BP&R Oct/Nov 2012

British Plastics

and Rubber THE MONTHLY MAGAZINE FOR BRITAIN’S POLYMER PROCESSORS

bp&r OCTOBER 2012

S T IC S A L P H IT W H C IN T O U

ALBIS has a new look!

Visit us at www.albis.com BP&R speaks to Shadow Waste and Environment Minister

Mould and tool making for plastics

CAE flow simulation for component manufacture

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bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk EDITORIAL Editor: Leanne Taylor T: +44(0)1829 770037 E: leanne@rapidnews.com

SALES Advertising Sales Manager: Lisa Montgomery T: +44(0)1829 770037 E: lisa@rapidnews.com

§As the weather gets cooler the plastics industry hots up

A

fter the summer shutdown across Europe, the plastics industry engine revs up at the start of September in anticipation of autumn’s vast array of exhibitions, conferences, shows and events that offer a platform to showcase the latest innovations, launches and developments across all areas.

The start of the industry’s silly season means a lot of time on the road for those involved - exhibitors, organisers, speakers and visitors, resulting in everyone falling in an exhausted heap after endless hall walking and standsearching. Well worth packing the extra batteries though, as the busiest time of year is the best to do big business.

I have been caught up in the ensuing melee and have hardly seemed to be at my desk at the moment. Mid-September I visited the RWM show in Birmingham.

There was an encouraging amount of plastics recyclers at the event and some groundbreaking innovations to boot.

Whilst I was there I managed to catch up with the Shadow Waste Minister, Gavin Shuker MP, who set out the Labour party’s agenda on waste and recycling.

You can read the full interview on page 40.

In other exciting news, at the end of September I visited Mediplas, the UK’s first show dedicated to the field of medical plastics. Covering all areas of the medical supply chain, including materials and machinery suppliers, the show acted as the perfect opportunity to showcase the importance of this rapidly expanding market.

To round off my hectic schedule of events I have just returned from Portugal where I visited the country’s bi-annual ‘Moulds Week’. This is my second visit to the country to discover more about its engineering and tooling industry for plastic injection moulds, one that is responsible for over 90 percent of Portugal’s export sales. To read the second instalment of my report, turn to our feature starting on page 20.

Finally, This is the last print issue of BP&R in 2012 to carry full editorial content – our next will be our annual directory – the must-have keepsake for anyone working in the UK plastics industry. In order for you to keep your company’s records up to date and ensure that your listing is correct – log onto the BP&R website and check your details.

Enjoy the issue.

Leanne Taylor — Editor

ART Production & Design Manager: Samantha Hamlyn T: +44(0)1829 770037 E: sam@rapidnews.com Production: adrian price T: +44(0)1829 770037 E: adrian@rapidnews.com

SUBSCRIPTIONS Subscriptions Manager: Tracey Nicholls T: +44(0)1829 770037 E: tracey@rapidnews.com

PUBLISHER Mark Blezard T: +44(0)1829 770037 E: mark@rapidnews.com British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (10 times/year) by Plastics Multimedia Communications Ltd, Unit 2, Chowley Court, Chowley Oak Lane, Tattenhall, CH3 9GA T: +44(0)1829 770037 F: +44(0)1829 770047 © 2012 Plastics Multimedia Communications Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.

Associated organisations

THE BIG STORY

ALBIS unveils a brand new look at Fakuma 2012

At the Fakuma exhibition in Germany, ALBIS unveiled its brand new image, with a new logo and website. The company states this new look brings a modern, updated image to its long established business, distributing one of the broadest and most diverse product ranges in the industry.

Serving the plastics processing industry with thermoplastic polymers for over 50 years from their headquarters in Hamburg, Germany, the Group has established a strong international base including ALBIS UK, based in Knutsford, itself approaching 50 years of trading. ALBIS UK said it is continuing to develop its business to better serve its customers and has made a number of key changes and improvements to its business recently.

New Appointments To Management Team The ALBIS UK management team has been strengthened with a number of new appointments. Richard Hicks has been promoted to Sales Manager for the UK and Ireland and Andy Pilling is also promoted into the newly created role of Business Development Manager. They each bring more than 10 years experience within ALBIS UK to their new positions and the company believes they will continue to promote and develop ALBIS UK’s business, serving customers old and new.

Further new additions to Andy Pilling’s team come with the appointment of two experienced Market Development Engineers. Mark Tibbetts brings a wealth of experience from the injection moulding sector, particularly focussed around

ts Various produc S BI AL om fr made nded Altech Compou range

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medical and healthcare, and Balu Gaddam joins the team bringing experience from the electrical and electronic sector with a strong education and development in engineering.

New Accreditations As well as distributing for many world class producers, ALBIS UK manufactures its own range of thermoplastic compounds at its Knutsford site and has recently further built upon the externally accredited recognitions it holds. The company has held approval to the TS16949 quality standard since 2005 and also Investors in People, as well as recently adding OHSHAS18001 and ISO 14001 certificates to its list of accreditations.

Commenting on the new appointments Ian Mills, Managing Director of ALBIS UK, said: “I am delighted to see these positive developments in our team and business which will strengthen the service and support we can provide to our customers across the UK and Ireland. In addition with the new accreditations we have recently received, this further underpins our quest to operate to World Class Manufacturing standards, and to assure our customers of the very best quality products manufactured to the highest operating standards.” further information: www.albis.com

19 21 36 16

on the cover H PL A ST IC S IN TO U CH W IT

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bp&r BRITISH PLASTICS &RUBBER

contents OCTOBER 2012

on the cover albis has a new look At the Fakuma exhibition in Germany, ALBIS unveiled its brand new image, with a new logo and website. The company states this new look brings a modern, updated image to its long established business, distributing one of the broadest and most diverse product ranges in the industry.

See page 4

24-27 REGULARS FEATURE INJECTION MOULDING Compounding Compounding masterbatch: The strategic, the technical and the commercial

28-31 FEATURE Antimicrobials

3 EDITOR’S LETTER As the weather gets cooler the plastics industry hots up

8-15 FEATURE Temperature Control New chiller cuts cooling costs for plastics processors

16-17 FEATURE Mould Flow Analysis Utilising CAE flow simulation for component manufacture

ENGINEERING MATERIALS

34 38

RECLAMATION AND RECYCLING 40 FROM THE FRONT LINE

42

CURRENCY CORNER

43

SOFTWARE

43

BUYERS’ GUIDE

44

Antimicrobials in the plastics industry – new problems, ancient solutions

32-33 FEATURE services Professional services for testing systems

36-37 FEATURE bioplastics From the kitchen to the lab: how cooking oil could make bioplastics cheaper

30

18-23 ]FEATURE Mould and Tool Making Engineering and Tooling from Portugal: One year on

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news

Scalebreaker descaling pumps

Descaling pumps available for large heating and cooling plants UK-based Kamco has developed a range of larger tank mounted pumps for descaling calorifiers, boilers, cooling circuits and heating systems. Descaling involves the use of powerful chemicals and Kamco Scalebreaker pumps increase safety during this process by safely enclosing chemicals within the tank, hoses or equipment being descaled at all times, therefore minimising fumes, splashes and risks to operators.

Pumps range in size from the 100 litre capacity Scalebreaker C130, up to the C230 with its 200 litre tank and a more powerful motor, giving a higher circulation rate and faster descaling.

The C230 is said to be ideal for cleaning calorifiers to remove the scale and debris which otherwise reduce efficiency and also screen legionella and other bacteria from the effect of biocide treatments. Other applications include acid washing package boilers and

descaling large plate and tubed heat exchangers without the need for dismantling.

The acid-resistant pumps are vertically mounted on a large integral tank, and come complete with flow and return hoses and a flow reversal device for faster descaling. Hoses have BSP threaded couplings for easy connection to the plant being cleaned.

