissions.

The organisation is calling for a fuller understanding of materials

amongst the wider public to help them make “informed” decisions, claiming it is “vital” that the public do not think ‘plastic-free’ means ‘better for the environment’.

The BPF has previously highlighted that plastic packaging also plays an important role in protecting products and reducing food waste.

Carbon footprint of the products we buy are typically far higher than their packaging. However, over a third of respondents did not agree that packaging is even necessary to increase the shelf life of food.

The poll also revealed 73 per cent said that they either ‘agree’ or

The BPF is urging consumers to realise that plastic free does not mean ‘better for the environment’

‘strongly agree’ with the statement: “I aim to buy packaging that is plastic-free because I think it is better for the environment”.

Philip Law, Director General of the British Plastics Federation, said: “The fact that nearly three quarters of the British public unfortunately assume that buying something that is plasticfree is better for the environment highlights how unbalanced the debate about plastic has become.

People should have a choice. But people need accurate information to make an informed decision – and that is what is lacking.”

He added: “We urge the government, brands and retailers to help us find ways to communicate why simply ditching plastic is not the best thing for our environment.

The last thing our planet needs is for us to make matters worse by switching to alternative materials and increasing global greenhouse gas emissions.”

The findings come shortly after a report from the Environment, Food and Rural Affairs Committee was released, which contained warnings that switching to alternatives risks increasing carbon pollution.

The BPF has also recently released a document called ‘Understanding the Debate About Plastic,’ which is intended to provide an accessible way of informing people about the current issues.

Joanne Liddle, Managing Director of IPC Mouldings says she is “thrilled” to receive the award

IPC Mouldings achieves SC21 Gold Award in the Aerospace Supply Chain IPC Mouldings, based in Carrickfergus, Northern Ireland, has become the fifth business in the UK to achieve the SC21 Gold Award in the Aerospace Supply Chain.

SC21 is a continuous improvement programme for improving operational effectiveness and achieving supply chain excellence within the Aerospace and Defence Industry.

The programme is the primary route on the improvement ladder and some of the outcomes for participating companies include the 8

achievement of 99 per cent delivery and quality performance, the reduction of supply chain risk and implementation of leaner production methods.

IPC Mouldings delivers 2.5million parts annually to the aerospace sector with a quality performance of 99.97 per cent and 99.7 per cent ontime delivery.

In 2018, there were 3.6 billion global air passengers and IPC

Mouldings’ parts travelled with over 900 million of them.

Managing Director of IPC Mouldings, Joanne Liddle, said, “We are thrilled to receive the SC21 Gold Award. This is an amazing achievement from an extraordinary team in IPC and reinforces our dedication to quality and delivery, ensuring that the products and services we provide to customers are of the highest standard.”

www.britishPLASTICS.co.uk

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The Hotbin Mini

DS Smith wins Horners Award for slimline home composting unit DS Smith’s Hotbin Mini has been announced as the winner of the Horners Award for Polymer Design and Innovation.

It was praised for providing homeowners around the country with a small, slimline unit to help process waste into compost up to 32 times faster than cold composting bins.

The runner-up, and recipient of the BPF Award, was announced as The R & D Factory Ltd, for its development of ‘Streamoulding’, a water foaming technology that fits to existing machines to enable lighter weight plastic material to be produced.

The Horners Award Chairman, David Williams, said: “Many of the entries this year demonstrated how smart applications of plastic help us solve everyday issues of reducing waste and live sustainably.”

He added: “I was extremely happy to see how the UK industry

is proactively responding to the concerns of the public over waste, and how innovations like the Hotbin Mini demonstrate that innovation in plastic is vital now more than ever.”

Due to such strong competition, three entries were given a Highly Commended certificate. These were 3DSeed, a 3D printer which works alongside a miniature plastic grinding unit to create 3D printed objects from recycled PET packaging straight from the home.

The second Highly Commended product was SecurInject, a singleuse dental safety syringe designed to prevent needle stick injuries and cross injections.

The third Highly Commended innovation was the Flip Pad, a strong and durable iPad case, which has been designed specifically to be anti-microbial, making it suitable for doctors and nurses to use in hospitals.

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UK wins bid to host 2029 rubber conference following recent success The UK has been successful in its bid to host the 2029 edition of the International Rubber Conference (IRC), after the recent event closed to great acclaim.

This is the earliest opportunity possible for the UK to re-host an edition of the IRC, which this year took place at the Kia Oval in London.

The 2019 edition was the first time the event has been held in the UK since 2001.

Hosted by the Institute of Materials, Minerals and Mining (IOM3) on behalf of the IRC from 3-5 September, the event saw a packed programme of more than 150 spoken presentations, 60+ poster presentations, 50 exhibitors and 600 registered delegates from 37 countries attend the event.

“The number one hot topics this year centred around making rubber products more sustainable by exploiting environmentally-friendly

Professor James Busf ield gives the opening address at IRC2019

this is one of the best conferences I have ever been to. materials or making elastomer products, such as tyres, consume less energy,” explained conference Co-Chair, Professor James Busfield.

“Big breakthroughs were reported in making rubber materials that are smart and/or responsive, rubbers that can be additive-manufactured or

rubbers that can exhibit self-healing behaviour.”

Testament to the success of the 2019 conference, Ed Miller, Executive Director of the Rubber Division at the American Chemical Society, said: “This is one of the best conferences I have ever been to.”

Dugdale’s premises in Sowerby Bridge

Benvic acquires Dugdale UK as it continues international expansion Benvic Europe SAS has closed the acquisition of UK-based independent PVC compounder, Dugdale Compounds Limited.

The acquisition of Dugdale marks the sixth add-on investment for Benvic in just over 18 months following the acquisitions of Italian companies Vinyloop, Plantura and 10

Modenplast, as well as Poland’s Alfa PVC and Ereplast in France.

Benvic says the acquisition of West Yorkshire-based Dugdale will enable the continued expansion of the company’s European footprint through the diversification of its product portfolio and enhancing its operational capabilities.

The two companies’ commercial and technical teams will work closely together going forward, to ensure seamless continuity of existing supply and service levels for customers.

The integration of a major player like Dugdale within Benvic will allow us to significantly strengthen our operations in the UK and Irish markets.

Luc Mertens, Benvic’s CEO, said: “The integration of a major player like Dugdale within Benvic will allow us to significantly strengthen our operations in the UK and Irish markets where the group has become a major player over recent years.”

David Outen, Dugdale’s Managing Director, added: “We are delighted to join Benvic and become part of an international group with diversified activities including the addition of new polymers and recycling capabilities.”

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www.ultrapolymers.com | Your partner from design to production

GTMA launches ReshoringUK platform The GTMA has launched a new reshoring website that represents leading industrial engineering associations, developed with the goal of connecting manufacturers with trusted and accredited UK suppliers capable of providing technical support and services.

Via the new ReshoringUK platform, users can select a category that is relevant to their needs, with subcategories to help focus the search, or choose from industry sectors, association membership or use a text box to specify their product or service requirements.

A region filter provides the choice between region and country-specific options for suitable suppliers, and, after filtering, potential businesses are pinned on a map, allowing users to look at each profile and individual company website link.

“It is an often-repeated misconception that the UK does not make things anymore. The

reality is that we are still the ninth largest manufacturing nation in the world and the sector plays a vital role as an employer, exporter and innovator,” said Julia Moore, CEO of the GTMA. “In fact, British-made goods are sought-after around the world, with manufacturing accounting for 44 per cent of all the UK’s overseas sales. Manufacturing still contributes a tenth of UK GVA and represents 70 per cent of all business R&D spend and directly employs 2.7 million people.

Matching the needs of businesses that are reshoring, or each searching for the ‘lost skills’ which the engineering marketplace can provide, demonstrates where the Reshoring website excels.”

She added: “It can make the compiling of an end-to-end supply chain much more efficient, minimising the leg work required to find businesses that are capable and competent enough to provide the support required.”

The GTMA has launched a new reshoring website

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Bunting joins Polymer Machinery Manufacturers and Distributors Association The European division of the global Bunting Group has joined the Polymer Machinery Manufacturers and Distributors Association (PMMDA).

The company says the move reflects its long-time association with the plastics sector.

The PMMDA provides information, representation and a mutual support for companies in the plastics industry, including through networking and events, provision of market statistics and industry data, communication of regular business and industry updates, representation and feedback on the development of EU and ISO Standards and negotiation of member advantage at exhibitions and events.

“Joining the PMMDA reflects the importance of the plastics sector to our business,” said Simon Ayling, the Managing Director of Bunting’s European division.

Bunting’s Simon Ayling (left) and Tom Higginbottam (right) with the PMMDA’s Richard Hird (centre)

Upcoming VinylPlus UK seminar to explore innovation in PVC The 2019 VinylPlus UK seminar will explore innovation in the PVC industry, examining changes that are driving sustainable development and improved product performance.

Speakers from organisations such as VinylPlus, Inovyn, retailer Kingfisher and architecture firm

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A UK-wide recycling programme for ring carriers has been launched

We are extremely excited to have launched this new initiative with TerraCycle, which means that our product is now fully recyclable in the UK.

TerraCycle and HiCone launch UK-wide recycling programme for beverage ring carriers TerraCycle has collaborated with Hi-Cone, a specialist manufacturer of beverage ring carriers, to launch a UK-wide recycling programme.

Consumers will be able to ensure ring carriers are kept in the recycling loop by downloading a freepost label from ringrecycleme. co.uk, then sending them to TerraCycle directly through the post.

The scheme also offers the chance for consumers to set up public access drop-off locations for whole communities to recycle their plastic ring carriers together.

The aim is to build a network of these public access drop-off locations across the UK to make it as easy as possible to recycle.

Both companies are keen to see ring carriers put to further good use in products such as park benches, outdoor furniture and composite lumber, as opposed to entering general waste streams.

It is the first time a beverage packaging manufacturer has been actively involved in such a programme anywhere in the world, and TerraCycle is keen to build on this going forward.

Walkers Crisps and Acuvue have already achieved great results through similar initiatives for their products with TerraCycle.

T. Kenneth Escoe, President of Hi-Cone, said: “We are extremely excited to have launched this new initiative with TerraCycle, which means that our product is now fully recyclable in the UK. This is a crucial step on our journey to recover and reuse as many plastic ring carriers as possible worldwide and is the first of many planned phases to help communicate to consumers that these carriers can be recycled to great effect.”

Flanagan Lawrence will examine what the future of PVC looks like.

Topics will include ‘A Retailers Perspective on PVC’, ‘Innovation with PVC Tensile Fabrics’ and ‘Designing for a Circular Economy With PVC’.

Accelerating Innovation in PVC will take place on 19 November 2019 at the Etihad Stadium in Manchester and is a VinylPlus UK event that is supported by the British Plastics Federation.

Roger Mottram, Chairman of VinylPlus UK, said: “Developments and innovations in the PVC sector have been coming thick and fast and this conference will provide a detailed overview, exploring what comes next for the PVC industry in the UK. “Whether you supply and manufacture PVC, or use it within your business, there is plenty for everyone to learn about the future of this amazing material.”

www.britishPLASTICS.co.uk

www.ultrapolymers.com | Your partner from design to production Jim Casey (Credit: Darran Moore Photography)

Nifco reports challenging year in automotive industry Automotive plastics parts manufacturer, Nifco UK, has reported a fall in sales as the result of challenging trading conditions.

The company, which produces parts used for some of the world’s largest carmakers, saw sales drop to £71.1 million for the 12 months ending December 2018, down from £75.9 million in 2017.

Nifco says the biggest single factor contributing to the year-end reduction in sales has been the impact of a main customer moving production of a new model from the UK to Slovakia in July 2018, which left a gap in sales for the second half of the year.

Furthermore, the automotive industry experienced an overall downturn in sales as a result of the diesel emissions scandal and the trade war between the US and China, in addition to the turbulence caused by continued Brexit uncertainty.

This is not a case for major concerns, but one for positive action.

“It is disappointing, but not surprising, that the company has reported a drop in sales for the first time in a number of years as a direct result of the external market conditions we are operating in,” said Jim Casey, Managing Director of Nifco UK. “As I have said previously, challenges present opportunities for improvement and while this is a setback for the team at Nifco, it is simply that, a setback.”

Casey said the company will continue to build on the relationships it has with its customers, invest in product development and in its people so that it is “in the best position possible” to address the challenges that may be ahead.

“This is not a case for major concerns, but one for positive action,” he concluded.

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VALUABLE A$$ETS

W ITH PUBLIC OPINION REQUIRING PLASTICS COMPANIES TO FOCUS MORE CLOSELY ON THE ENVIRONMENTAL SUSTAINABILITY OF THEIR PRODUCTS, THERE IS AN OPPORTUNITY TO INVEST IN MANUFACTURING PROCESSES AND GROW BUSINESS. HERE, IAN BARKER, MANAGING DIRECTOR FOR MANUFACTURING AT CLOSE BROTHERS ASSET FINANCE EXPLAINS HOW ASSET FINANCE CAN HELP UK PLASTICS COMPANIES SUCCEED.

A

sset finance is an alternative form of funding used by businesses to obtain the equipment, vehicles, or capital they need to grow. However, it can be difficult to ascertain the types of finance available and how it works in practice.

Common examples include Hire Purchase, which allows a company to buy equipment on credit. The finance company purchases the asset on behalf of the customer and owns the asset until the final instalment is paid.

Refinancing, sometimes known as Capital Release, is where a finance company purchases the asset from a business and finances it back, releasing the equity raised into cash flow. Repayments are calculated in line with the income stream that will be generated by the asset; at the end of the refinance term, the asset is owned by the business.

£

Other options include Finance Lease, where the full value of the equipment is repaid to the finance company, plus interest, over the lease period. At the end of the term, the business can choose to continue to use the asset by entering a secondary rental period; sell the asset and keep a portion of the income from the sale; or return it.