High flow rates, combined with a 20 metre head, ensure vigorous and turbulent movement of descaling solutions to reduce the time taken for the operation.

All of the pumps will also handle biocides and hypochlorite solutions, and so can be used for sterilisation of pipework and water supply systems.

Although capable of handling large descaling jobs, even the largest pump, the C230, reportedly weighs only 20 kg and may be easily transported by one man in a small van. further information: www.kamco.co.ukv

New high-performance temperature control system Manufacturer of hot runner temperature controllers for the plastics processing industry, Gammaflux, has launched a new temperature control system, which it states combines improved performance with a smaller footprint.

The G24 temperature control system is said to be simpler to operate, less expensive to run through the use of fewer electronic components and smaller, taking up 48 percent less floor space than the company’s TTC controller.

Gammaflux states input/output interfaces to the injection moulding machine ensure that no reject mouldings are produced and no serious damage can occur to the mould. Due to its screen input facility, the G24 software is said to simplify the interlock between the mould and the machine and also interlock simulation during machine set-up prior to commencement of production. further information: www.gammaflux.com

The new G24 high-performance temperature control system Photo: Gammaflux, Wiesbaden/Germany

temperature control

www.temp-control.net 01933 442623

temperature control

www.temp-control.net 01933 442623

news Temperature control and mould maintenance in one Engel has announced that its ‘Flomo’ system, a compact temperature controlling water distribution system with electric monitoring, is now available as a stand-alone unit, stating that it has a wider range of uses than before.

Said to be the world’s first system of its kind, the Flomo can be used directly on injection moulding machines as a mobile mould maintenance device, making it a cost-effective solution in the injection moulding industry.

The portable system is equipped with its own control unit and can be used in many different positions. This means that moulds no longer have to be dismounted for routine checks, which will reduce the amount of time and money spent on maintenance.

On the latest model the supply and return manifold circuits are thermally separated from each other, which Engel states allows for even greater reproducibility of the measured values.

The electronic box has also been built directly into the distribution device. It is configured before delivery, which accelerates the set-up process. further information: www.engelglobal.com

IsoCool’s new mould heater

New mould heater controls temperature and cost A new water temperature control unit from process cooling specialist, IsoCool, is said to boost cycle times, productivity and product rate.

The new, British-built EWTC thermoregulator boasts a range of features, such as solid state relays and PID control for temperature accuracy, designed to optimise manufacturing efficiency. The EWTC is reportedly offered at a highly competitive rate, making upgrading more achievable and maximising return on investment.

Ensuring precise temperature control for injection moulding machines, cylinders and extrusion barrels is key to improving product success rates. In the EWTC this is said to be achieved via intelligent PID control, which regulates process temperature to better than +/- 1°C during heating and cooling phases. This constant monitoring of process temperature makes the EWTC particularly beneficial to systems with variable loads, as it automatically helps the unit to compensate for any changes.

In addition to advanced microprocessor technology, the EWTC comprises an indirect heat exchanger for process cooling, and solid-state relay controlled immersion heaters for quiet, reliable and fast operation. The solid-state heater switching - combined with the PID controller – is also said to offer fast rampup time with minimal overshoot. A submersible centrifugal pump ensures that the process fluid circulates at a constant pressure and flow rate.

The EWTC also features an audible alarm, which sounds if the temperature falls outside of the desired range.

Furthermore, in the event of a leak a mould leak stopper is included to act as a failsafe mechanism. The controller has an easy to read LED display, a mould drain system, which saves time during mould changes, and automatic water make up for ease of use.

FURTHER INFORMATION: www.isocool.ltd.uk

As a stand-alone unit, the ENGEL flomo can be used as a portable mould maintenance device too.

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news New chiller cuts cooling costs for plastics processors A new kind of ultra-efficient chiller for cooling plastics injection moulding machines is claimed to cut users’ energy costs by between 30 and 60 percent, with the savings cutting payback time to less than a year for some projects.

The new ‘Turbomiser’ uses a new type of compressor based on virtually frictionless magnetic bearings. When combined with high efficiency EC fans and its onboard intelligent control system, it is said the chiller can more than halve the energy costs associated with conventional chillers.

The chiller is the fruit of a five-year development programme by UK specialist Cool-Therm, its partners and Italian manufacturer, Geoclima. The technology is proven with some 200 successful installations to date in offices, hotels and computer centres across the UK. Its inventors are now targeting the

ion The new Turbomiser in act

temperature control

www.temp-control.net 01933 442623

plastics processing industry, which depends on effective cooling to ensure consistency, maintain productivity and deliver high quality results.

Cool-Therm states the technology is proven for use in cooling buildings, with the Turbomisers already having been used to replace ageing chillers at Colt’s West-

London data centre resulting in energy savings of 55 percent a year, according to the company’s own consumption figures.

These savings are said to continue to accrue over the life-time of the plant, which is normally between 10 to 15 years.

“The energy performance is staggering,” commented Ken Strong, Managing Director of Cool-Therm. “The savings go on accumulating throughout the life of the plant. Year on year, it’s also delivers a huge reduction in carbon emissions.”

The latest generation of Turbomiser is equipped with an evaporative system on the face of condenser coils. This “adiabatic advantage” is said to effectively reduce temperatures in the vicinity of cooling coils by up to 8°C, further improving the chiller’s energy performance.

Cool-Therm states water consumption is extremely frugal, with a standard unit in UK conditions using around £600 worth of water a year to deliver energy savings worth some £8000.

Ken Strong continued: “The latest generation of Turbomiser chillers is also now available using HFO1234ze refrigerant, which has a global warming potential 217 times less that conventional refrigerants. It is almost certainly the greenest and most efficient chiller in the world.”

The Turbomiser chiller is available in capacities from 250kW to 1.5MW, suitable for use in plastics processing applications of all sizes. further information: www.cooltherm-chillers.co.uk

The broad perspective is what counts! (QT [QWT RTQFWEVKQP GHƂEKGPE[ – and for our product range. That‘s why our large ALLROUNDER S machines are also available with servo-

ARBURG Ltd. Tachbrook Park Drive Warwick CV34 6RH Tel.: +44 (0) 1926 457 000 Fax: +44 (0) 1926 457 020 e-mail: uk@arburg.com

www.arburg.co.uk

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temperature control

Quality suppliers of large cooling water systems to the UK market

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news New high-performance cooling system for film manufacturers Reifenhäuser Kiefel Extrusion has added a new high-performance cooling system to its new ‘Evolution’ blown film line generation.

The company states this advance will make it possible for film manufacturers to significantly increase output capacity.

The new Evolution Ultra Cool design is said to evenly cool from inside and out, with a height-adjustable cooling ring and an air-cooled inner cooling system that optimise the air conduction inside the bubble, keeping the bubble stable even at high throughput. The system’s high cooling capacity is said to permit a die factor well above two, making it possible for manufacturers to produce more efficiently.

Reifenhäuser Kiefel states due to the high bubble stability, low thickness and width tolerances are possible even at high throughputs. Short startup times and job changeover times ensure that high-capacity production is efficient.

Priorities in the development of the Evolution Ultra Cool were not only improved performance, but also the user-friendliness of the line. Optimised cooling elements and a heightadjustable cooling ring are said to ensure that the line can be started up and operated during production.

The cooling system can be used for numerous film applications including general packaging film, collation shrink film, stretch hoods, hygienic packaging film and stand-up pouches. further information: www.reifenhauser-kiefel.com New high-performance cooling system Evolution Ultra Cool in operation

www.temp-control.net 01933 442623

news Single launches new alternating temperature technology Single Temperiertechnik GmbH launched its energy-efficient Alternating Temperature Technology (ATT) at Composites Europe 2012. The company claims that the technology introduces more versatility to the production of composite parts.