There is also Operating Lease, which allows a business to rent the asset from the finance company whilst needed. The key difference between the two is that an Operating Lease is only for part of the asset’s useful life. This means a business pays a reduced rental because the cost is based on the difference between the asset’s original purchase price and its residual value at the end of the agreement.

MAKING THE UNAFFORDABLE, AFFORDABLE The beauty of asset finance is its flexibility – it can be used to fund any asset, including (but not limited to) injection moulding machines, window manufacturing machinery, bottling machinery and vertical machining centres.

It can even be used to help with the refurbishment of assets, for example, where refurbishment costs are paid by a finance company taking security of an asset to aid cashflow, via sale and Hire Purchase back.

This makes the otherwise unaffordable affordable, because it gives businesses access to the equipment they need without incurring the cash flow disadvantage of an outright purchase.

Agreements can also be customised to the business’s needs, with flexibility on both the term and repayment schedule.

Asset f inance is an alternative form of funding used by businesses to grow

It is important to choose an asset finance funder with experience in working with SMEs through all economic cycles, so they understand your business needs, whether you are looking to expand your range of equipment or replace it.

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AUTOMATION & ROBTICS | NEWS

SEE ME AT K2019 HALL 12 STAND A49

Sepro demonstrates flexibility and collaboration in plastics injection moulding Sepro Group will demonstrate automation solutions with injection moulding machinery manufacturers and technology partners when it exhibits at K 2019.

The company is inviting visitors to ‘Experience Full Control’ with a series of demonstrations and exhibits that show the power of collaboration to achieve productivity, quality and flexibility in plastics injection moulding.

A total of eight robots will be operating on the stand, including 3-, 5- and 6-axis models as well as collaborative units (cobots), provided through a recently-announced partnership with Universal Robots.

Several of the robots will be part of automation cells centred around two operating injection moulding machines. Sepro products also can be seen operating on the stands of eleven IMM partners exhibiting at the show.

Campetella to display coffee capsule production as part of robotics showcase Campetella will be demonstrating its expertise in the field of industrial automation with a wide range of new and enhanced robot systems, handling equipment and fully automated manufacturing solutions at K 2019.

Campetella will also exhibit an X-Series Modula for the IML decoration of coffee capsules made of home-compostable material.

This is a four-cavity application with a total cycle time of six seconds, a robot cycle time of 5.1 seconds and an IMM interlock time of 0.9 seconds.

One of the two automation cells on the stand will feature a Sumitomo Demag moulding machine producing a technical component that will be removed from the mould by an SDR Speed 7 robot.

The other moulding cell will also include a Sepro-Universal Robots cobot together with a Sepro Success 11 Cartesian robot operating on a moulding machine from Haitian International, which will be producing drinking cups.

A second cobot will be running in a stand-alone demonstration of robot/human interaction. Visitors to the booth will be able to choose between a round box of sweets and a square one then, with the help of a machine-vision camera and a flexible feeding system, the cobot will pick the appropriate shape and hand it directly to visitors.

A section of the Sepro stand will be dedicated to existing and future projects aimed at providing technologies that makes it easier for moulders to use Sepro robots efficiently and profitably.

Wittmann releases first-of-its-kind WX193 Wittmann has released its new WX193 robot, designed for applications involving extremely large parts manufactured on injection moulding machines with clamping forces of 4000 tonnes or more.

Like all other Wittmann robots, the WX193 comes with a flexible, modular design, as its main linear axes are all available in a number of different lengths to enable optimal adjustments to the individual application and injection moulding machine.

In its standard configuration, the WX193 can handle loads of up to 150kg, and an additional pivoting servo C-axis is used in this configuration.

In contrast to the conventional pneumatic pivoting axes, which are the standard equipment for many robots and enable pivoting movements of up to 90 degrees, Wittmann has chosen the servo variant.

This version offers a pivoting range from 0 to 180 degrees, a torque of 250Nm, and an accuracy of 0.1 degrees.

The new WX193 is delivered with the latest version of the integrated Wittmann CNC9 control system and the R9 TeachBox as standard.

SEE ME AT K2019 HALL 12 STAND C20

Sales Manager, Elia Campetella, said: “Combining and linking proven components systematically and imaginatively we build complex automation solutions, based on our many years of experience and designed to meet new customer requirements.”

Mr Campetella added that the company has scaled up the number of sales and service personnel so that it is able to expand its business to a pan-European scale.

“We are looking forward to the new tasks and challenges which we

will master with the knowhow we have acquired over decades,” he concluded.

Campetella will showcase an IML production cell www.britishPLASTICS.co.uk

17

Launch of Gimatic in the UK

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Having been operating in the field of automation for more than 30 years, Gimatic can today boast a vast range of products supplied and used worldwide on a variety of different markets. To improve its competitiveness on the market, Gimatic has opened a UK branch to support and grow its brand.

Hall 10 Booth E55

EMAIL

Info.u k@gimatic.com WEB

gimatic.com OFFICE

0161 470 4129

Gimatic UK, Earl Business Centre, Dowry Street, Oldham, OLS 2PF

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Moulding success

into UK manufacturing

IN

F

ollowing staff growth numbers reaching an impressive 83 per cent in five years and establishing itself as a supplier to a number of OEM and tier one companies across the HVAC and automotive sectors, Hull-based Advanced Plastics says one of the reasons for its success is its adoption of the latest industrial technology, including automated systems and industrial robots.

' THE FOLLOWING CASE STUDY, BP&R LOOKS AT HOW ONE PLASTICS INJECTION MOULDING FIRM BASED IN EAST YORKSHIRE HAS ACHIEVED SUCCESS FOLLOWING INVESTMENT IN ROBOTIC TECHNOLOGY.

The company’s investments have allowed it to grow at pace, thanks to the automated processes in place ensuring a high demand of technically-challenging orders are delivered on time.

Edwin Darling, Process Manager at Advanced Plastics, explained: “Our moulding machines produce the parts, but we now use robots to tend the machines on a constant basis, with consistent cycle times and dependable overall equipment effectiveness (OEE). All of our injection moulding machines have a robot, which is situated inside a cell and performs various applications, many with vision systems to provide 100 per cent automated verification.”

The M-10iA

Moulding a diverse range of products, from gas boiler front panels, to automotive interior, exterior and air filtration components, Advanced Plastics requires a multitude of different robotic technologies to be able to commit and complete the desired components on time.

As a result, Advanced Plastics has purchased and utilised a number of different systems from Fanuc UK, based in Coventry, including the M-10iA, M-20iC, M-6iB and R-2000 series, as well as Roboshot injection moulding machines.

Fanuc says one of the benefits of its R-2000 robot is its ability to work with pre-existing automation equipment. At Advanced Plastics, two R-2000 robots work with a moulding machine and deliver the parts to another piece of equipment that help place foam gaskets around plastic components, such as boiler covers. The R-2000 series features high performance capabilities and is perfect for applications involving high payloads. Its compact design makes it an ideal solution for Advanced Plastics to ensure compact and efficient cell designs.

Advanced Plastics’ facility in Hull, East Yorkshire

TIME SAVINGS AND GROWTH PLANS One of the robots that has proven to increase the capacity at the manufacturing site is the M-10iA. Through working with Fanuc, Advanced Plastics has moved from a 3-axis robot to Fanuc’s 6-axis M-10iA robot. Processes which were complicated and difficult to handle are now automated, including picking up inserts and putting them into the moulds, some of which can reach between 80-90°C making them unsafe to handle, as well as trimming tab gates from cavities once the plastic has been injected.

Additionally, the adoption of the M-10iA robots has seen Advanced Plastics’ effectively double its payload, compared to its previous system, from 6kg to 12kg.

The compact system has also helped the manufacturer improve its cycle time, providing significant time savings over a year, as Darling explained: “The machines are fast and, because they have a constant cycle time, they can provide time savings of two seconds or more each time. While this doesn’t sound like a lot, by reducing the time by one to two seconds each cycle, we can save around four to five weeks of time per year. Given the increase in orders that we have received, this time helps us to keep growing as a business.”

Using robots in a variety of different sizes, Advanced Plastics is able to mould a vast range of different products of varying technical difficulty. Currently using Fanuc robots that range from 6kg to 165kg, Advanced Plastics is able to fulfil orders for many different components at the same time.

When it moved into its current home in 2012, Advanced Plastics had 16 injection moulding machines. Today, this number has increased to 37, effectively more than doubling its capacity in the last seven years. As it continues to grow, the company is now looking to expand its capabilities with a new car park and warehouse facility, freeing up an additional 40 per cent of manufacturing space.

www.britishPLASTICS.co.uk

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Inside the cell:

T HE INTRODUCTION OF ROBOTICS AND AUTOMATION IS NOW SEEN AS ESSENTIAL IF PLASTICS PROCESSORS ARE TO REMAIN COMPETITIVE, CAPTURE NEW MARKETS, AND INCREASINGLY ADD VALUE TO THE PRODUCTS THAT THEY MANUFACTURE. IN THIS ARTICLE, CRAIG FORRESTER, GENERAL MANAGER OF STÄUBLI UK LIMITED, SHARES WITH BP&R AN EXAMPLE OF HOW ONE UK INJECTION MOULDER IS USING THE TECHNOLOGY TO ITS ADVANTAGE.

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Robots add value for UK plastics processor

M

idlands-based WHS Plastics operates across three UK sites and has 1,000 employees supporting major international companies, in a variety of industries including automotive, electronics, industrial and hygiene products.

In addition to its state-of-the-art injection moulding technology at the heart of its business, the company has also invested heavily in robotics and automation to support the moulding process. A large suite of Stäubli 6-axis robots perform a diverse range of tasks, ranging from insert loading prior to moulding, to sophisticated post-moulding handling and assembly operations, such as the assembly of trim clips to an automotive tailgate moulding.

Details of this particular process we’ll now look at more closely.

INSIDE THE CELL This production cell uses a Stäubli TX200 six-axis robot to remove a rear tailgate component from the injection moulding machine. The robot then moves the part to an assembly fixture, where the component, whilst still retained by the gripper, is located and datumed for a clip assembly process. Trim clip components are presented from a bulk hopper and vibratory bowl feeding system situated within the cell. Each part is accurately located at an escapement before being collected by a second Stäubli six axis robot, in this case a TX60 model. The robot then proceeds to position and assemble multiple trim clips to the moulding.

Dual Stäubli six-axis robots perform a combination of de-moulding and assembly tasks in this cell at WHS Plastics

On completion of the assembly operations, the TX200 robot, which has retained its grip on the part throughout the assembly process, then removes the part from the fixture and transfers it to an output conveyor. This cell, which is just one of a number of similar systems at WHS Plastics, makes use of both technology and manual resource, with man and machine performing the tasks that they are best suited to.

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VOLUME AND REPETITION The volume associated with the production of automotive parts means that there are many repetitive tasks as each component or sub-assembly progresses to its final stage. In the case of injection moulded parts, and especially where additional process or assembly tasks may be required, 6-axis articulated robots have demonstrated their ability to add value by performing a series of often complex post moulding operations directly at the mould press.

Such has been the success of this concept for WHS Plastics that robots are now routinely ordered as part of a package with every new injection-moulding machine.

Further benefits from the use of robots are that they can also alleviate the problems sometimes encountered by manual operators, where the highly repetitive nature of the operation may ultimately cause physical strain or be at the root of unintended errors. In addition, robots make it possible for operators to acquire new skills, such as managing the automated cell and perhaps performing quality control functions.

The int r at the oduction of the ro mould bots in signif icant b g cell deliv e e rs handl nefits ing, po st mou as all trans lding fe and perfor r operation s are med w ithin t cycle he wi manua thout the ne mould l inter e ventio d for any n.”

QUALITY AND CONSISTENCY Manufacturing and supplying into automotive OEMs requires the highest levels of quality and consistency, and this can only be achieved through the use of technology that is in itself robust, and capable of meeting the rigorous demands of this sector. Stäubli robots have a reputation for their speed, performance and reliability, attributes that were a key part in their selection by WHS Plastics for integration within their production facility.

The use of a six-axis robot, or in the case of this application, a pair of six-axis robots, makes it possible to perform tasks which were traditionally either manually completed at the machine, or carried out within a separate workstation away from the moulding cell. In either case, the introduction of the robots at the moulding cell delivers significant benefits as all handling, post moulding and transfer operations are performed within the mould cycle

without the need for any manual intervention. Further benefits include the fact that in process checks can be carried out during the post moulding operations, enabling a ‘no fault forward’ approach to the process.

ROBOTS ADD VALUE The introduction of robotics and automation is now seen as essential if plastics processors are to remain competitive, capture new markets, and increasingly add value to the products that they manufacture. However, for this strategy to be effective, a close working partnership between the plastic

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processor and the robot supplier is essential to ensure that both press side and downstream operations can be automated successfully.

The relationship between WHS Plastics and Stäubli spans some 20 years and is firmly based upon ongoing mutually beneficial collaboration between the two companies. Stäubli’s understanding of the plastics sector’s unique requirements, together with the fact that the company offers 4 and 6-axis robotic arms specially designed for the plastics industry, will ensure that this partnership continues far beyond the existing 50 Stäubli robots already at work within WHS Plastics.

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COMPOSITES | NEWS Covestro increases investments in thermoplastic composites Covestro is further developing its offerings and capabilities in continuous fibre-reinforced thermoplastic (CFRTP) composites in response to both market trends and a growing demand from customers.

The firm has invested in a new R&D tape line and hybrid injection moulding machines to support the expansion of its Maezio brand of CFRTP composites, which are based on continuous carbon fibres impregnated with thermoplastics such as polycarbonates.

The new tape line, commissioned in its Leverkusen laboratory, will assist Covestro in the development of new products with different fibre and resin combinations.

Their manufacture will in turn be scaled and commercialised at its production site in Markt Bibart in South Germany.

“We’re witnessing strong market demand for thinner, lighter, and aesthetically competitive products where thermoplastic composites like Maezio are making a difference,” explained Lisa Ketelsen, Head of the Thermoplastic Composite Business of Covestro. “To meet the needs of a growing range of applications we need a broader base of portfolio with different matrix materials and properties. The new tape

line in combination with our mass production lines will allow us to do quick iterations and scaling based on market demand.”

One such product under development is thermoplastic polyurethane (TPU) -based CFRTP, which Covestro says boasts excellent chemical resistance properties and superior flexibility in a wide temperature range. There’s a strong demand, it says, especially from the footwear and sports equipment industries for such a strong and versatile product.

“Thermoplastic composites enable significant increases in production speed for mass production, and their ability to be moulded with features and produced to near net shape eliminates the need for many secondary operations,” commented Dr.-Ing. Christian Wilms, Head of Technology of the Thermoplastic Composite Business of Covestro.

“Also, they are inherently recyclable, making them a genuine answer to the growing need for scalable and sustainable material solutions.”

At the same time, new hybrid injection moulding machines are commissioned in Covestro’s CFRTP locations in Germany and China to build on processing know-how of complex, three-dimensional composite parts in support of application development across industries. A hybrid injection

Thermoplastic composites enable significant increases in production speed for mass production, and their ability to be moulded with features and produced to near net shape eliminates the need for many secondary operations.

moulding machine combines the thermoforming of semi-finished composite parts with in-mould injection moulding – a fully automated one-step processing technology which reduces cycle times and improved productivity of mass produced composite parts.

“We’re working closely with our machinery and processing partners such as Krauss Maffei and Engel to offer customers full support in their product development process,” said Dr.-Ing. Olaf Zoellner, Head of Application Development Europe at the Polycarbonates Business Unit at Covestro. “A fully functional and supportive value chain with the know-how for mass production of composite parts is critical to bringing such solutions to the mainstream market.”

The Covestro team for thermoplastic composites headed by Lisa Ketelsen (third from right)

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Solvay expands aerospace thermoplastic composites capacity Solvay is expanding its thermoplastic composites capacity with a new production line at its U.S. facility in Anaheim, California.

The new line comes as Solvay looks to meet strong demand growth from aerospace customers for this high-performance material and Solvay’s proprietary technology.

Solvay will have multiplied its qualified capacity by four since 2016, with the commissioning of this new tape line and upgrades to existing lines. It says through the expansions it aims to not only improve output, but also quality, consistency and industrial reliability.

“This significant expansion in a short time, coupled with our unrelenting attention to overall quality and productivity improvement, illustrates our engagement to serve our

customers best,” explained Augusto Di Donfrancesco, Member of Solvay’s Executive Committee.

“Their strong demand shows they value how our materials reduce manufacturing time and cost, helping to raise the build rate of aircraft. Solvay is in leading position to drive breakthroughs in materials innovation and accompany our customers in their growth requirements.”

In May this year Solvay announced the creation of its first horizontal strategic platform

Victrex and Safran Cabin to launch flexible composite platform for multiple aircraft bracket projects Safran Cabin, a leading supplier of cabin interiors, and Victrex, a highperformance polymer materials company, have worked together to qualify thermoplastic composite parts on aircraft.

A flexible platform is being designed to cut planning and time-to-market of multiple brackets, with the first being a hybrid overmoulded aircraft cabin bracket made of Victrex AE 250 carbon-fibre-PAEK composite and Victrex PEEK polymer.

During the project, Victrex provided the material, process and tooling expertise required and Safran Cabin provided expertise in design and manufacturing to ensure applicability in aerospace service and certification environments.

“We need to respond to many demands for aircraft brackets and similar structural parts, with each case having many loading, constraint and exposure conditions,” said Tyler Smithson, Senior R&T Engineer at Safran Cabin. “The key to success is to develop a flexible composite

Hybrid overmoulded cabin bracket (Credit: Victrex)

platform that can be used for multiple projects, lowering our part count and design complexity, cutting time-to-market, speeding time-to-revenue. Working with Victrex, we think that’s what we’ve achieved.”

Victrex and Safran Cabin utilised an innovative technique where its Victrex AE 250 thermoplastic composite is overmoulded with Victrex PEEK high-performance polymer. This ‘hybrid overmoulding’ technique is a scalable, repeatable technology with potential to help commercial aerospace customers face the challenges of needing much lower scrap rates, faster cycle times, part consolidation and reduction in the number of secondary operations.

Stringent testing and qualification work have indicated that structural

to accelerate the development of thermoplastics composites in order to leverage its portfolio and its expertise in the areas of speciality polymers and carbon fibre composites.

These lightweighting materials help lower emissions of planes and cars as they replace metal parts and facilitate their design and integration. Other applications include pipes in the oil and gas industry as they are a strong and cost-effective alternative to existing steel solutions.

aircraft parts produced from VICTREX AE 250 via hybrid overmoulding can withstand high levels of mechanical stress.

With Safran Cabin, the design process focused on defining parts and moulds adaptable for multiple brackets, with the goal of achieving a family of designs compatible with the same mould.

This involved establishing a cost and weight advantage while considering the flexibility of the platform to be used in various applications.

Following the initial design phase, mould-filling and structural simulation methods were combined with various physical testing techniques to identify and mitigate new technology failure modes and to streamline injection moulding manufacturing and cost constraints. Critical characteristics were refined, and a productive, repeatable design process has been developed.

Compared to the original aluminium part, the prototype composite brackets have shown up to 20 per cent cost savings; 50 per cent weight savings; and a 5x better buy-to-fly ratio.

Currently the bracket is scheduled for final testing and qualification of production parts.

The plan is to put the composite bracket in service later in 2019.

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Fit for a Porsche

AS CONTINUOUS FIBRE-REINFORCED THERMOPLASTIC COMPOSITES ARE INCREASINGLY BEING CONSIDERED FOR LIGHTWEIGHT CAR DESIGN, BP&R LOOKS AT HOW A COMPOSITE INSERT DEVELOPED

BY LANXESS AS A STRUCTURAL REINFORCEMENT FOR A-PILLARS IN THE PORSCHE 911 CABRIOLET IS HOLDING ITS OWN AGAINST PREVIOUS DESIGNS IN STEEL.

(Credit: Porsche AG).

The excellent mechanical performance of the hybrid A-pillar demonstrates that hybrid inserts based on steel sheet, Tepex blanks, polyamide 6 or polyamide 66 variations of Durethan as a backinjection material and on a structural foam such as L-5235 also offer considerable potential for use in structural lightweight vehicle body design.

The potential of Tepex, a line of continuousfibre-reinforced thermoplastic composite materials from speciality chemicals company, Lanxess, for use in lightweight applications extends to the design of structural components in passenger cars, which need to be capable of meeting very stringent requirements in the event of a crash.

One example of this is a lightweight A-pillar developed by Porsche’s 3D hybrid design. It is intended for use in cars such as convertibles and roadsters and is being employed for the first time in the Porsche 911 Cabriolet.

The pillar contains an insert made from high-strength steel.

This is supported from the inside by a formed blank of the polyamide-6-based Tepex dynalite 102-RG600(6)/47 per cent and by a ribbed structure made from Durethan AKV30H2.0, which is based on polyamide 66 and contains short glass fibres.

This structure is bonded by friction with the L-5235 structural foam developed by L&L Products at its site in Strasbourg, France.

The strength and rigidity of the hybrid insert ensures that the A-pillar is just as good at withstanding rollovers as previous designs featuring highstrength steel tubes. However, it is around five kilograms lighter. The weight reduction is achieved in the greenhouse area of the vehicle, lowering the car’s centre of gravity and thereby improving vehicle dynamics.

A WEALTH OF POTENTIAL IN STRUCTURAL LIGHTWEIGHT BODY DESIGN “The excellent mechanical performance of the hybrid A-pillar demonstrates that hybrid inserts based on steel sheet, Tepex blanks, polyamide 6 or polyamide 66 variations of Durethan as a back-injection material and on a structural foam such as L-5235 also offer considerable potential for use in structural lightweight vehicle body design.

That applies to electric vehicles in particular, as their heavy batteries give them a high impact mass,” explained Henrik Plaggenborg, Head of Tepex Automotive at the Lanxess High Performance Materials (HPM) business unit. “The weight reduction also extends the range of the electric vehicles that use this technology,” he added.

Other potential applications for the hybrid composite elements include reinforcing crossmembers and side members, B- and C-pillars, load-bearing battery parts or door components that are critical to safety.

FORMING AND BACK-INJECTION IN A SINGLE PROCESS OPERATION The hybrid composite elements are developed and manufactured by L&L Products.

The first step in the manufacture of the reinforcing elements involves forming and overmoulding the Tepex blanks in a single operation using the hybrid moulding technology. The resultant composite component is then coated with an epoxybased foam bonding system that expands in response to heat.

The coated part is mounted on the body and goes through the cathodic dip coating (KTL) process with it.

The high temperatures of the KTL process cause the structural foam to expand and bond with the highstrength sheet steel, which is also affixed The 3D hybrid to the A-pillar casing, to A-pillar produce the reinforcing (Credit: Lanxess) hybrid insert. This last step takes place in an entirely automated manufacturing process that was developed by Porsche and is subject to ongoing quality control.

ASSISTANCE IN PART DESIGN For its role in the development of the part, Lanxess provided Porsche and L&L Products with extensive support in the development of the hybrid inserts and the A-pillar. “Services included simulating the forming (draping) of the Tepex blanks, simulating filling for back-injection and calculating warpage. We also determined material characteristics to simulate the mechanical behavior of the A-pillar and made these figures available to Porsche,” said Jean-Marie Olivé, Expert in Application Development at HPM. FIRST ALL-PLASTIC BRAKE PEDAL This is not the first application at Porsche to use Lanxess materials. Tepex dynalite, which consists of multiple layers of continuous fibre reinforcements in a matrix of engineering thermoplastics, is already used in series production for another safety-critical component. It is used in the hybrid moulding process to make the brake pedal for cars including the Porsche 918 Spyder, Porsche Macan and Porsche Panamera NF. The component is the first all-plastic brake pedal to be used in series production.

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27

© Stäubli 07/2019 - GettyImages/Westend61

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Visit us at our booth Hall 11 - Booth H21

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bp&r K PREVIEW PART II

K2019: The plastics industry heads to Düsseldorf NEW LAUNCHES The latest innovations making their debuts

CIRCULAR THINKING Company leaders talk circular economy ahead of the show

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EXHIBITOR PREVIEWS The new products launching in Düsseldorf 11.07.19 15:15

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WWW.BUNTINGEUROPE.COM | VISIT US AT K SHOW HALL 10 STAND J47 BIOBASED PLASTICS

ALBIS supplies sustainable plastics for BOY´s ‘Live Show’ BOY will demonstrate an extensive live show at K 2019, with items produced using sustainable plastics from Albis.

These include design trays produced using CELLIDOR (CP 41010 BK 32/082), a plastic based on cellulose from sustainable, natural sources of raw materials. The material is said to be characterised by good gloss, depth effect and a self-polishing property.

BOY will also use CELLIDOR in grade CP 400-10 CC to produce a magnifying glass, where it displays high transparency comparable to PMMA and the same self-polishing surface.

The live production display will also include a 2-component (2K) ice scraper, for which Albis is supplying ALFATERXL ECO with Shore A75 hardness as a soft component.

It is recommended due to good 2K adhesion on polyolefins in combination with 100 per cent PP recyclate and biobased EPDM. “The share of our portfolio of products based on renewable raw materials or recyclates is increasing from year to year,” said Philip O. Krahn, CEO of Albis. “With the decision to use sustainable products, Dr. BOY is setting an example.

We are very excited about the cooperation.”

ALBIS Hall 8B, Stand A61

PROCESS CONTROL

Engel to release iQ process observer Engel is to start a new chapter in the development of intelligent assistance with its new iQ process observer.

To date, assistance systems have been used to optimise individual steps in the injection moulding process, such as injection and cooling, but the new iQ process observer goes several steps further, providing an overview of the entire process for the whole batch.

This makes it possible to identify changes in the process at an early stage, allowing operators to determine their causes and find a solution more quickly.

The iQ continuously analyses several hundred process parameters across all four phases of the injection

Wittmann releases new TEMPRO plus D100 temperature controller Wittmann will introduce its new TEMPRO plus D100 temperature control model at K. The new model belongs to the range of temperature controllers recommended for use as components of Wittmann 4.0 production cells.

TEMPRO plus D100 can be fully integrated in the control system of a Wittmann Battenfeld injection moulding machine.

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moulding process, and the results are immediately visible. The software automatically defects drifts by continually checking the results against the previous cycles, as well as comparing certain process parameters with a set reference condition.

Paul Kapeller, Product Manager for Digital Solutions at Engel Austria, said: “The iQ process observer is currently the only assistance system on the market based on live data, which actively indicates changes in the process and counterproductive settings, helping to improve stability throughout the process.”

ENGEL HALL 15, STAND B42 – C58

The new temperature controller is capable of a 9kW heat output and stands out by its magnetcoupled stainless steel pump, which ensures sufficient flow quantities.

The pump capacity is 0.5 kW, with a maximum flow quantity of 40 l/min and a maximum pressure of 4.5 bars.

It is equipped with a wearresistant, maintenance-free flow quantity measurement device as standard.

WITTMANN HALL 15, STAND C06

TEMPERATURE CONTROL

WWW.BUNTINGEUROPE.COM | VISIT US AT K SHOW HALL 10 STAND J47

SABIC to showcase certified circular polymers from chemical recycling project SABIC will highlight its pioneering initiative to produce certified circular polymers at K 2019.