User-defined time setting for activating several valve modules per system and free selection of maximum or minimum temperatures per mould section are among the new features. These developments mean that energy consumption of the temperature alternation process can be optimised. The new functionality is the result of research Single conducted in cooperation with Steinbeis Innovationszentrum Kunststofftechnik of Aalen University into the development of temperaturedependent control of injection moulding processes.

The latest generation of ATT systems also offers a new data logging option: process parameters can be logged to a USB stick via an integrated USB interface.

Single also says it has been looking at ways to help in optimising foam injection moulding processes, in boosting the

productivity of two-component and threecomponent rotating moulds and in operating with vertical moulds.

The ATT active alternating temperature control offers benefits for composite production cycles that require fast temperature changes. Reportedly within seconds, the system can switch between two circuits with cooling fluids at different temperatures, and actively heat or cool the mould. Single provides a wide variety of active alternating temperature control systems for temperatures of up to 200°C. They allow temperature changes of more than 100°C in mould inserts used in

critical areas or in complete small moulds.

As an alternative, slow temperature changes in longer cycles can be achieved by standard temperature control systems: thanks to programming, these systems can change the temperature of the circulating medium from one temperature level to the next. This way, moulds used for composite production can be kept cool during the filling phase and warm during the curing phase.

FURTHER INFORMATION: www.single-temp.de

The new ATT technology from Single

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SolidWorks unveil plastics software to help get design right Dassault Systèmes, the 3D design software company, has unveiled ‘SolidWorks Plastics’ software tools, which are said to enable users to predict and avoid manufacturing defects during the earliest stages of plastics part and injection mould design.

The new products have been designed to provide part designers and mould makers with familiar and intuitive workflows so they can quickly optimise their part and mould designs for manufacturability.

The ability to make design changes early helps ensure that the mould works right the first time, reducing or eliminating the need for rework and improving part quality. SolidWorks Plastics is claimed to provide users with valuable knowledge so they can determine whether changes to the part geometry, mould design, material

The new SolidWorks Plastics

MOULD FLOW ANALYSIS

news

software will aid the design of parts and moulds

selection or processing conditions will have a positive impact on the ability to easily manufacture their products.

“For a lot of industries, such as consumer package goods, using plastic moulds provides added value in quality, time and cost savings. We believe a significant percentage of our installed user base is involved in plastic part or injection mould design, and will benefit from the robust features in SolidWorks Plastics,” said Monica Menghini, Executive Vice President, Marketing, at Dassault Systèmes.

“The addition of SolidWorks Plastics into our product portfolio allows us to

expand into new areas while following the traditional SolidWorks focus on ease-ofuse and features that provide real benefits to customers. The new offering provides designers fast, accurate and easy-to-use tools that make plastics simulation-driven design a reality.”

SolidWorks Plastics will be offered in two packages – SolidWorks Plastics Professional for part designers, and SolidWorks Plastics Premium for mould designers and mould makers. further information: www.solidworks.com/plastics

The moulded cover is produced using 30 percent glass long fibre filled Nylon

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Mould analysis software ensures precision for parts A Leicestershire company that produces a polymer cover for a waterpowered rock drill for mining operations is using injection moulding analysis ahead of tool production to ensure precision.

The cover, manufactured by Dudley Associates, encloses the drill’s rotary drive mechanism and protects the workings from damage at the working face of the mine, up to two kilometres underground.

Work Director, John Churchard, said the accuracy of the cover, which is manufactured from 30 percent long fibre

design and moulding process parameters.

This ‘preventative analysis’ detects a wide VISI is used to validate part thickness range of potential manufacturing issues and identify potential issues such as warpage, weld lines, air traps, filling issues and hot spots, while determining the optimum gating position.

Design Engineer, Kevin Steele, said without it many problems would not be identified until the moulding trial: “If there’s difficulty filling the part it may mean changing the gate, or even moving the gate and runner. This can’t be done on the press, so the mould would have to go back to the toolroom to be reworked, and then back into the mould shop to be sampled again.”

When it comes to analysing how glass filled Polyurethane, is critical: “The moulds for components such as the rock flatness aspects are particularly drill cover will perform, the tools within important. As the component has the drive VISI are used to validate part thickness gear running through it, any distortion or and remove any features such as small warpage would cause the whole drive to fillets or engravings to ensure optimum bind and thereby have a detrimental effect flow simulation. Once satisfied with the on the drill efficiency.” He said weld lines part quality, the gates are added. and weak points were also crucial factors Utilising VISI Flow’s features gave in making the moulded cover robust Dudley Associates a full picture of how the enough to cope with the conditions tool would perform in the moulding underground while drilling blast holes. machine, giving them the confidence to Before they start to create such commit to making the aluminium mould. technical moulds, Dudley uses VISI Flow (plastic injection analysis and simulation further information: from Vero Software) to optimise the tool www.vero-software.com www.dudleyassociates.com

John Goff, of G&A Moulding Technology, writes for BP&R on the importance of utilising ComputerAided Engineering flow analysis for part design, troubleshooting and material selection.

Computer Aided Engineering (CAE) flow analysis is well known and established as an excellent method of predicting how a mould will fill, as well as optimising part design, and it is also as an invaluable troubleshooting tool. It demonstrates the optimum point of melt entry (gate position), optimum wall sections, cooling capabilities, heat removal capabilities, identifies areas of possible gas entrapment, flow defects and the extent of shape change upon melt solidification, etc. It also demonstrates whether the part design is feasible for its end use and material selection.

G&A receive many enquiries where a company is experiencing issues when attempting to produce the same component but from a different thermoplastic material. Quite often poor quality or incomplete mouldings are produced when undertaking moulding trials using the same moulding

equipment/mould tool, leading to the possibility that changes to the existing component geometry are necessary. CAD data of the original component, together with the cooling circuitry, feed design and geometry, hot runner, etc of the mould tool, will enable a CAE flow analysis to be carried out that will provide an understanding of what can be achieved without going through a lot of effort, heartache and expense.

Separate 3D flow simulation studies involving the use of different grades of material, melt and mould temperatures, filling times compared to the processing conditions used for the existing material and those used for the unsuccessful trial/s will further illustrate whether a fit for purpose component will be achieved and whether it is necessary to alter its geometry. Furthermore, by reviewing the results of using different material grades of various melt viscosities, the process

window to be used will either increase or decrease, i.e. the degree of difficulty will be clearer. More importantly, the requirements of the processing equipment to manufacture the part may also need to be changed.

CAE therefore provides the information and confidence with which to carry out practical trials. More importantly, it highlights the reasons for a previous, unsuccessful trial.

What is very important, when using CAE simulations, is a true understanding and clear interpretation of the results of a full analysis. It will not provide a pass or fail tick box but information that needs to be fully interpreted with suitable recommendations made, i.e. it is a highly effective technical tool. Partial analysis provides a quick review.

MOULD FLOW ANALYSIS feature

Utilising CAE flow simulation for component manufacture

further information: www.gandamoulding.co.uk

Images: Software is used for plastic part analysis

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mould and tool making

news

An injection mould tool produced at Belfast for manufacturing plastic aerospace components

ARRK’s Tooling and Moulding Centre in Petersfield

The latest CNC plastic injection moulding machine to be installed by Crossen is a DEMAG ergo-tech 50-200 compact with 50 tonnes clamping force

Irish subcontractor opens aerospace division Toolmaker and subcontract machinist, Crossen Engineering, increased its aerospace business last year to 20 percent of turnover and announced that it was aiming to expand it further to 75 percent by 2015. As part of that plan, the group has started a new division called Crossen Aerospace at its factory near Belfast and will take on additional, dedicated staff plus two apprentices during the course of 2012.