The company launched the project in Q4 of 2018, with the goal of driving a value chain transformation from a linear economy to a circular economy for plastics.

SABIC’s certified circular polymers are being produced using a pyrolysis oil feedstock from the recycling of mixed plastic waste. As part of the intended project, SABIC is now introducing this alternative feedstock into its Chemelot production site at Geleen in The Netherlands.

MuCell Extrusion to introduce ‘industry first’ recyclable barrier packaging MuCell Extrusion, part of the Zotefoams Group, is introducing an industry first in recyclable barrier packaging at K 2019.

Launching under the brand name ‘ReZorce’, this is a range of HDPE mono materials and HDPE-based materials offering barrier properties that it says meets or exceeds all food industry standards as an alternative to composite packaging.

The multi-layer structure of ReZorce also allows incorporation of recycled material while meeting these standards.

we are proud to say that we are first in the industry to scale-up this innovative chemical recycling process.

“We are introducing a range of barrier packaging made from foamed HDPE film that competes with existing composite materials, offers high quality print finish and can incorporate recycled content, which is very appealing to the industry at this time,” said Zotefoams Group CEO, David Stirling.

“Further, the foaming process is consistent with the HDPE float-sorting recycling process and is compatible with kerbside systems, which is very appealing to consumers, local authorities and recycling companies.”

ZOTEFOAMS GROUP HALL 5, BOOTH A24

PACKAGING

The resultant certified circular polymers are to be supplied to customers such as Unilever, Tupperware Brands, Vinventions and Walki Group.

SABIC intends to build a semicommercial plant specifically to refine and upgrade pyrolysis oil feedstock, with the plant anticipated to enter commercial production in 2021.

Bob Maughon, SABIC’s Executive Vice President for Sustainability, Technology and Innovation said: “We are proud to say that we are first in the industry to scale-up this innovative chemical recycling process.”

SABIC HALL 6, STAND D42

CHEMICAL RECYCLING

motan colortronic to introduce new Spectroplus dosing system Motan Colortronic will introduce its new Spectroplus dosing and mixing unit that it says can be adapted to the most diverse dosing requirements.

Specially developed for the extrusion and compounding sector, the Spectroplus ensures perfect and constant dosing for continuous processes.

As one of the most flexible Motan systems, the synchronous dosing and mixing unit can be supplied in either gravimetric of or volumetric versions, or a combination, and for both starvefed and flood-fed extrusion systems.

Up to eight dosing modules are mounted on a frame and can easily be removed and installed without tools. The exchangeable modules, as well as the easy-to-clean dosing hopper enable a quick material change and therefore shorter MATERIALS production downtimes.

HANDLING Motan Colortronic says the installation is not only simple, but also saves space due to its compact design.

To complete the unit, a completely new control system has been developed.

MOTAN COLORTRONIC HALL 9, STAND C64

www.britishPLASTICS.co.uk

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Evonik to present new rubber process additive Evonik will present its new Vestenamer process additive, which allows waste rubber to be efficiently processed into a tough

ADDITIVES

material that can be used again in a variety of applications such as road construction, sports, or playgrounds.

The company says in the recycling of waste rubber, the addition of Vestenamer has already led to the production of items such as floor coverings, mats and stand systems for signposting of roadworks and barriers.

“As a process additive Vestenamer improves the flowability of the rubber compound, as a result of which the material can be processed much more efficiently,” said Dr

EVONIK HALL 6, STAND B28

IN-MOULD DECORATION

Sumitomo Demag to unveil the future of minimalist modern car dashboards Sumitomo Demag will unveil the future of minimalist modern car dashboards, with the aim of making driving more comfortable for millions of motorists.

At K 2019, the company will demonstrate its largest In Mould Decorating (IMD) display to date. The asyet unseen IMD touchfoil interactive decoration for a vehicle console will be produced on a brand new IntElect 500 being unveiled at the show.

The new IntElect series, now ranging up to 500 tonnes, features the company’s latest innovation in servo drives, enabling improved repeatability and shorter cycle times.

MASTERBATCH

Peter Hannen, Market Development Manager for Vestenamer at Evonik.

“The reactivity and polymer structure of Vestenamer are also important here, as both lead to a good network density between the rubber particles.

This in turn positively impacts the mechanical properties.

In short, Evonik’s process additive improves both the cost effectiveness of processing and the quality of the rubber parts when rubber is recycled.”

As a result of the big tiebar spacing, increase in mould height and opening stroke, the new IntElect models can accommodate larger moulds. The result is a less energy intensive machine for automotive applications that would previously have required a larger tonnage.

“As society moves towards more integrated touchscreen electronic components in vehicle interiors, injection moulding machines need to adapt.

All of the technological enhancements in the IntElect 500 are designed to give moulders the tools, machine synchronisation, mould safety and real-time production monitoring required for tomorrow’s automotive smart factories,” said Henrik Langwald, Business Development Director Automotive at Sumitomo (SHI) Demag.

SUMITOMO DEMAG HALL 15, STAND D22

Clariant to launch new masterbatch for PET

Clariant will use its presence at K 2019 to launch a new masterbatch for PET destined for the food and beverage market.

The patented oxygen scavenger is based on a new molecule that goes beyond existing solutions for PET in protecting content shelf life and taste. Clariant says it is proving a real success in initial customer trials, offering the potential to address a number of challenges for packaging producers in one solution.

The firm will also unveil a number of collaborative sustainability projects as part of a focus on solutions in reduction, reuse and recycling.

In one such project, together with Finnish oil refining company, Neste, which is passionate about giving fat residues and discarded cooking oils a second life, Clariant has been exploring opportunities to use renewable hydrocarbons, derived from this waste. It says more will be revealed at K, including new products for plastic applications based on mass-balance certification for usage of renewable polyolefins.

CLARIANT HALL 8A, STAND J11

www.britishPLASTICS.co.uk

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The improved tensile properties of Creamid P compounds enableS them to meet the demands of certain structural applications where, traditionally, PA 6 compounds did not perform due to high moisture uptake.

Teknor Apex to launch PA6 compounds that outperform standard PA6 Teknor Apex will introduce its new Creamid P Series PA6 compounds, that it says absorb nearly onethird less water at saturation than standard grades, provide 15 to 25 per cent improved tensile properties in the conditioned state and exhibit higher flow and excellent surface characteristics, even in highly glass-filled formulations.

The Creamid P Series is the newest product family of higher performance speciality polyamide compounds designed for structural components in metal replacement applications.

The compounds are based on advanced formulation technology that Teknor Apex says can be applied to lower the moisture uptake of a broad range of PA6 and 6/66 based compounds.

These include grades with various types and loading of reinforcements or fillers, as well as impact-modified toughened grades and other speciality compounds.

Creamid P Series compounds can further employ an advanced heat

ENGINEERING PLASTICS

stabilisation system that extends continuous-use temperature.

Markus Krippner, Director of New Business Development ETP at Teknor Apex, said: “The improved tensile properties of Creamid P compounds enables them to meet the demands of certain structural

applications where, traditionally, PA 6 compounds did not perform due to high moisture uptake. In some cases they may provide a practical alternative to PA 66 compounds as well.”

TEKNOR APEX HALL 6, STAND C58-01

Ascend launching several new speciality polyamides Ascend Performance Materials is to add to its polyamides portfolio with the launch of several new grades.

Among the new products are Vydyne XHT, long-chain polyamides and high-temperature polyamides.

Vydyne XHT, a new portfolio of heat-stabilised polyamide 66 and copolymers, is capable of withstanding prolonged exposure to temperatures up to 230 C. Using a combination of unique polymer chemistries and a multistage heat stabilisation technology, the company says XHT products push the boundaries of temperature resistance without compromising the processability, durability and mechanical properties PA66 is known for.

With a high weld strength and long-term temperature resistance up to 230 C, Vydyne XHT performs well in under-hood parts like integrated air intake manifolds.

“Consistent high heat performance is critical in under-thehood applications to accommodate for various load, torque and speed

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conditions in engines,” said Vikram Gopal, Ascend’s Senior Vice President of Technology.

“We created Vydyne XHT to perform across a broad operating window for our customers, who are today limited to products with narrow operating windows and poor performance outside those windows.”

Ascend will also introduce a new portfolio of PA610 and PA612 longchain polyamides, with low moisture absorption, high chemical and UV resistance.

ASCEND PERFORMANCE MATERIALS HALL 06, STAND A07

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A HEAD OF K 2019, GERMAN TRADE ASSOCIATION, VDMA, HAS SPOKEN TO A NUMBER OF EXHIBITORS ABOUT ONE OF THE CENTRAL THEMES OF THIS YEAR’S SHOW – CIRCULAR ECONOMY – COVERING TOPICS RANGING FROM HOW THE VIEW OF PLASTICS HAS CHANGED SINCE 2016, AND WHERE THEY EXPECT THE FUTURE TO LEAD. IN THIS SPECIAL FEATURE, BP&R TAKES A LOOK AT THE HIGHLIGHTS.

WORDS TOM WALKER

COMING FULL CIRCLE A

lfred Stern, CEO of polyolefins producer, Borealis (right), is clear about the need to act now when it comes to the implementation of a true circular economy for the plastics industry.

“The sooner we prepare for real circular economy, the [more] positive the effect will be on our economic growth, the environment, our customers, and the society as a whole,” believes Stern.

Speaking in an interview ahead of K Show with VDMA, Stern said plastics are “too valuable to be dumped” and that the firm’s vision is to eliminate waste and recycle plastics as a raw material.

“The world population is growing constantly, and disposable incomes are also increasing. This means that the demand for materials in general and for plastics in particular will continue to rise,” he explained.

“If the current linear economic model remains in place, it will lead to more waste, irrespective of the material utilised. The solution is switching to a circular model, which also allows for a reduction in the use of primary raw materials and thus for cutting CO2 emissions. In the majority of applications, plastics are still the most ecologically efficient material.”

Stern, like many, believes banning plastics isn’t a sustainable solution. “On the contrary, it obstructs innovation,” he continued. “It is better to set concrete long-term goals, but to leave open how these goals are achieved in order to ensure full effectiveness of competition and innovation.”

He added: “Moreover, we need uniform, constructive legislation at European and international level; national solo efforts do not get us anywhere.”

During K, Borealis will exhibit under the theme of ‘Building Tomorrow Together’, where it will outline its commitment to achieving circularity in plastics through its own efforts, as well as working in close collaboration with value-chain partners.

“The principles of circular economy drive us to develop new products with enhanced recycling capabilities. We already take this into account in the design phase and work closely together with our customers and partners to create products that can be recycled more easily, and to find new applications for these recyclates,” Stern added.

Hall 6, Stand A43

“WE ARE PART OF THE CYCLE” We can fully Andreas understand the Lichtenauer, outrage about Managing plastic waste on our Partner at beaches and oceans. extrusion blow As we all know moulding this is not only machinery packaging but also manufacturer, all kinds of plastic Kautex waste. It is clear Maschinenbau, to us that we also has called on carry responsibility fellow machine for the products manufacturers to manufactured with ask themselves our machines.” what role they can play in the process towards sustainable handling of plastics to help the move towards a functioning circular economy.

He told VDMA: “We are part of the cycle. That means, as the link between the raw material manufacturers and those processing them, we contribute to providing consumers with recyclable products.

“We can fully understand the outrage about plastic waste on our beaches and oceans. As we all know this is not only packaging but also all kinds of plastic waste. It is clear to us that we also carry responsibility for the products manufactured with our machines.”

While Lichtenauer acknowledges that there is a need for urgent action, he insists that the benefits of plastics should not be glossed over, drawing attention to how Kautex can be a part of this.

“Our work includes options for saving material for hollow plastic parts. In the end, this leads to a reduction in the overall use of plastics, which also contributes to cutting CO2 emissions.

“It is important to consider that plastics packaging uses less energy in its production than glass or paper alternatives, which is why it is extremely important to start global recycling processes, and why we are working hard to optimise this, and cut materials.”

At K Show, Kautex will present its solutions for more sustainable production under the theme of ‘Creating Change Together’. As part of this, the company will present various technologies, such as a newly developed extrusion head that drastically reduces the consumption of raw materials when changing colour and material.

Hall 14, Stand A16

www.britishPLASTICS.co.uk

37

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“MANY CONSUMERS ONLY ASSOCIATE PLASTICS RECYCLING WITH PARK BENCHES OR WASTE BAGS” Martina Schmidt, Head of the Recycling and Waste Division at Vecoplan AG, which produces machinery for shredding, conveying and processing recovered materials, believes China’s ban on importing waste played a key part in the gaining of momentum around the circular economy. “This import stop was the initial impulse,” she told VDMA. “It was the moment when demand for shredding and sorting technologies were noticeably increasing and that investments were being and still are made in capacity and quality. After all, the question was where to put the plastic waste, and they realised that a good deal of recycling technology was required to achieve better material quality for the market.”

Schmidt says that it is important that plastics recovered from recycling systems are upcycled into products of equivalent value, or high-quality products. “We, as machine and systems manufacturers as well as our customers harbour the wish to feed these packaging materials back into the circuit as new packaging or other high-quality products,” she explained.

“Many consumers only associate plastics recycling with park benches or waste bags. However, presentday technological development has progressed much further and will continue to develop in future. When we refer to recycling, we mean upcycling and not downcycling. In the end, identification of consumers with new products from recycled plastics is the crucial key to effective circular economies.”

During K Vecoplan AG will be exhibiting machines and systems that shred, convey and process primary and secondary raw materials. Visitors will be able to get their first glimpse of a highly efficient shredder that is equipped with a flexible drive concept.

The company will also demonstrate its work in chemical recycling.

Hall 9, Stand B59

“WE WILL DEMONSTRATE THAT CLOSED LOOPS ARE A POSSIBLE SOLUTION” Thorsten Kühmann, Managing Director of the VDMA Plastics and Rubber Machinery trade association, says that it will use its presence at K 2019 to put a spotlight on circular economy due to the image problems that the industry is facing when it comes to plastics.

He said: “Nowadays, plastics only attract public attention when causing problems, pollution the environment, or being suspected of endangering our health.

“Images and reports of how plastic waste is littering our oceans and the countryside are ever-present. These are serious problems indeed, and the industry needs to offer solutions.

“We want to use K 2019 as an opportunity to show what needs to be done to avoid these waste problems and the resulting damage.

We will demonstrate that closed loops are a possible solution.”

At the VDMA exhibition pavilion, which will be located outside the halls, it will present the entire cycle of circular economy in the plastics industry, from production, to

We want to use K 2019 as an opportunity to show what needs to be done to avoid these waste problems and the resulting damage.

We will demonstrate that closed loops are a possible solution.

collection, sorting, recycling and the subsequent return to production.

Kühmann said he wants visitors to K 2019 to experience what is meant by a circular economy, as well as helping consumers realise how such a model has progressed over the last three years.

He said: “To achieve this, we will be working with partners from the entire plastics value chain, including raw material suppliers, processors, and recyclers and we will demonstrate how a closed loop works.

“At K 2019, it should become clear that the plastics industry is taking care of the waste problem and that it already has proposals for effective solutions.”

Booth 16.1 – Exhibition Ground

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“WITH EQUAL CONDITIONS FOR EVERYONE, NOBODY WOULD HAVE A COMMERCIAL DISADVANTAGE” Michael Baumeister, Managing Director for Technology and Logistics at film equipment manufacturer, Brückner Maschinenbau, has praised his company for intensively looking for ways to improve recyclability of plastic products in the move towards a circular economy.

Brückner has been addressing the question of how to produce packaging by using easily recyclable mono-structures, by, as Baumeister explained: “Practically applying a preliminary stage of circular economy that makes recycling possible for many products in the first place.”

Baumeister also spoke about how important regulation can be, as he said: “With regards to the EU pushing towards a circular economy for plastics, it is important that these regulations apply in the same way to everyone operating in the European market, otherwise competition would be disrupted.

“With equal conditions for everyone, nobody would have a commercial disadvantage. As a positive result of regulation, I would expect essentially more intensive research on recycling possibilities, for example, on chemical

recycling. As a consequence, there would be much more serious attempts to produce better recyclates,” he said in his interview with VDMA. However, Baumeister does concede that an issue with this will be manufacturing high-quality products from recyclates, such as film which can come into contact with food again, as: “This is extremely difficult to achieve with mechanical recycling due to hygiene requirements. Political specifications necessitate more complex processes for sustaining raw materials, a fact that constitutes the same obstacle for everyone.”

During K Show, Brückner will present ‘Innovations for the demands of a Circular Economy.’ The company is to showcase how it is developing ways to make films with the highest possible recycling capabilities producible on film stretching lines.

The focus is on mono-material film with superior mechanical and optical properties, which will be able to substitute previous multi-layer films made from different materials. These are ideal for the use in new, singleorigin packaging and guarantee good sortibility in waste separation and optimal recycling.

Hall 3, Stand C90 - E90

Brückner’s high performance f ilm stretching lines

“PLASTICS ARE AN IDEAL MATERIAL FOR MANY APPLICATIONS” Ulrich Reifenhäuser, CSO of extrusion technology producer, Reifenhäuser Group, has cited the “mountains of waste” piling up around the world as the major reason why the topic of plastic waste has gained prominence throughout the world, and has said that “the world of plastics needs to change” in order to combat this.

He said: “This is a very complex and multilayered problem. It’s paradoxical. Plastics are an ideal material for many applications. They are light, easy to process, relatively inexpensive and available in sufficient quantities.

“Because of these benefits, their importance to competing materials is constantly increasing. This is positive.

However, plastics are not usually dealt with correctly after use. Instead of being collected, they’re thrown away. This is negative, and the real major issue at hand. “ He believes that the most important thing to do is to attach value to plastic waste, to prevent it from being landfilled or littered. He also believes political intervention is required, with recycling quotas and regulations set for new plastics products to drive up demand for recycled materials.

When asked about how mechanical engineering can support the sustainable management of plastics, Reifenhäuser said that a resourceefficient process is key.

“As a manufacturer of machines for processing plastics, we develop resource-efficient processes which allow a reduced use of plastics. One example is using thinner films that have the same protective properties as thicker ones,” he explained.

“We also develop machines that produce products with no waste at all. All waste from production is immediately recycled. All these measures concern production.

Regarding use, mechanical engineering provides all the technologies which enable plastic waste to be recycled.”

At K 2019, Reifenhäuser will engage in further discussions around the circular economy and how mechanical engineering can assist in moving towards a more sustainable future when he participated in the VDMA’s Circular Economy Forum, starting October 16.

Hall 17, Stand C22

www.britishPLASTICS.co.uk

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RECYCLING MACHINERY | NEWS SEE ME AT K2019 HALL 9 STAND B38

NGR expands cuttercompacter-extruder combinations Next Generation Recyclingmaschinen GmbH (NGR) is expanding its product portfolio of cutter-compactor-extruder combinations to include sizes with higher throughput capacities.

The NGR C:GRAN series has been extended to machines for outputs of 2,200 kg per hour and over, following the market trend of increasing plastic recycling quantities and modernisation of recycling plants to satisfy the increased demand for high quality rPellets.

Patrick Steinwendner, Product Manager and Marketing Manager at NGR, said: “NGR has a broad

Lindner Washtech to launch new hot-wash system for effective plastic recovery Lindner Washtech has developed a new three-stage hot-wash system which it says is a key component in its new system solutions for plastics recycling.

The system, which will be launched to the market at K 2019, has three stages and does not require any additional conveyors.

In the first stage, the shredded and pre-washed plastics are fed into a reactor, mixed with hot water and washed.

The double discharge screw conveyor then feeds the plastics into the new hot-wash rafter in optimally dosed quantities.

In the third and final stage, a machine specifically designed for this application, the Twister friction

The new NGE C:GRAN series

portfolio of recycling machines with very different, specialised technologies.”

“We recommend shredderfeeder-extruder combinations, especially for dry industrial waste, but for high moisture mixed plastics for the post-consumer waste stream cutter-compacter-extruder combinations offer advantages.”

Thomas Pichler, Technical Director at NGR, said: “Thanks to the modular design of the NGR systems, we can significantly reduce development times.”

“In this project, we were able to assemble over 80 per cent of the system components from parts that had already been tested in other machines. This is very much in line with our rapidly changing market and customer requirements.”

SEE ME AT K2019 HALL 9 STAND E75

washer, removes the hot water or the hot caustic solution. The liquid is then separately treated.

Harald Hoffmann, Managing Director of Lindner Washtech, said: “When developing the new components, we focused on effective cleaning and continuous processing so that all preceding and subsequent equipment can be operated productively at all times.

That is why we based this solution on our tried-and-tested technology, combined it with the advantages of hot washing and deliberately left out the otherwise common, but often vulnerable, batch processing.

Enva increases UK’s recycled plastic compound production after £1.8m investment Enva, a UK producer of recycled, extruded plastic compounds, has significantly increased the availability of recycled plastic compounds in the UK following a £1.8 million investment to double its output capacity.

The investment at the company’s facility in Lincolnshire includes a new extruder unit that will enable Enva to produce over 2000 tonnes of extruded compound per month.

Enva recycles and recovers 85 per cent of all the small waste electrical and electronic equipment (WEEE) generated in the UK every year.

Waste separation technologies are used to sort the plastics, which are then converted into a range of high-quality regrinds and compounds. These compounds, which have comparable quality and characteristics as virgin plastics, can then be reused in the manufacture of electrical goods.

The company says the increase in extruded compound will also significantly reduce the amount of material being sold as ‘regrind’, adding further value to this secondary resource.

Steve Bell, Enva Plastics General Manager, said: “Manufacturers recognise the need to develop more sustainable supply chains and reduce their dependence upon virgin materials. This investment makes us the UK’s largest supplier of extruded compounds from WEEE enabling our customers to further increase their use of recycled plastic and realise the associated environmental and commercial benefits.”

www.britishPLASTICS.co.uk

Enva recycles and recovers 85 per cent of all the small waste electrical and electronic equipment (WEEE) generated in the UK every year.

41

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University of Birmingham purchases Eddy Current Separator for laboratory The University of Birmingham has purchased a laboratory-sized Eddy Current Separator and Drum Magnet modular system from BuntingRedditch.

The new Metal Separation Module will be used by students and professors undertaking research at the university to determine the recovery and recycling capabilities of a wide range of materials.

The laboratory Metal Separation Module comprises of a Vibratory Feeder, Drum Magnet and Eddy Current Separator.

The Vibratory Feeder ensures an even feed of material feeding onto the high strength Drum Magnet. The Drum Magnet attracts and removes strongly and weakly magnetic materials. The remaining non-magnetic fraction falls onto the belt of the Eddy Current Separator.

An Eddy Current Separator comprises of a conveyor revolving

Bunting Eddy Current Separator built for the University of Birmingham (credit: Paul Fears photography)

around two-pulleys. The head pulley has a non-metallic shell housing a high strength Neodymium Rare Earth magnetic rotor.

“We have a long-history of working with the University of Birmingham,” explained Adrian Coleman, General Manager of Bunting-Redditch.

“Allowing students and research professors access to the latest technology is vitally important.

Reclaiming, recycling, and reusing our waste materials is one of the most important issues of modern times. The research undertaken by Universities will identify new ways to successfully manage our waste, which will benefit the whole planet.”

SEE ME AT K2019 HALL 10 STAND E60

Sesotec to expand portfolio with new recycling technology launches at K 2019 Sesotec, a manufacturer of metal detectors and sorting systems for the plastics industry, is launching several new products as part of its showcase of circular economy solutions at K 2019.

The company is presenting tailored technology that it says helps to conserve resources and increase production efficiency at the most critical points in the plastic cycle.

This included its Rapid Pro Sense 6 metal detector, which is equipped

with a newly-developed reject mechanism designed for compound manufacturers that have frequent colour changes, or that manufacture or process abrasive materials.

It will also showcase its Flake Scan plastic flake analysis system, which is designed to be the perfect size for laboratory use, for the first time at the show.

Another new attraction is the ASM Quasar optical sorting system, which can be used in granulate quality assurance in plastics manufacturing to ensure that granules with black spots, for example, are removed.

Sesotec will launch new, circular solutions at K 2019

Andreas Reckziegel, Group Director of the Product Inspection Sales Division, said: “Plastics manufacturers and processors are going to use more and more recyclates – first because they have to, second because the products are designed to be recyclable, and third because it is more appealing to do so from a price perspective.”

www.britishPLASTICS.co.uk

43

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RECLAMATION AND RECYCLING | NEWS Heathrow aims to improve airport recycling rates with new trial Heathrow Airport will kick-start a new trial turning unrecyclable plastic passenger waste – including food packaging and plastic film – into airport furniture, uniforms and lower-emission jet fuel by 2025.

In a UK first, the airport will test a new recycling unit that will help solve the issue of waste from terminals and aircraft cabins for which there are limited commercial recycling options.

Currently at Heathrow, close to 50 per cent of airport and aircraft cabin waste is recycled, despite the strict regulations in place for cabin waste from international flights, which mean most of that waste must be sent for incineration or landfilled.

The pilot plant, developed by the winners of Heathrow’s Innovation Prize for sustainability, Sheffield-based company, Catal, and University College London’s Dr Massimiliano Materazzi, has the potential to save up to 5,000 tonnes waste from incineration by turning it into its original oil state for recycling every year.

If successful, it will enable Heathrow to recycle all plastic waste from the airport where regulations permit. This technology, the airport says, could also help to salvage aircraft cabin waste should government review and adopt a more risk-based approach to regulations for waste from international flights which currently

mean tens of thousands of tonnes of recyclable products across UK airports have to be sent for incineration.

Once the waste is refined using this new technology, the resulting oil will be collected and processed in a separate facility which makes use of renewable hydrogen to upgrade the oil into new generation, low-carbon products such as furniture and uniforms. It is estimated that between 5 and 8 kg of plastics oil will be produced for every 10 kg of waste handled each hour. Researchers say it’s also possible that this oil can be transformed into Jet A1-type sustainable fuel and will investigate further during the trial.

This autumn, Heathrow will help to kick start the R&D unit by awarding researchers a cash boost of £30,000. By 2025, Catal and UCL plan to roll out commercial units to other airports.

Heathrow Sustainability and Environment Director, Matt Gorman, said: “People are rightly concerned about plastic waste.

Tens of thousands of tonnes of it are produced by UK air passengers every year, which is something we must tackle. That’s why we’re helping to fund this R&D project which could make Heathrow the first UK airport to be able to recycle all plastic waste generated at the airport. Coupled with new regulations from Government on processing cabin waste, it would create a step-change in how airports across the UK manage plastic waste – giving passengers the confidence to travel knowing their plastics are sorted.”

Coca-Cola Great Britain launches further campaign to encourage recycling Coca-Cola Great Britain has launched a major new advertising campaign called ‘Round in Circles’.

Launched to coincide with Recycle Now’s ‘Recycle Week’ last month, the multi-brand campaign highlights that all the plastic bottles used for Coca-Cola’s full range of brands in Great Britain are 100 per cent recyclable and can be made into new bottles.

Kris Robbens, Marketing Director, Coca-Cola Great Britain said: “With this campaign we want to raise awareness that all of our bottles can be recycled and turned into new ones.