Crossen Aerospace, alongside the preexisting Crossen Engineering division, designs tools and moulds for legacy, current and future parts based on customers’ CAD models or drawings.

Alternatively, it reverse-engineers aerospace components on coordinate measuring machines using both touchprobe and laser-scanning data acquisition.

The same metrology equipment, running under the industry-standard PC-DMIS operating system, verifies the tooling it makes against CAD files supplied by customers or generated on site.

Simulation software allows optimisation of tool design according to

the material to be processed and ensures that any potential bugs are eliminated in the virtual environment before production starts. Machining of tools and moulds is completed in-house to exacting tolerances and surface finish, prior to component manufacture.

Design and manufacture of plastic injection mould tools followed by prototyping and volume production of aircraft parts in the mould shop, plus assembly if necessary, are further services provided. So far, most work in this area has been for the marine and military sectors, such as mission-critical Eurofighter pilot life vest parts and components for ejector seats and parachutes.

The mould shop comprises the latest, digitally controlled machines rated from 50 to 650 tonnes. Parts can weigh from five to 2,100 grams. The most recent plastic injection moulding machine to be installed is a Demag ergo-tech 50-200 compact with 50 tonnes clamping force.

The firm operates 24-hour working for larger production runs and critical supply. further information: www.crossenengineering.co.uk

Appointments mark new era in ARRK EU Group collaboration ARRK has announced that Tony Lowe has been appointed as the new Managing Director of the Shapers Group.

Shapers, who are an ARRK-owned operation with sites in France, Germany, Poland, Russia, India and China, provide tooling and moulding services predominately to Automotive OEMs, Tier 1 and Tier 2 suppliers. The group, which includes the companies Sermo and Zimmerman, has a turnover of €85m and employs around 900 people worldwide.

Tony Lowe said: “I am delighted to have taken up this new position within ARRK. Part of my role will be to ensure ARRK companies in Europe work more closely together to offer a complete range of ‘joined-up’ services to our customers.”

ARRK continues its programme of integration across Europe, with Royden Morgan, who was previously the General Manager of ARRK’s Petersfield site, becoming Managing Director of ARRK Europe Ltd in the UK. Mr Morgan commented: “The changes in Management across Europe, along with the more ‘hands on’ approach by ARRK Japan, will enable our customers to benefit from a truly global company with experience and expertise in full-line service supply. The high level of investment in machines and people at ARRK’s UK plants is evidence of the future direction of the company.”

Earlier this year ARRK’s invested in a new 3200 Krauss Maffei injection moulding machine at its Tooling and Moulding Technical Centre in Petersfield and two new Mazak CNC machines at its Nuneaton facility. further information: www.arrkeurope.com

Engis Diamold polishing brushes

Rotary polishing brushes for mould and die Superabrasives specialist, Engis, has announced its wide range of rotary finishing consumables, including polishing brushes for mould and die applications, can benefit the user by performing under the harshest of conditions.

The brushes, which are manufactured using natural stiff bristle to ensure a long machine life, are designed to hold diamond compounds longer, in order to provide more cutting action at lower production costs and bring out the full lustre of the finishing process.

The brushes are available in a number of shank diameters, with long shanks for straight hand-pieces and short shanks for contra-angle hand-pieces, and in three shapes. further information: www.engis.uk.com

it switch 1420…/ lim The new Z

Exact position monitoring with new limit switch Mould and tool manufacturer, Hasco, has launched a new limit switch used in injection moulding tools to exactly monitor the position of the ejector assemblies.

The company states the new ‘Z1420/…’ works through precise control of the end position, meaning costly mould damage can be avoided. There are said to be many additional applications for the limit switch in the construction of tools and appliances where it is vital to determine the exact end-positions – for example with moving cores and stripper plates.

The Z1420/… has an extremely flat design. The working height of 3–5 mm can be individually adjusted via a hexagonal spanner and a 1 mm spacer.

Subsequent assembly and dismantling is also possible on the injection moulding machine.

With its moisture sealing to IP41, a maximum service temperature of +80 °C and a supply voltage of max. VAC/24/VDC, Hasco states the limit switch Z1420/… offers optimal conditions for a controlled injection moulding process. further information: www.hasco.com

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Words | Leanne Taylor

r to In 2011 I travelled to Portugal in orde ling find out about its engineering and too of industry and found a large cluster companies dedicated to quality, customer service and technical in competence. One year on, I returned time for the country’s bi-annual ‘Moulds Week’ – a programme of around conferences and exhibitions based well the development of the sector, as The events during Moulds Week attracted compan ies from across the engineering an d tooling sector

as to find out whether economic any uncertainty in the Eurozone has had stry. affect on what was a thriving indu

Engineering and Tooling from Portugal:

I

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t is easy to see why Marinha Grande and Oliveira de Azemeis are considered Portugal’s main tooling centres.

In both cities the whole supply chain is represented in areas spanning just 20-30 kilometres, from steel suppliers, companies specialising in hot runners, mould trials and mould bases, as well as rapid prototyping facilities. There is a wide support network specifically set up for the outsourcing of work including EDM, polishing, CNC milling and tool component manufacture. In addition, many of the global injection moulding companies are represented here.

A year on and the Portuguese mould makers say that despite the turbulence felt by the economy, their order books are still looking healthy. There is obvious competition with other mould making countries, especially Germany, as well as in the sector itself. With such a vast population of mould makers in one area all vying for the big business, companies are striving to differentiate themselves. One company director told me: “To offer the best service you need to be more than just a mould maker. It is about virtual integration – a company might be good but it needs to be innovative.” This is manifesting itself in different ways across the industry, from companies investing heavily in R&D facilities, new machines and expansions to those offering a completely turn-key service. With customers requesting ever more technical and complex work, many of the developments have been borne out of the need to satisfy their needs, with the challenge of a complex project the perfect platform to demonstrate their skill and remain profitable.

One such example of this is seen at an engineering and tooling factory in Marinha Grande, where they are investing 10 percent of turnover in R&D projects in order to develop ideas brought to them by potential customers. The company has invested in a medical cleanroom facility, certified to ISO

cleanroom standard, where it is using its experience in highly technical projects and equipment to develop a plastic disc designed for microfluidic blood analysis. By creating tiny micro channels in the CD, blood is spread by the centrifugal force from an analysing machine, enabling its separation for testing. This innovative product is already available on the medical market in Germany, Switzerland and Spain. The manager of the company explained: “We are keen to develop customer ideas in order to improve our business. Sometimes our customers have a concept for an idea but don’t have the technical knowledge to develop it – so we invest, research, develop and work closely with research departments at local universities in order to find the answer. We have done this here and it has resulted in the production of a highly technical innovation for the plastic medical device market. We have also very recently had an enquiry from an automotive company wanting to use micro optics. So we have looked at some designs and will now help them develop these and help them explore completely new markets. We will tell them what’s possible and hopefully gain another new customer.”

Another company, located only 10 minutes away on the other side of Marinha Grande, is concentrating on a unique method of surface finishing to distinguish itself from the competition. The company specialises in Electro Chemical Polishing (ECP), a Japanese technology that improves surface finish to a mirror-shine. ECP is an effective method for removing recast and heat affected layers from moulds and dies produced using Electrical Discharge Machining (EDM).

The process removes material uniformly and leaves a pure metallic surface without defects and residual stresses. By removing all surface defects where fatigue cracks can start, ECP is said to increase the working life of moulds and dies. It is a non-contact, low-voltage system performed by chemical

reaction. Increasingly popular for use in the production of moulds for light reflectors, there is said to be no way of getting this kind of polishing without using this process. The ECP process can reportedly reduce polishing time from one week to just four hours. Across the whole of Europe, this technology is said to be unique to this company alone. The company’s director said: “You have to think of a way to make moulds but also make money. By finding new ideas and technology you can do this, and this is what we have done.”