“Across all of our brands we want to use more recycled material in all of our packaging, however that requires more of it to be collected so that it can be reused to make new bottles.”

The campaign has been launched as part of Coca-Cola’s ongoing sustainable packaging strategy and is the latest in a series of actions.

Across all of our brands we want to use more recycled material in all of our packaging, however that requires more of it to be collected so that it can be reused to make new bottles.”

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Farmers will now be able to recycle non-packaging agri-waste

Nationwide UK farm plastics recycling scheme launched A new, national collection scheme for non-packaging agricultural plastics has been launched.

The initiative, launched by Agriculture, Plastic and Environment UK (APE UK) was announced at the annual RECOUP recycling conference in Peteborough. The objective of the scheme is to provide farmers with a sustainable solution for end-of-

Circular Plastics Alliance sees over 100 signatories to plan to boost recycling On 20 September, over 100 public and private partners spanning the plastics value chain signed the declaration of the Circular Plastics Alliance, which promotes voluntary actions for a well-functioning EU market in recycled plastics.

The declaration lays out how the alliance will reach the target of 10 million tonnes of recycled plastic used to make new products every year in Europe, by 2025. This target was set by the European Commission in its 2018 Plastics Strategy, as part of its efforts to boost plastics recycling in Europe.

First Vice-President Frans Timmermans, responsible for sustainable development, said: “I welcome the industry’s commitments to rethink the way we produce and use plastics. By efficiently recycling plastics, we will clean up the planet and fight climate change, by substituting fossil fuels with plastic waste in the production cycle.”

The declaration endorses the

life management of plastics used in agricultural processes.

Around 44,000 tonnes of agricultural plastics are put on the UK market every year, with less than 35 per cent being collected for recycling.

Farmers have had limited options available to them once used beyond landfill or incineration.

Now, however, the major manufacturers of non-packaging agriplastics, representing 80 per cent of the UK market, have reached an agreement for a voluntary initiative

10 million tonnes target and calls for a shift to zero plastic waste in nature and zero landfilling and lays out concrete actions to reach the target, including improving the design of plastic products to make them more recyclable and integrate more recycled plastics; identifying untapped potential for more plastic waste collection, sorting and recycling across the EU; building a Research & Development agenda for circular plastics; and establishing a transparent and reliable monitoring system to track all flows of plastic waste in the EU. The declaration of the Alliance will remain open for signature on the Commission’s website for more signatories to join over time.

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to implement a National Collection Scheme called ‘APE UK’, to be launched before the end of 2019.

The principles behind the scheme will be firstly, equal and costeffective access for all agricultural business under the principles of an Extended Producer Responsibility (ERP) framework; secondly, collective, collaborative and shared responsibility of the scheme between all stakeholders: farmers, distributors and producers; and finally, full coverage throughout the UK for all non-packaging agri-plastic products.

The scheme will also provide educational, technical and financial support through R&D to improve the quality of the waste collected so as to improve the efficiencies of recycling it. This will enable producers to integrate more recycled feedstock into the production of new products, thereby improving the efficiency of the Circular Economy.

In other countries in Europe operating a similar national collection scheme, more than 70 per cent of used agri-plastics are collected for recycling.

DuPont gains industry recognition for LuxCR depolymerisation process DuPont Teijin Films was presented with the award for the UK Best Recycled Plastics Product 2019 at the Plastics Industry Awards.

The award was for the LuxCR process, which represents the only source of BOPET films which have high levels of chemically recycled polymer and is compliant with EU food legislation.

The process was praised by judges as a real demonstration of chemical recycling which is available now.

Steven Davies, EMEA Packaging Market Manager at DuPont Teijin Films UK, said: “We are extremely proud to have won this award, and it reflects the hard work and dedication put in by the team to get us to this stage of our project.

“We believe the LuxCR process can be seen as a case study to prove the economic and technical feasibility of chemical recycling working alongside mechanical recycling, opening up a wider range of high value, technically advanced end uses for plastic waste.”

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IN THIS EXCLUSIVE INTERVIEW FOR BRITISH PLASTICS AND RUBBER, BRIAN LODGE, DESIGN MANAGER AT BERRY GLOBAL AND WORKING WITH THE BPF AS A SUSTAINABLE DESIGN CONSULTANT, GIVES READERS GET AN INSIGHT INTO THE WORK HE HAS DONE ON PACKSCORE, A NEWLY-LAUNCHED, ONLINE DESIGN TOOL FOR SUSTAINABLE PLASTIC PACKAGING.

ABOUT THE AUTHOR

Brian Lodge is working as a sustainable design consultant for the British Plastics Federation (BPF) on a number of initiatives regarding design for the circular economy. He has a wealth of experience in product and packaging design and is currently Design Manager at Berry International.

Recently, his work has centred around design for sustainability and has been involved in many UK and international initiatives on improving the recyclability and circularity of plastics, especially in packaging.

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EXCLUSIVE

SCORING

WITH PACKAGING DESIGN

B

y way of background, the newlylaunched ‘PackScore’ is a tool developed for brands, retailers and designers to use at the earliest stages of packaging design, to assess whether the packaging can be easily recycled, and adjust the product’s features to ensure it can. It allows users to answer a series of simple questions in order to receive a recyclability rating from A – F. The tool also highlights features of the packaging, such as light-weighting or the use of recycled content, that help ensure efficient use of resources.

PackScore promises to help designers create products that are more sustainable. By experimenting with combinations of materials and decorations, brands can improve their packaging recyclability rating at an early stage, before the product is manufactured.

reduce its suitability for conventional recycling.

The development of the grading tool came out of this need to inform decisions at the earliest stage of a pack’s design to ensure the best decisions are made.

The idea for the grading system came from work I was doing at Berry International, where we realised that we needed a way to illustrate to our customers the impact of the decisions they were making. Using the information generated we could quickly and visually show better options that could be adopted. The BPF realised the importance of this and took that original system and developed the online tool to make it available to everyone. This came to be known as PackScore.

Q: Brian, what led you to developing a grading system?

There is a lot of pressure on the plastics industry at present, especially on packaging, from NGOs, the media, the government and, consequently, the general public to produce more sustainable products. The fact that the majority of plastic packaging is already recyclable is a great starting point but as an industry we can (and should) ensure every packaging format that can be recycled is designed to make this easy to do, and where this isn’t possible the packaging is designed to be contribute to sustainability in other respects (e.g. by being reusable, reducing weight, containing recycled plastic, etc.) There are many people who have an input into the final design of a piece of packaging from marketers to packaging technologists and material suppliers to moulders. Often these individuals may not have all the information they need to assess whether an item is as sustainable as it could be, but they can be making key decisions on things that can

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Q: What does it do?

The grading system has two main parts, an indication of the pack’s recyclability and a series of symbols showing its sustainable features.

By answering a few questions on the material, decoration and colour you can quickly get a rating for your proposed pack design.

The A to F recyclability grade is based on the Plastic Recyclers Europe RecyClass system and has been developed to follow widely accepted rules from organisations such as Recoup and WRAP. This is important as the parameters used need to be widely accepted within the industry.

Additional questions can add symbols to indicate if the pack is light weighted, designed for reuse or to be refilled, or contains postconsumer recycled material (PCR) etc.

One thing we are keen to point out is that this is not a ‘certification’ system in any way, and it cannot be used as an endorsement for a product. There are several great tools that do this, including Recoup’s Pack Reviews or RecyClass itself, which test packs against a set of defined criteria and can then certify the suitability of a pack for recycling.

Q: Who do you see using the tool?

The system was originally developed for packaging designers and is a very quick and effective tool to assess ongoing projects. It is also a great asset for anyone involved in the design and development process, especially those for whom sustainability is an important consideration but who may not be up to date with the latest thinking such as marketers, packaging technologists and buyers.

Within Berry Global the system’s predecessor has been used across the business very successfully not only by designers, but by sustainability managers, sales teams, technologists and management.

Also, alternative uses have been found, like conducting product line reviews to compare the sustainability of different packs, comparing your pack to a competitor’s and even as a sales aid.

Q: Why is it different to the other tools already out there?

There are many tools already available for the industry. The BPF will soon be launching an interactive, online overview to make them all easy to find. However, there are no tools specifically aimed at the ‘front end’ of the design process, as most need fully developed and specified packs to be assessed.

PackScore is different to the other tools available as it can be used interactively to find better solutions rather than to assess a final design. This is great for designers, as it allows many iterations to be reviewed quickly and easily so better results can be achieved.

It is conceived as an ‘on the go’ tool that is quick and easy to use but gives a credible assessment of a pack option.

However, it is not so good for use later in the development process as it does not take into account more detailed items that may affect a pack’s recyclability (glue on the label, printing ink etc.) which do not have a big effect earlier on in the design process.

Therefore, we see this grading system as one of a suite of tools to be used during the development process. The BPF’s soon-tobe-launched interactive overview of these various tools will help highlight the best one for the user’s current project. These include the Recoup/BPF’s Recyclability by Design guidelines, PRE’s RecyClass system, LCA tools, industry-specific requirements and other guidelines that can be used to fully assess a completed pack.

PackScore was tested thoroughly by the BPF membership before launch and their feedback was invaluable during its development. Companies were able to highlight specific cases where more explanation was needed, and we are now looking at adding good examples of each option to show good practice. Also, we realise it has to be a dynamic system. There is a great deal of development in the industry with new materials, new processes and new methods appearing all the time, like chemical recycling and compostable materials, which will mean classifications will change in the future.

Q: Where can we find it?

The tool is available to access online for free at– www.PackScore.co.uk

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PROCESSING AGENTS | NEWS Purging compounds offer certainty in a time of uncertainty, says CJP A South Wales-based distributor of purging compounds says that UK plastics processors can give themselves one less worry in the face of an unclear Brexit by ensuring their machinery is running optimally and parts are of high quality.

Connor Benyon, Sales and Marketing Manager at CJP Sales based in Bridgend, says contamination, scrap and start-up problems can be avoided by implementing a purging compound into a production routine.

“Once again, British industry is faced with uncertainty in the face of a very unclear Brexit plan. But one thing that is certain, 1st November 2019 will bring us the same difficulties all plastic processors face, including a troublesome production start-up after any period of shut down and costly scrap waste,” Benyon commented.

“Purging compounds offer plastic processors with a cost-effective solution to production waste caused by machine contamination and long difficult colour and material changes.”

CJP, which is the UK distribution agent for the range of Dyna-Purge compounds, says that purging products should be considered by processors of all types, as they are effective across a full range

An example of using purging compound

of processes, covering injection moulding/hot runners, extrusion, blow moulding, blown film and sheet extrusion.

“Dyna-Purge offers plastic processors a simple method to reduce start-up scrap in production by providing a sensible shut down procedure that won’t put undue wear on your processing machinery,” Benyon continued.

“It works with a gentle continuous scrubbing action that’s nonabrasive and has no corrosive chemicals, neither do you have to mix it or blend it prior to use. The principle is straight forward and very cost-effective using a blend of compounds to produce a

commercial purge that is very simple to use without the need for long soaking times and multiple machine setting changes.”

Regardless of the quality of a purging product, Benyon says it is advisable for machinery operators to receive training on their use to ensure that the full benefits are achieved.

“Although Dyna-Purge has been designed to be straight forward and simple to use, we have developed many good purging practices that can reduce the amount of purge needed to achieve the most costeffective outcome,” he explained.

“It’s always a good idea to consult your supplier for advice.”

New Lusin LU1201F

customers trying to achieve SQF Certification.

Antje Scholl, Business Development Director for Thermoplastics at Chem-Trend, said: “Chem-Trend understands the complexity of food packaging manufacturing. Our vast research and development team set out to create an innovative product line that supports food safety management systems.

“We’re pleased to offer this full suite of products, providing food-packaging customers with customisable options that will fit their unique needs and, in many cases, achieve a competitive edge.”

Chem-Trend develops food-safe packaging lubricant for plastics Chem-Trend, a producer of high-performance release agents, purging compounds, and other process chemical specialities, has

Our vast research and development team set out to create an innovative product line that supports food safety management systems.

announced the release of Lusin LU1201F, a lubricant specifically created for the thermoplastics packaging industry.

Lusin LU1201F completes a larger portfolio of chemical speciality product developed in support of

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LANXESS launches lubricant additive for passenger car and high-performance engine oils Speciality chemicals company Lanxess has launched an organic additive for passenger car and highperformance engine oils.

The new Additin RC 3502 has been specifically developed to reduce friction and deliver sustained performance and anti-wear protection.

The friction modifier is noncorrosive, compatible with all synthetic and mineral engine oils, and has zero SAPS (sulphated ash, phosphorous, sulphur).

The Additives business unit (ADD) of Lanxess offers a broad portfolio of lubricant products for a host of different applications and industries.

These products, such as base oils, lubricant additives, additive packages and formulated lubricants help clients to meet increasingly stringent, legally prescribed standards for emissions and fuel efficiency.

The automotive industry is currently focusing particularly on the latter, and

The new Additin RC 3502 organic lubricant additive is designed to reduce friction

the new friction modifier from Lanxess caters to this development, since an effective engine lubricant plays an important role in fuel efficiency.

Dr Frank DeBlase, Application Technology Manager in the Lubricant Additives business line of ADD, said: “The new Additin RC 3502 is

a durable organic friction modifier developed fro today’s extended drain, high mileage applications, typically up to 20,000 miles, with exceptional solubility in the full range of commercially available passenger car and high-performance engine oils.”

temperature range of the system ensure greater efficiency and lower energy consumption.

In addition to providing energy savings, Millmax EE is also said to show outstanding oxidation stability – more than double that of the industry standard hydraulic oil – which extends oil drain intervals and also reduces oil consumption and downtime.