One company has invested considerably in a completely new extension dedicated to the production of moulds for medical plastic parts. Equipped with several new CNC milling machines that will run in a completely automated production line, the new facility will see the addition of eight new staff members when it is fully completed in February 2013. “You need to continually invest in new technology, or you will no longer exist,” the director of the company said.

Some companies are branching out into the provision of turnkey solutions, including product development, mould concept and building through to injection moulding and

mould and tool making feATURE

r a uld fo A mo al part ic techn

shipping of a product. “I am surprised how few companies combine mould making and production,” one managing director told me. The companies that do, however, are producing on an impressive scale. One factory had a neatly formed row of nine all-electric injection moulding machines, set up to produce some 4.5 million plastic coffee capsules per week when running at full production. Each of the capsules is inspected by visual equipment to ensure that products are perfect.

Engineering and tooling is not new in Portugal. Since its conception in 1945, the plastic moulds industry now comprises approximately 530 companies, with 60 percent located in Marinha Grande and 35 percent located in the industrial North in Oliveira de Azemeis. The Portuguese engineering and tooling industry is the source of employment for over 8250 people, with substantial investment being made in training and education to prepare the next generation to follow suit. During Moulds Week, the Portuguese Secretary of State of Economy and Regional Development, António Almeida Henriques, visited some of the

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companies in the cluster as a result of it being a huge source of export trade for the country.

As the mould making industry has grown worldwide, so have the dynamics of the Portuguese industry’s work. Having clearly defined themselves as specialists in the production of technical and complex parts, it is no surprise that 70 percent of their work is in the field of automotives, with new areas such as medical, aeronautics and electronics also bringing lucrative new business. “Last year was a record in business for us. We are finding that as the automotive industry gets more technical cars have more electronics and for us, more electronics means more moulds,” one manager explained.

“Also, there is huge demand in the communications industry right now, mobile phones and tablet computers for example.

Even in a recession some areas continue to thrive.”

Boasting an impressive portfolio of customers including BMW, Volkswagen, Mercedes, Jaguar, Ford, Porsche, Renault, Toyota and Audi all requiring an array of external and internal parts, in a variety of sizes and complexities, the industry is thriving on demand not only coming from car manufacturers in Europe, but also from the emerging markets, such as India.

“The automotive industry is increasingly interested in using plastic parts for lightweighting,” one manager commented.

“This means that the demand for moulds is high.” The Portuguese industry has also got competence in providing specialist services, such as stack moulds, 2K moulding, gasassisted injection, overmoulding and IML. But it is only recently that the automotive market has been a major source of work for the Portuguese mouldmakers, with their ability to adapt to a changing market place increasingly evident. One company had a showroom that was akin to a museum in terms of size and scope, documenting many of the plastic products it had made from the company’s conception. The company claimed to have made the first ever Barbie plastic caravan, as well as replica Rolls Royce children’s pedal cars for a well known UK department store. It was a fascinating treasure trove of toys, furniture, suitcases and household products that demonstrated generations of skill. The general manager explained to me that the company, like many in the area, no longer have any contracts for toys, as once China

State of Economy and The Portuguese Secretary of Almeida Henriques ónio Ant ent, Regional Developm companies in the cluster (middle), visited some of the

started to build its own mould making industry, the offer of a cheap price lured the toy manufacturers away without return.

He went on to explain that although prolific in the world tooling market, China is a different beast entirely. “Of course we regard the Chinese as competition, but they also have a niche. For the highly specialised moulds required by the automotive industry, tight tolerances and precise dimensions are absolutely essential for safety and quality and that’s where our strength lies,” he said. The manager went on to explain that Portugal’s main competition is European-based, Germany in particular. He told me that whereas the quality is on a par with their main competitors in the EU, customers chose Portugal because of its flexibility on price. “We can offer a more cost-effective service,” the manager commented.

In order to remain successful in such a competitive arena, the Portuguese have made a concerted effort their ability to communicate with new markets. Not only do many of the managers speak fluently in English as well as other European languages, they are also dedicated to proving the highest level of customer service by learning even the most difficult of languages. One director told me that due to a new, collaborative project with a partner in Russia, he had been

FAR LEFT: Companies are increasingly producing moulds and tools for plastic medical device parts, such as this defibrillator

LEFT: A complex mould producing small and technical components

learning the language. The Portuguese believe that the customer is key, and would seemingly go to any lengths to ensure that good relations are upheld.

Testament to this, one manager told me that this is the reason for the ongoing investment in new equipment, R&D facilities and expansions, because they want to prove to the customer that “nothing is impossible.”

The Portuguese state that the reason they have retained such strong relationships with their customers comes down to quality, service and on-time delivery. One manager told me that material is everything, choosing only to use quality suppliers. “Quality is what we pride ourselves on, we will only buy high-quality material for our moulds. It is a question of quality and not price when it comes to materials buying and this is what separates us from the competition,” he commented. With the rising cost of materials, I asked whether this affected the price the customers paid for their moulds. “In my opinion, our prices are not high enough. We want to be flexible with the customer but we have to make sure that we survive too,” one director told me. He maintained that price is only one aspect when considering mould production, with quality, reputation and timeliness part of the whole package that Portugal can offer.

This shows in some companies where repeat business is their lifeblood thanks to strong partnerships that have built up over decades. An example of this is a company whose top clients include luggage giant, Samsonite. The company has a team solely dedicated to the design of Samsonite’s products, to ensure that the very best results are delivered. “Samsonite only has one tool supplier in the world for suitcases and we have developed all sorts of new plastic models over several decades. All the tools have been made here and we have regular meetings for the designs,” the company manager explained.

In conclusion it would seem that the Portuguese have an astute awareness for the changes in the market, as well as where their strengths lie. The age of the machine has not displaced the need for human skill, and craftsmanship, design excellence and technical astuteness is still very apparently being passed on from generation to generation. It is obvious that the Portuguese are not resting on their laurels, and that they are aware that continual investment in both R&D and technology, as well as sideline innovations, is the way to survive. By ensuring that they have a technical edge, and insisting on quality, the Portuguese are carving a niche for themselves that sees them as the name in highly specialised engineering and tooling, where it would seem the impossible is indeed possible. further information: www.toolingportugal.com

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Teknor Apex expands range of ETP compounds for European processors Custom Compounder, Teknor Apex Company, has restructured and expanded its portfolio of engineering thermoplastic (ETP) compounds for use by European processors, offering products ranging from general-purpose formulations to a wealth of specialty modified grades, and now including many polyamide (PA) compounds developed for automotive applications.

“We now offer European customers a product range that is broader and more globalised than ever, providing customers with an unlimited choice of custom formulations based on PA, PET, and PBT, along with full technical backup, product development support, localised service, and worldwide availability for any compound required by companies that manufacture internationally,” said Neil Croucher, Sales And Marketing Director, Teknor Apex.

The products now fall into two broad families: Beetle, a range of PA, PET, and PBT compounds including products for automotive, electrical, consumer, industrial, construction, sport and leisure, and wire coating applications and Chemlon PA, a range of compounds for automotive applications including dozens of formulations developed for powertrain, chassis, exterior, and interior components.

The latest example of a PA automotive compound available worldwide is the new Chemlon 800 Series of injection moulding compounds. These are based on

Chemlon R for automotive applications

Beetle applications

compounding

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polyamide 6 /12 but are said to provide comparable performance in the fuel-line components that comprise the major application for polyamide 12. The new compounds provide a practical alternative

for processors amidst industry concerns about PA 12 supplies. further information: www.teknorapex.com

Some of the Luxus team gather on the development site for the new lab

UK compounder invests in innovation with the creation of a new lab UK technical plastics recycling and compounding company, Luxus, has invested heavily in the development of a new £600k laboratory that’s currently in the initial stages of its build and is expected to be completed

by December 2012. The lab investment will also lead to the creation of three jobs with its dedicated R&D team.