“With ISO 50001 and ISO 14001 marking out a new era for energy efficiency, and a political and economic agenda shaped by growing environmental awareness, the plastic industry – like many others - is having to make changes to meet these expectations and demands,” said Emma Law, Industrial Platform Manager at Miller’s Oils.

“New Millmax EE is an ideal product for manufacturers looking to reduce energy consumption.”

Millmax EE is available in ISO 32, 46 and 68 viscosities as well as zincfree formulations for applications where ash-less product is specified.

New oil could reduce energy consumption for moulders by 10 per cent Independent British oil blender, Millers Oils, has launched a new hydraulic oil that it says offers significant energy efficiency for plastics moulders.

Thanks to the inclusion of specialist additives from Dynavis, the new Millmax EE blend has led to reports of a reduction in energy consumption by as much as 10 per cent.

The inclusion of the Dynavis technology, developed by speciality chemical company, Evonik, serves to optimise the oil’s viscometric properties. This viscosity index, or the tendency of a fluid’s viscosity to change with temperature, is a key property for hydraulic oils. Fluids with constant viscosity over the operating

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The Berlin Wall: 1961-1989 Dugdale Ltd â&#x20AC;&#x201C; Making PVC Construction Compounds for over 50 years

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NO APOLOGIES

AS ZERO TOLERANCE OF ANYTHING LESS THAN PERFECT PRODUCT QUALITY COMES AS STANDARD FOR MANY PLASTICS MOULDERS, PURGING COMPOUNDS ARE A WAY OF ENSURING THAT MACHINERY IS RUNNING AT OPTIMUM CONDITION, WITH NO BLACK SPECKS OR ‘MILKY’ MOULDINGS CAUSING COSTLY SCRAP. BP&R SPOKE TO JOHN STEADMAN, TECHNICAL DIRECTOR AT AQUAPURGE, ABOUT WHY USING THE RIGHT PURGING COMPOUND MEANS NEVER HAVING TO SAY “SORRY” TO CUSTOMERS.

Aquapurge’s BBU compound has helped multiple moulding customers

A

quapurge, a producer of purging compounds based in Hayes, Middlesex, says it is currently reaping “several sales benefits” from demonstrating its purging technology in action across plastics processing sites in Europe.

The company is undertaking ‘factory days’ across the continent, which include product trials and training in purging methods, in order to impart knowledge to plastics processors about how to use the purging compounds and demonstrate the difference they can make to both the production process and the quality of an end product.

Aquapurge’s Technical Director, John Steadman, says that purging compounds offer tremendous commercial advantages to plastics processors who need minimum downtime along with elimination of production cost and waste.

“Our acid test is that – unlike many alternatives – our purging compounds succeed in completing stripping out all carbon black deposits from plastics machinery; rendering the production equipment as new,” he explained.

“Our technical staff show our customers exactly how this is done via the most effective methods.

Our materials cost money on the open market but our expertise comes free, and, is often delivered at times of emergency.”

CUSTOMER SATISFACTION When over half the cost of a finished moulding is comprised of material costs (expensive engineering polymers and colorants), Steadman says there can be zero tolerance of less than perfect quality. He says many moulders have found that the application of the BBU is making a real difference in ensuring quality remains high.

“Subsequent to the Plast 2018 tradeshow in Milan, one Italian customer for example, went on to save over half a million euros in annual cost, simply through intelligent and strategy application of BBU,” Steadman continued. Another example, he explained, an injection moulding customer based in the North of England, owes their continuing business to the debottlenecking that BBU facilitated.

“When it comes to delivery and lead time, today’s supply chains increasingly admit of no excuses whatsoever. Deploying BBU purging compound therefore means never having to say you’re sorry,” Steadman concluded.

REFINING THE RANGE At the forefront of the firm’s recent success is its Barrel Blitz Universal (BBU) compound.

This product, which has been undergoing development for almost the whole of Aquapurge’s 25-history, has been shaped by the firm’s customers.

“The April 2018/April 19 period saw final material innovation touches put to BBU – in terms of chemistry and physical composition - further refined and adapted to the needs of today’s injection moulders worldwide,” explained Steadman.

“Our current phase of development sees an expansion of qualified staff who are demonstrating and delivering the BBU transformation to processors who value the extensive savings and production peace of mind.”

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When it comes to delivery and lead time, today’s supply chains increasingly admit of no excuses whatsoever. Deploying BBU purging compound therefore means never having to say you’re sorry.

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celebrating 180 years

MACHINERY | NEWS KraussMaffei appoints AutoRIM as distributor for EcoStar and RimStar products in UK & Ireland KraussMaffei has appointed AutoRIM Limited as distributor for the entire range of high-pressure polyurethane metering and mixing equipment within the UK & Ireland.

The company says the move is to expand and develop relationships within the insulation and standalone machine sectors.

KraussMaffei’s EcoStar and RimStar metering and mixing machines are of modular design, allowing them to be tailored to a customer’s processing requirements.

From left to right: Stephen Lambert, Business Manager RPM Division; Philip Hindson, MD AutoRIM and Mike Bate MD KraussMaffei UK.

Based in Whaley Bridge, AutoRIM will work closely with KraussMaffei Group UK to provide customers with technical support

What happens with the dust in the conveying system?

Dust particles can cause a variety of problems in plastics processing, from quality loss and waste to problems during processing. But dust can also cause problems during material supply, for example reduced conveying throughput due to an obstructed air flow to the blower; in the worst cases blocked pipe lines or dust in the production areas. It is almost impossible prevent the creation of dust. The fine particles are created by the friction of the granules among themselves and against the walls of containers and pipes during filling and conveying. Even regrind generally has a high dust content.

In principle, one differentiates between two aspects in combination with the material supply with granulate and regrind.

One - filtering dust in order to protect the environment and the vacuum pump. Here the filter is normally in the material loader; the dust mainly stays in the material.

Often a central filter is integrated into the material supply system, which protects the vacuum pump from fine dust.

Two - dedusting the material in order to avoid waste. Here the dust is separated from the material and transported to a central filter.

The dedusting of material can occur either at separate stations (during batch processing) or in inline processing on the machine, for example with a dedusting attachment.

The frequent cleaning of the filter is important for both variants, in order to avoid performance losses of the conveying system. The filter is often cleaned mechanically (e.g. with a vibration mechanism), with pressurised air, or with the help of implosion cleaning.

In the next instalment, we will explain the different variants of filter cleaning as well as the dedusting module’s mode of operation.

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from a countrywide combined network of polyurethane (PU) technology specialists. The aftersales service will cover both process and technical assistance.

“AutoRIM’s respected reputation is based on almost 40 years of manufacturing and innovation for the PU industry,” said Mike Bate, KraussMaffei UK’s Managing Director. “They have a proven track record of meeting or exceeding the requirements of their customers, correctly specifying processing equipment, before delivering it on time and on-budget. Their specialist PU machinery service engineers will also ensure that equipment is correctly maintained and optimised, providing an extended and productive service life.”

IN THE LATEST INSTALMENT OF OUR ONGOING SERIES ANSWERING THE MOST FREQUENTLY ASKED MATERIALS HANDLING QUESTIONS, THE EXPERTS AT MOTAN COLORTRONIC OUTLINE THE SECURITY MEASURES THAT SHOULD BE TAKEN AGAINST DUST CONTAMINATION.

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AS A NEW DECADE DRAWS EVER NEAR, RESEARCHERS AT THE ATHLONE INSTITUTE OF TECHNOLOGY (AIT) IN IRELAND ARE WORKING ON FUTURISTIC ‘MADE TO ORDER’ PERSONALISED HEALTHCARE TECHNOLOGY THAT WOULD ENABLE THE MASSCUSTOMISATION OF MEDICINES USING A COMBINATION OF 3D PRINTING AND INJECTION MOULDING. BP&R LOOKS AT HOW THE TECHNOLOGY COULD HAVE THE POTENTIAL TO CHANGE LIVES.

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celebrating 180 years

MADE TO ORDER

R

esearchers have long suspected the concurrent prescription of multiple medications, otherwise known as polypharmacy, to be a leading cause of therapeutic non-compliance among patients.

For many, remembering to take a cocktail of medications – in varying sizes, colours and contexts – can be confusing and overwhelming, ultimately leading to a poorer quality of life and estimated compliance rates of between 50-70 per cent.

If prescribed, dosed and managed correctly, however, the benefits of polypharmacy can far outweigh the costs, leading, among other things, to an increased life expectancy.

With this in mind, researchers from Athlone Institute of Technology’s Materials Research Institute in Co. Westmeath, Ireland, combined their extensive knowledge of material science, additive manufacturing and injection moulding to ‘fix’ the issue of high pill burden and poor therapeutic compliance.

A BLUEPRINT FOR CUSTOMISABLE TABLETS Doctoral candidate, Evert Fuenmayor, and his supervisor, Dr Ian Major, have developed a blueprint for customisable tablets, capable of combining and releasing drugs in the correct quantities and conditions over a prolonged period of time.

This drug delivery technology, which can be either ingested orally or sub dermally implanted, can be tailored to the specific needs of the patient as determined by their genetic profile.

“Using pharmacogenomics, doctors can use the patient’s genetic profile to predict drug efficacy and guide dosages,” Fuenmayor, whose background is in mechanical engineering, explained. “It essentially tells us how an individual will respond to medications.”

The duo began by questioning if biocompatible, biodegradable polymers via 3D printing would be suitable vehicles for customisable drug delivery.

“When we started this research, the idea that 3D printing with polymer could be used to deliver drugs to the body was really novel – no one was doing it,” Fuenmayor said. “What we’ve managed to create is highly personalised, adaptable healthcare technology.”

THREE YEARS TO PERFECTION It took three years for Evert to perfect the printing 3D technology for tablets which relies on specific polymers and printing parameters to deliver active ingredients and formed the basis for his first two PhD publications.

He started off using caffeine as an active ingredient and soon realised that he could change the tablet’s release profile – basically how and when it was delivered - by making small, incremental changes to the settings on his 3D printer.

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www.britishPLASTICS.co.uk

www.kraussmaffei.com

|

celebrating 180 years

Doctoral candidate, Evert Fuenmayor

This new technology heralds an era of modern, highly specialised healthcare that has the capacity to help people live longer, healthier lives.”

“We blended and melted the material, made filament with it and fed it into the printer.

Depending on which settings we selected, we’re able to get entirely different drug profiles,” he explained. “With as little as two clicks, I could make it so that the tablet could last three days in the body or six hours - it just depended on the needs of the patient.”

The next phase of research, which focussed on bilayer tablet development for the delivery of multiple drugs, saw them experiment with more clinically relevant drugs.

LONGER, HEALTHIER LIVES Heralding a new era of modern, highly specialised healthcare, 3D printing technology has the capacity to help people live longer, healthier lives. Potentially, customisable drug technology could be brought to the high-street and tablets of different drug profiles could be 3D printed in-situ by pharmacists all over the country.

“Pharmacists will be able to make up the drug profile based on a patient’s unique needs there and then. With the right drug-loaded polymers

in stock and a small 3D printer, they’d be able to print your tablets in the actual pharmacy itself,” he explained.

“We’re still learning about how different people react to different drugs and dosages and therapy approaches so while we’re not there just yet in terms of making this a reality, this is where medicine dispensing is going and what we’re hoping for.”

A key enabling technology for this new frontier of personalised medicine, 3D printing can easily and cheaply produce tablets that are customised for individual patients or population sub-groups.

As exciting as this new technology is, however, it’s not without limitations: “For Evert to print a batch of 30 tablets on a desktop printer takes something in the region of four hours,” Dr Major pointed out, adding: “Whereas traditional methods of production can produce thousands of tablets an hour on one tabletting machine.”

SCALING UP WITH INJECTION MOULDING To tackle this issue, the researchers have adopted a mass-customisation approach which combines a high volume process, injection moulding, with 3D printing to produce customised tablets at a significantly higher rate of production.

While still at an early stage, this work has shown considerable promise in being able to produce customisable tablets which will facilitate revolutionary ‘made to order’ personalised healthcare.

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MATERIALS | NEWS Dow develops new resin made with 70 percent recycled plastic Dow has SEE ME AT K2019 announced the HALL 8A development STANDS K48-1/4 of a new resin made with 70 percent recycled plastic.

Dow Agility CE is the first post-consumer recycled (PCR) product offering of Dow’s plastics circularity portfolio to incorporate a high percentage of postconsumer plastic waste.

This new resin consists of a lowdensity polyethylene (LDPE) into which recycled plastic shrink film is incorporated without altering material quality and functionality in the final application.

This is the first grade of Dow Agility CE and is intended for use in collation shrink films as secondary packaging for transportation of cans or bottles.

It enables converters to incorporate more than 50 percent recycled content in the formulation of the final film, without altering its functionality.

Dow believes the availability of this high quality recyclate will help retailers and brand owners meet their sustainability goals while helping reduce the amount of waste going into landfills.

“What is exciting about Dow Agility CE is that previously mechanically recycled content has often diminished or degraded in quality,” said Carsten Larsen, Commercial Recycling Director for Dow’s Packaging and Specialty Plastics business.

“Here we have a consistent and high-quality product – taking back used shrink film directly from a retailer and using our material science to recreate a resin which can be used directly back into the same quality shrink film.”

Dow will be showcasing Dow Agility CE, as well as many other technologies, to customers at K 2019.

The new f ilm incorporates used shrink-f ilm (Image: Shutterstock)

Bebo trays have clear sustainability benefits for Quorn Trays from Bebo, a Berry Global company, are playing a key role in supporting Quorn Foods’ move to eliminate nearly 300 tonnes of black plastic packaging from its supply chain.

Bebo is producing a range of white and opaque recyclable PP trays for the Quorn range, including some of its best-selling products.