The new 750 sq. m laboratory will equip Luxus with the facilities it needs to accelerate its technical development of high performance thermoplastic polymers with a high recycled content, primarily for global automotive industry needs. Its automotive customers include: Nissan, Ford, Jaguar, BMW and most recently, Renault.

The investment has been made possible thanks to the £6m in lending Luxus received as a regional winner of the HSBC ‘Business Thinking’ award in 2011. This latest investment will enable the company to maintain its competitive edge and satisfy new markets as it extends its reach into Asia and Europe.

Luxus’ Managing Director, Peter Atterby, explained how the lab will make a significant contribution to its growth in the coming years: “Our team will be housed in a new state-ofthe-art facility that will enable them to continue to undertake thermoplastic polymer testing, development and analysis research work that provides bespoke solutions for niche market needs.

“For example, we are achieving improvements in compound design through a new European collaboration project that focuses on the technical aspects of recycled polymers in car interiors. It has recently lead to the development of a new lightweight polymer, Hycolene, that reduces interior component weight to enable manufacturers meet tough CO2 targets - its route to market will no doubt be speeded up thanks to the lab.” further information: www.luxus.co.uk

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compounding

news Evonik expands PPA product portfolio Evonik has expanded its metal substitute materials range, Vestamid HTplus, to include PA6T- and PA10Tbased polyphthalamide (PPA) products in a growing number of compounds, including a new product variant with a glass-fibre content of 45 percent.

The company states its biobased PA10T is even more efficient than PA6T, reportedly being easier to process, with better mechanical properties and offering a lower water uptake.

According to Evonik, the new reinforcement capabilities of the basic polyphthalamides take into account many highly demanding automotive applications, with coal, mineral, glass fibre, and mineral fibre reinforcements able to be used to create virtually any combination of properties.

“With the new products, we’re not only creating completely new fields of application but also offering our customers significantly heightened design freedom and, in turn, even greater weight-savings potential,” said Dr. Nina Hoppe, Evonik’s Director of Strategic Planning.

Dirk Heinrich, Director of Business Management, added: “Our portfolio expansion is precisely aligned to the demands of the market. Our customers can expect particularly great things from the launch of new tribologically equipped polyphthalamides and the water/glycolresistant options for the automotive industry.”

Elasto Müller Kunststoffe expand TPE capacity Elasto Müller Kunststoffe, Hexpol’s Thermoplastic Elastomer (TPE) compounding group, has announced plans to expand capacity in Germany with a sixth TPE production line.

The investment includes plans for high-quality twin screw technology and supporting sub-systems and will be installed at the group’s site in Lichtenfels, Germany. The new line is expected to

come on-stream in early 2013 and will increase TPE production by 4,600 tonnes per annum, bringing the capacity of the Group to more than 55,000 tonnes.

Elasto Müller Kunststoffe specialise in the development of custom formulated TPE compounds, based on SBS, SEBS, TPO and TPV technologies, with sales to a range of end markets including automotive, medical, caps and closures, construction, toy and household.

“This project will ensure business

further information: www.evonik.com Evonik has expanded its PPA portfolio. Credit: Evonik

expansion by increasing capacity to meet growing customer demand both in our home markets and worldwide. We serve international companies as a world partner, providing custom-formulated, consistent, high-quality materials,” commented Ralph Wolkener, President Europe and Asia for Hexpol Compounding. further information: www.elastotpe.com

nt The Lichtenfels pla

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The Strategic, the Technical and the Commercial Headquartered in the United Kingdom, Colloids has been compounding masterbatches and concentrates for the thermoplastics industry since 1967.

Here the company’s Managing Director, Russell Livesey, along with Technical Director, Bob Thomas and Sales and Marketing Director, Josephine Bagnall explain to BP&R the strategic, technical and commercial aspects of compounding.

The Strategic In the plastics industry, compounding masterbatch is growing ever more competitive. In today’s business environment, with global consolidation, it is ever more important to be investing for the future, through new equipment, technical capabilities, additional production lines, commercial infrastructure and - where relevant – acquisitions. It is also important to make the most of intellectual property in terms of how materials are processed, and configure equipment to ensure results are consistent and repeatable - to the relevant standards (including the highly demanding automotive ISO/TS 16949:2009). It is worth learning how others, especially in allied or adjacent industries use equipment so processability is improved or manufacturing edge is gained, as well as applying knowledge transfer for the benefit of the customer.

compounding feature

Compounding Masterbatch:

The Technical There is an extra dimension to compounding the best masterbatch - call it art - which exists alongside and goes beyond the scientific. Of course, knowing the scientific theory is important, but success at the highest level depends on more than just reading data off a fact sheet or a computer display. It means knowing the theory and learning from people who have not approached things from a theoretical point of view alone, but from hard-won experience. It also includes not taking things for granted, and thinking laterally as well as realising the significance of whatever happens in R&D or production, and asking the right questions to follow up.

These are all as close to art as science. And the benefits of calling on both are witnessed in concrete examples, such as with additive masterbatch you need to take into account, not just individual properties but also the combined effect of multiple additives - to avoid unwanted surprises. Getting the best results in black is a balancing act: the highest jet carbon blacks are by far the most difficult to disperse, so at the very outset you need to look at a judgement between extremes. It is also worth remembering that a metamerism cannot be resolved with a spectrophotometer alone.

The Commercial When compounding masterbatch today, the need to combine both the technical and the commercial is clearer than ever. The technical needs to advance within a solid commercial framework, and examples of innovations in this area include the use of new pigments not based on heavy metal (lead/cadmium), a range of masterbatches to be used in biodegradable polymers, higher strength (super-concentrated) formulations which allow lower dosing, as well as highly stable colour formulations essential for outdoor weathering, such as artificial grass or stadium seating - to give longer product life. further information: www.colloids.co.uk

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Sanitized reveals three innovations in material protection for polymers Sanitized presented three new product innovations at Plast 2012, including a new generation of silver technology with greater efficiency, environmentally friendly antimicrobial solutions for biodegradable plastics in agriculture and PVC with biobased softeners. “With our three new or further developed solutions for antimicrobial protection, we can completely fulfill both a growing demand for sustainable products as well as meet the demand for conserving resources in the production and application of final articles,� explained Maria Toscan at Sanitized AG. The new generation of antimicrobial silver-based additives has a faster effectiveness despite a lower active ingredient concentration. The basis for this patented technology is a small silver particle, which is encapsulated in a glassceramic material. Because of its process

Sanitized revealed developments for protection of biodegradable plastics in agriculture

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stability, it is said to be perfectly suited for the manufacture of masterbatches and can be worked into practically all plastics.

Sanitized states that through the flexibility and durability of the material, a whole new range of application possibilities opens up, including coatings and vinyl flooring.

The company also presented its solution for long-lasting protection for PVC using bio-based softeners.

Environmentally friendly, bio-based softeners can lower CO2 emissions in the manufacture of PVC products up to 40 percent, but since they are completely biodegradable and largely made from plants, they are also at risk of microbial

infestation. Sanitized has developed longlasting protection for this type of article— claiming a technological breakthrough.

The third area in which the company revealed developments was in the specific protection for biodegradable plastics in agriculture. By offering a solution for extending the useful life of the protective foil coverings often used in agriculture, while still retaining their biodegradability, Sanitized states the products can contribute to improved quality and greater earnings for farmers. further information: www.sanitized.com

RTP Company adds antimicrobial products using BactiBlock additive Global custom engineered thermoplastics compounder, RTP Company, has expanded its line of antimicrobial compounds and additive masterbatches to include new products using BactiBlock technology from NanoBioMatters of Valencia, Spain.