In addition to the change in material, Bebo has also worked on the further lightweighting of the

trays, delivering valuable additional material savings while still ensuring the trays retain durability, reliability, and functionality throughout the supply chain.

A spokesperson for Quorn said: “Quorn is at the forefront of diversifying the modern diet, and as well as being health-conscious, our customers are equally concerned about the wellbeing of the environment and our planet.

“We are delighted how these new trays have made such a positive change towards the increased sustainability of our products.”

The new, opaque recyclable PP trays

www.britishPLASTICS.co.uk

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www.ultrapolymers.com | Your partner from design to production

Versarien pioneers robust grapheneenhanced polymers for large-scale industrial structures Versarien, the advanced materials engineering group, has teamed up with several major global collaboration partners to commercially develop large-scale industrial deployment of high-purity, low-defect graphene materials.

Most recently, Cheltenham-based Versarien supplied its proprietary few-layer graphene nanoplatelets to develop a structure that will serve the UK’s transport infrastructure.

In this instrance, Versarien’s proprietary graphene materials have enabled a structure to be manufactured that is significantly stronger than similar assemblies using conventional polymers, and with better thermal stability.

Versarien produces a range of graphene powders and inks for different applications and markets, which can be blended with a vast array of polymers and other materials.

The company’s Polygrene range can be used in industrial extrusion, moulding and 3D printing processes.

Neill Ricketts, CEO of Versarien, said: “Graphene can address so many complex structural engineering challenges that were once considered impossible to solve. Greater mechanical strength and thermal dynamics are just a couple of the benefits offered by our Polygrene solution. We plan to reveal details of new major collaboration projects from all over the world in the coming months.”

Versarien is pioneering grapheneenhanced polymers for large-scale industrial structures 60

Lucy Hughes with MarinaTex. (Credit: Stuart Robinson/Sussex University)

Marine bioplastic wins UK National James Dyson Award A new form of bioplastic has been awarded the UK national James Dyson Award.

Lucy Hughes from the University of Sussex is attempting to solve the problem of both single-use plastics and waste by harnessing fish offcuts to create a unique plastic alternative, MarinaTex. The bioplastic is made of organic fish waste ordinarily destined for landfill or incineration and locally sourced red algae.

Using a unique formula of red algae to bind the proteins extracted from fish waste, MarinaTex has strong overlapping bonds giving it strength and flexibility.

It is a translucent and flexible sheet material, making it ideal for applications in packaging.

The material is relatively resource-light, requiring little energy and temperatures under 100 degrees to produce.

It biodegrades after four to six weeks, is suitable for home composting and does not leach toxins, removing the need for its own national waste management infrastructure.

As MarinaTex uses byproducts from the fishing industry, this helps to close the loop of an existing waste stream for a more circular product lifespan.

According to Hughes, one Atlantic cod could generate as much organic waste as is needed for making 1,400 bags of MarinaTex. “Plastic is an amazing material but we’re too reliant on it as designers and engineers. It makes no sense to me that we’re using plastic, an incredibly durable material, for products that have a life-cycle of less than a day," she explained.

“For me, MarinaTex represents a real commitment to innovating plastic use and incorporating sustainable, local and circular values into product design. As engineers, we shouldn’t limit ourselves to designing to form and function, but rather form, function and footprint.”

As national winner of the Award, Hughes will receive £2,000 as well as moving on to the international round of the competition, for a chance to win £30,000. She aims to commercialise her invention sustainably, using her award money for further research.

www.britishPLASTICS.co.uk

IN THIS EDITION OF HIS REGULAR COLUMN, OUR RESIDENT MATERIALS EXPERT, MIKE BOSWELL, REFLECTS ON THE RECENT DRONE ATTACKS ON TWO OIL PRODUCTION FACILITIES IN SAUDI ARABIA AND LOOKS AT THE IMPLICATIONS OF UNPLANNED EVENTS ON THE SUPPLY OF PLASTIC RAW MATERIALS.

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 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

Be aware of the unexpected The terrorist attack at the beginning of September on two oil production facilities in Saudi Arabia served as a stark reminder of the potential influence of geo-political events on the markets for crude oil, petrochemical derivatives and energy prices.

of hours in parts of East Texas. Many polymer production units were idled as a precaution and it is understood that one major facility suffered significant damage and was rendered non-operational as a result of storm damage. In a related incident, some river barges broke loose from their moorings causing them to collide with the piers of an interstate These drone attacks on Saudi Arabia’s road bridge causing sufficient structural oil installations are an attack on damage. This meant traffic had to be the ‘whole world’ and its economy, severely restricted, pending further according to the newly appointed Saudi assessment and repairs ambassador to London. to the structure. In Given the close spite of the extensive connection between railroad network in the oil industry and the US, local trucking petrochemicals The terrorist is a vital link between markets there is attack at the packing polymers in potential for this beginning of bags/sacks, putting type of event to September on two those goods into 40’ impact downstream oil production shipping containers activities such as and moving those polymer production. facilities in Saudi containers into the In the case of Saudi Arabia served as port for subsequent Arabia, there is very a stark reminder export to plastic significant plastic raw of the potential processors, including materials production, influence of geomany here in the UK, including world-scale political events who increasingly are plants producing PE on the markets using US manufactured and PP. Such was polyethylene. the concern of some for crude oil, polymer producers petrochemical that their order books So as 2019 draws derivatives and were closed while the to a close it may be energy prices. implications of the worthwhile considering damage resulting from the potential impact of the drone attacks was unplanned events on fully assessed. Worries concerning an the supply of plastic raw materials, and, escalating oil price were quickly quelled, as with Brexit contingency planning, it as US President Trump announced might be worth undertaking appropriate the willingness to release inventory due diligence into the supply chains that from America’s strategic inventories in serve the polymer raw requirements order to address any shortfall in global of your business and selecting supply production; it is noteworthy that the USA partners which are capable of providing has recently become a net oil exporter the level of resilience that you and your and that in a pre-US presidential period customers require. that rapid consumer price inflation resulting from rocketing oil prices is not very desirable for a candidate seeking re-election.

In addition to deliberate acts of sabotage, there appears to be an increasing frequency of natural disasters that have the ability to severely impact polymer supply. In mid-September, Tropical Storm Imelda dropped 500mm of rain in a matter

www.britishPLASTICS.co.uk

61

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PROCESS OPTIMISATION SOFTWARE RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E info@rjginc.co.uk Zero Defect Moulding – What’s your target?

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The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result.

PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture.

PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.

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Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com

When it comes to matching colour, no one gets closer.

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InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

50mm high and 35mm

PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk W: www.incontrolultrasonics.co.uk

• We want to bring your colour inspiration to life.

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Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service.

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polymers

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• We develop amazing new colours and special effects for some of the worlds leading brands.

• Performance is built-in, and cost designed out.

• Any colour, Anywhere, Anytime.

Telsonic UK Ltd

Performance Masterbatches Telephone: +44 (0)1495 310583 Email: customer.service@pmb.co.uk

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since 1982

Unit 3 Vitrage Technical Park 27 Witney Road , Nuffield Industrial Estate, Poole, Dorset BH17 0GL T: 01202 697340 F: 01202 693674 W: www.telsonic.com Blog: telsoniccuk.wordpress.com

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Branson Ultrasonics

STOCKISTS & DEALERS OF ENGINEERING THERMOPLASTICS PA6,66,610,612,1010 PMMA, PBT, PET, TPE, PC, ABS, PPGF, ACETAL 00 44 (0)1428 723 900 sales@chcinternational.com

MATERIALS

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

COMPOUNDS

Purging Compounds Release Agents Mould Maintenance

QUALITY PVC PELLETS FOR EXTRUSION

www.ChemTrend.com www.UltraPurge.com

vekacompounds.com +44(0)1933 427 750

Motan Colortronic Ltd

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

MACHINERY & EQUIPMENT

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UK Manufacturers est. over 60 years

Shredders Plastic separation Conveyors | Bailers Full recycling systems

01943 875104 sales@wrightsltd.co.uk

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Infrared Welding Ultrasonic Welding Hot Plate Welding Heat Staking

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CHILLERS/ TEMPERATURE CONTROLLERS

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CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd

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

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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

DEHUMIDIFIERS Motan Colortronic Ltd Cavity pressure measurement systems and sensors for control of the injection moulding process and automatic hot-runner balancing, provides zero-defect production with 100% quality control.

T: F: E: W:

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 MANDY O’BRIEN 01244 952519

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63

BP&R BUYER’S GUIDE HEATING EQUIPMENT

MACHINERY & EQUIPMENT DRYERS

HEATING EQUIPMENT

induction heating for platens and tools

HOT RUNNER SYSTEMS

MF Induction Heating

hot runner controllers

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 E: sales@mfinduction.com W: www.mfinduction.com

MATERIALS HANDLING AND STORAGE gravimetric/ volumetric blending

Motan Colortronic Ltd

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MATERIALS HANDLING hopper loaders

METAL DETECTION

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Servicing & Maintenance Commission/Decommission Robotics Projects Planning Servo Kit Installations Component Supply Training - Any Level Beston Sales

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

14 Years’ Engel Experience

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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

SCREWS & BARRELS

HOPPER LOADERS Engineers to the Plastics & Rubber industries, specialising in the following:

www.magog.co.uk Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries.

• 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

Tel: 01952 671918 Fax: 01952 608579 Email: connectors.uk@staubli.com

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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

POLYMERS

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.

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FILTRATION ALUMINIUM MATERIAL STORAGE BINS Off the shelf or made to order with very competitive pricing!

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METAL DETECTION AND SEPARATION EQUIPMENT Motan Colortronic Ltd

TO ADVERTISE HERE CONTACT MANDY O’BRIEN ON 01244 952519 MOULD CHANGE

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Motan Colortronic Ltd

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SECONDHAND AND RECONDITIONED

Cooper Plastics Machinery

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.

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

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Contact Paul Holohan in complete confidence on 07798 530684 or info@Kingswoodbusinesssales.co.uk

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For Sale Rubber and Plastic Moulding Company Established for over 20 years Existing Customer Base Turnover of £3.5 million 30 Experienced Employees Further Financials on request For further information email us on rubbermouldings1@gmail.com • Rubber • Plastic • Silicone Mouldings • Injection Mouldings

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Single Machines to whole plants purchased Tel: David 07540 633552 info@plasticinvestments.co.uk www.plasticinvestments.co.uk

Ultrasonic Plastic Welders New & Used

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TransXL International Ltd

Wanted

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Gammadot Rheology Testing & Consultancy Services

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hardness - IRHD and shore

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

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PRINTERS

in Plastic & Rubber

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comment

NEWS FROM THE FRONTLINE

IN THE LATEST INSTALMENT OF HIS EXCLUSIVE COLUMN FOR BP&R, DIRECTORGENERAL OF THE BPF, PHILIP LAW, URGES PLASTICS COMPANIES TO ENGAGE WITH THEIR LOCAL MPS, REFLECTS ON THE POTENTIAL OF A DOUBLE PLASTICS TAX AND LOOKS AHEAD TO UPCOMING EVENTS.

I

n this year’s Annual Dinner speech, BPF’s President, Martin Althorpe, majored on the need for plastics industry firms to establish better contact with their local Members of Parliament.

Indeed, it has been alarming to see MPs with plastics industry firms in their constituencies rush to sign Early Day Motions and other petitions seeking to limit, even ban, plastic products. There’s certainly an element of wanting to or having to run both with the hares and the hounds here, but in many cases the root cause is sheer ignorance. We have to compete for their attention alongside Mrs Jones of Acacia Avenue with her mortgage problems. The difference is that a plastics company employs a lot of people and funds a lot of mortgages.

We can’t emphasise enough the importance of getting the MP into your plant to understand the dynamics of your business and social and environmental benefits of its products.

BPF took a great initiative when, on 13th September, we organised a round table of key members in the Wilton area which was joined by local MPs Andy McDonald, Shadow Transport Minister; Anna Turley; and Simon Clarke, the Exchequer Secretary to the Treasurer – in fact the man in charge of developing the plastics packaging tax. This was highly successful and forcefully made the point that plastics are a vital part of the local economy in Teeside. The politicians were given a tour of the local Biffa plastics recycling plant. More sessions are planned in areas where there are concentrations of member firms in one constituency.

We have a wealth of information for you to play into meetings with MPs. BPF members have been recently sent a copy of ‘Understanding the Plastics Debate’ which positions the industry as a progressive force, capable of change and as part of the solution. It gives the Government recommendations on the framing of the proposed packaging tax and encourages science

We can’t emphasise enough the importance of getting the MP into your plant to understand the dynamics of your business and social and environmental benefits of its products.” rather than emotion in the debate. It’s received many plaudits for its contribution. Download it from the BPF website, www.bpf.co.uk It is likely that we will not be alone in having a plastics packaging tax. An idea has been generating in Brussels for months that the European Commission will allow Member States to tax unrecycled plastics packaging to provide Brussels with financial contributions to fill the hole in the EU’s budget vacated by Brexit. Needless to say, this will be resisted as the last thing we want is to be hit by a double whammy of a charge in the UK plus the consequences of a charge in the rest of the EU. In fact, BPF itself has just launched a design tool created to enable a higher level of recycling of plastics packaging. ‘Packscore’, on which there is a full feature on pages 46-47 of this issue of BP&R, will help retailers, brands and manufacturers to evaluate the recyclability and broader sustainability of the packaging they are proposing. It is supported by RECOUP and draws on ‘Recyclass’ and Berry International’s design guides.

Meanwhile, post-Brexit, we will look forward to seeing you at our annual recycling seminar on 7th November at the Squire Patton Boggs office in London. This will be followed by ‘Accelerating Innovation in PVC’ at the Etihad Stadium in Manchester on 19th November, and a BPF Packaging Seminar will be held at BPF House on 28th November. www.bpf.co.uk

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