Efficacy testing has proven the naturally sourced, silver-functionalised clay BactiBlock antimicrobial additive to be compatible with a variety of thermoplastic resin systems including ABS, nylon 6 and 6/6, polypropylene, polyethylene, olefinic thermoplastic elastomers, and EVA with evaluation in other polymers ongoing.

“Additive masterbatches and custom compounds using BactiBlock are an

exciting addition to RTP Company’s family of antimicrobial products because its unique clay carrier provides a very efficient and durable delivery system for silver ions to effectively protect plastic articles against degradation,” said Jean Sirois, General Manager of RTP Company’s Colour Division.

Products incorporating BactiBlock are said to be fully colourable, easy to disperse and process at normal polymer temperatures. Loading levels vary by application and can be tailored to end-use environments to maintain desired effectiveness.

Demand for silver-based antimicrobial solutions, such as BactiBlock, are increasing due to their effectiveness at protecting polymers from degradation while being widely recognised as safe for human contact. Antimicrobial additives can be used to combat the growth of microbes like bacteria, fungi (mould and mildew), and algae that, left unchecked, can cause unsightly discoloration, unpleasant orders, or other polymer degradation issues. further information: www.rtpcompany.com

The new range of h sealants wit antimicrobial technology

Silicone building products seal the deal for antimicrobials SteriTouch has announced a new partnership with Everbuild Building Products Ltd, a UK manufacturer of sealant, adhesive and building chemical products.

SteriTouch is being used in Everbuild’s Forever White range of silicone sealants, where the antimicrobial technology will protect the application area from the growth of mould, and the build-up of bacteria and biofilm, ensuring that it is easier to clean and maintain.

In addition to preventing the growth of germs such as E-Coli, MRSA and Salmonella, the Forever White range boasts a 10-year guarantee against black mould, of particular importance in bathroom and kitchen areas where damp and humid conditions can lead to discolouration and deterioration of sealant and adhesive products.

Nick Corlett, Director of SteriTouch, commented: “In the short time we have worked with Everbuild, it is evident that we share their philosophy of growth through quality and reputation. This partnership brings together two very strong brands and we’re delighted to play our part in Everbuild’s continued growth in the building market.” further information: www.steritouch.com

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antimicrobials feature

Antimicrobials in the plastics industry – new problems, ancient solutions Andrew Summerfield, a microbiologist and regulatory officer at BioCote, a supplier of Silver based antimicrobial technology, looks at the increasing use of antimicrobial protection in plastics, including production methods and how additives can be incorporated as well as their importance in a growing number of industries.

The antimicrobial properties of metals such as silver and copper were identified in ancient times and their antimicrobial action utilised by a broad range of civilisations up to the present day.

However, the use of silver and copper as antimicrobials in medical and public health applications waned following the proliferation of the antibiotic industry after World War II. In the late 20th Century increasing hygiene awareness coupled with the emergence of healthcareassociated, multi-drug resistant, disease causing bacteria prompted healthcare professionals to look for different solutions to hygiene problems, such as the incorporation of inorganic antimicrobials into plastics and other polymerised materials. In recent years there has been a significant development of polymer technology, which may benefit from antimicrobial protection. So what is the most effective way to protect plastics from microbes?

Synthetic antimicrobials such as triclosan gained worldwide attention during the 1960s and, although widely heralded for their broad-spectrum activity, have come under scrutiny from The incorporation of antimicrobials into plastics is increasingly popular

government bodies such as the FDA due to environmental and toxilogical questions, with some countries considering its use banned or further restricted. Naturally occurring antimicrobials have avoided much of the negative press associated with synthetics, coming to be regarded as the cleaner, safer and ‘natural’ alternative.

Within the category of common, naturally occurring antimicrobials, silver and copper are the most widely used, and are well suited to different applications.

Copper is commonly used in solid alloy form in public health applications such as hospital railings, but is rarely used as an antimicrobial additive in other materials such as plastics due to environmental concerns over certain formulations, and its tendency to discolour materials.

Silver ion technology can be added to polymers in a number of ways, most commonly through the incorporation of a masterbatch via a dosing unit on the injection or extrusion machine, in the same way other colour or additive masterbatches would be introduced to the polymer melt. Raw additive powder can be mixed with virgin polymer before it is introduced into the hopper. Some machines (twin screw) will be able to mix the raw powder into the polymer melt.

Once the polymer has been moulded the silver ions are situated in the polymer voids and the material is protected from colonisation from microbes. So where does antimicrobial plastic fit with the current situation in healthcare and other industries such a food preparation?

Inorganic antimicrobials utilise the oligodynamic effect for efficacy against microorganisms. The exact nature of this action is not fully understood, however evidence suggests inorganic ions act in a multitude of ways to damage microbial organisms, and this action occurs at low

ials icrob Antim stop help ad of pre the s tion infec

ionic concentrations. Upon contact with silver ions, microbial proteins and DNA are bound resulting in conformational changes, inhibiting cell growth; oxygen free radicals are formed within the cell, resulting in further cellular damage. The antimicrobial effect with regards to silver based antimicrobials is due to the silver ion, an action independent of the carrier.

Silver ion technology is particularly well suited for use in plastics for a number of reasons. When carefully dosed it should not affect the physical, mechanical or thermal properties of the plastic in a negative way, ensuring, for example, the appearance and tensile strength etc. remain. The multi modal, non-specific action of silver ensures it is extremely unlikely microbes will develop resistance in the same way they can with drugs or molecular site-specific antimicrobials. The technology is thus suitable for widespread treatment of surfaces with a reduced concern of propagating resistant organisms. Incorporation of silver ion technology complements cleaning and hygiene methods in many environments, such as primary healthcare and public health, food preparation, medical devices and many more. Antimicrobial additives are a rapidly expanding field, with solutions being sought internationally for an increasing number of applications. further information: www.biocote.com

services

news Ex-S now offering Twin-Barrel laser alignment Extruder Services (Ex-S) has recently added to its existing laser alignment equipment to offer twin-barrel laser ‘borescoping’, claiming to be the only UK-based plastics industry consultants to offer this service.

The equipment uses a shaft mounted laser, which is trued to the drive shaft before passing a self-centering target along the bore and measuring deviation from the projected centre line. Parallel bores from 50mm upwards can be checked and tapered and under 50mm bores can be checked from drive shaft to bore end.

“Many people under-estimate the importance of correct extruder barrel and drive alignment, we recently performed a ‘health-check’ on a clients 4.5” 34D single screw machine and found that an 0.088”(2.23mm) misalignment and bend in the barrel had caused 0.040” (1.01mm) wear in two places on the screw in six months, the worst of the wear

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Ex-S has recently invested in additional laser equipment to allow twin-barrel alignments

corresponding with the apex and the front of the bend,” commented John Morgan of Extruder Services. “Twin-screw machines are arguably more susceptible to issues caused by misalignment; back-flighting, poor mixing, uneven melt temperatures and accelerated wear.”

Ex-S have also just completed a move to larger premises on the same Leicester site where they plan to expand their machine shop capacity and facilities for machine refurbishment and development. further information: www.extruder-services.co.uk

development and servicing of Thermal Analysis instruments Analysing and Testing specialist, Netzsch, has announced its Japanese division has acquired Bruker’s Thermal Analysis instruments business in the country.

Together with the international Netzsch group, Netzsch Japan will further develop, produce, distribute and service the existing and new Thermal Analysis product lines.

In Japan, Netzsch has previously been distributing its Thermal Analysis instruments via Bruker AXS K.K., headquartered in Yokohama. Bruker has distributed Netzsch Thermal Analysis products in Japan in parallel with Bruker’s routine Thermal Analysis product line.

Mr. Yoshio Shinoda, President of Netzsch Japan K.K., stated: “We are convinced that having a large R&D and production site that understands the needs of the Japanese market is an excellent way to further develop our future business in Japan. With an additional 30 employees joining us from Bruker, Netzsch can now serve our Japanese customers even better.” further information: www.netzsch.com

Professional services for testing systems Following the acquisition of Ceast into its product range in 2008, Instron states it can now address each and every critical area during the lifecycle of a plastic material from packaging to automotive, electronics to healthcare and construction to aerospace.

As an original equipment manufacturer, Instron Professional Services states it has developed comprehensive support options to maximise the return on Ceast system investments. These include installation, planned preventative maintenance, verifications, calibrations, onsite training and consultation.

Where accurate performance verifications are required, Instron states it can offer a wide range of factory and onsite services with all calibrations traceable to national and internal standards.

Instron’s on-line calibration certificate repository delivers the flexibility of electronic files with confidence of data integrity. Instron states it is the only UKbased company that can offer performance verification, maintenance and adjustment with digitally encrypted access to meet Ceast manufacturing specifications.

Dr.Tony Franks, Managing Director of RTech services, a company using Ceast technology, said: “as part of our growth strategy, R-Tech has recently established a facility for third party accredited testing of resins and fibre composite materials, in our new laboratories in Port Talbot, South Wales.

One of the tests required for the resins is the determination of Temperature Deflection Under Load (TDUL), according to BS EN ISO 75-1:2004 and BS EN ISO 752:2004. We acquired a Ceast HDT VICAT test machine in order to perform these tests. The Instron engineer enabled us to set up the equipment, giving helpful instruction and advice on running and maintenance. He also provided a service, including verification of the equipment’s thermocouples and LVDTs. This has enabled us to speed up the process of achieving UKAS accreditation for these tests – a vital step in establishing this new business stream.”

Instron believes that having a personal resource can prepare businesses to meet manufacturing specifications, ISO standards, and ultimately, customer demands. Instron Professional Services states it addresses individual needs as well as extending the life of each testing system. further information: www.instron.co.uk

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www.kraussmaffei.co.uk

news

a global for affei is KraussM rer of machinery u t c a manuf lding, tion mou cess the injec nd reaction pro a fei n io ussMaf extrus redit: Kra C . s t n e segm

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Onex to acquire KraussMaffei for €568 million Onex Corporation has acquired machinery giant, KraussMaffei AG, for €568 million. The transaction is anticipated to close by March 31, 2013, subject to conditions and approvals.

KraussMaffei designs and manufactures machinery and systems for the processing of plastics and rubber. For the twelve months ended June 30, 2012, the company generated approximately €1.0 billion in revenues.

“We’re very pleased to be partnering with Onex given its track record and experience in our industry,” commented Jan Siebert, Chief Executive Officer of KraussMaffei. “With Onex’ backing, we intend to strengthen our global presence and build on our success at the high-end of the industry.”

Onex Partners III, Onex’ $4.7 billion flagship private equity fund, will make an equity investment of approximately $340 million, of which Onex’ share is about $86 million as a limited partner in the fund.

Including this transaction and the recently announced acquisition of SGS International, the fund will be approximately 60 percent invested. further information: www.kraussmaffei.com

ntainer strial co 16.8L indu sing thin-layer u produced uperfos) (S s s e proc

Billion develops thin-layer coinjection process Billion has developed a material distribution system which combines coinjection and thin wall processes for injection-moulded parts.

Depending on the characteristics of the component, Billion states up to 40 percent of the total volume can be core material based on a 1.4 mm wall thickness.

Traditional materials such as PP can be utilised, although the application is also said to be compatible with recycled polymers, filled materials and natural fibre materials.

The process of co-injection, which is applied to a twin-shot injection moulding machine equipped with a special distribution nozzle, allows for production of a component with a different skin and core material. This technique is already used widely in the automotive industry, particularly for certain aesthetic parts.

However, for thin wall components, as often found in packaging applications, the implementation of this process is notoriously difficult and unprecedented.

Infrared emitters for injectionmoulded parts At Fakuma 2012, Heraeus Noblelight showcased application-optimised infrared emitters for plastics processing.

Intake pipes, ventilation parts and containers for brake fluid or windscreen wiper water in cars have to withstand pressure. These pipes and containers are often injection moulded as plastic half shells before being welded together to form the finished product.

Infrared heating technology helps to join the parts securely together without creating particles in the insides of the tubes. In many cases, a combination of infrared pre-heating and vibration welding can prove particularly advantageous. The infrared radiation melts the plastic surface so that particle formation is minimised during the vibration process. This is said to create a more secure joint and a flawless container.

According to the type of plastic, large particles can be created during vibration welding and these can find their way subsequently into cooling water, servo oil or brake fluid, with adverse effect on function. It can also be uncomfortable for a driver to have particles blown into the inside of the car through the air ducting.

Heraus Noblelight states a combination of infrared emitters with vibration welders

Billion states that co-injection is feasible with its thin-layer process: for example, a 16.8 litre industrial container (diameter: 336 mm height: 260 mm) in polypropylene with a 1.4 mm wall thickness can be produced with a 40 percent core volume. The finished parts are said to be of a high quality in terms of strength and impact resistance. In addition, the co-injected part is produced in the same cycle time as a single injection process. further information: www.billion.fr

provides a practical remedy to this problem, with an infrared module passing between two plastic parts and heating the surfaces of both parts without contact.

When the specified temperature is achieved, the infrared module is removed and the actual welding process begins.

The company states tests carried out with users have shown that the seams welded with the aid of infrared radiation are able to withstand very high pressure.

Carefully chosen infrared emitters help to provide high quality joining of plastic components for cars. As the infrared emitters need only be switched on when the heat is actually required, welding with infrared heat is also extremely energyefficient. further information: www.heraeus-noblelight.com Infrared heating helps to achieve particle-free welding of plastic tubes. Credit: Heraeus Noblelight 2012

injection moulding

Engineering Passion

bioplastics

news New bioplastic bottle for schools A UK-based company that manufactures water bottles for use in schools has launched a bioplastic version.

Osprey UK, based in Prenton, states the new Activ-R bottle is 100 percent biobased, made from Braksem’s medium density polyethylene derived from

Brazilian sugar cane ethanol.

The company has launched a recycling initiative for the bottles, designed to encourage schools to return the bottles once used in exchange for credits against further orders.

The returned bottles will be collected

by Osprey and recycled before being used again in the manufacturing process. further information: www.ospreyuk.com The water bottle is 100 percent biobased

NGR machinery recycling bioplastic film

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Pellets made from film

NGR develops solution for bioplastic recycling In most plastic production processes scrap and waste is generated, with recycling machinery available to convert this waste back into re-usable material.

With the growing use of bioplastics in production processes, Next Generation Recyclingmaschinen GmbH (NGR), has developed bespoke technology specifically aimed at reprocessing this type of waste.

Production waste can be melt lumps, sprues and defective parts in injection moulding, parison waste in blow moulding or edge trim, cutoffs and off-spec startup material in film and fibre production processes.

NGR has suggested that its new technology can only gain importance for bioplastics, which often cost as much as â‚Ź3 per kilogram or even more.

The easiest way of recovering these materials is to shred them to chips and refeed them into the process together with the new material, but as easy as that is, it can lead to process difficulties such as inconsistent feeding performance of the production extruder, air inclusions in the melt that lead to defects of the finished products and no way of removing process materials like printing inks.

NGR’s solution involves recycling machines that feed the material to the extruder with an integrated cutter-feeder, which consists of a slow rotating cutter shaft with knives that cut against fixed knives like scissors, and a feeding zone that conveys the material to the extruder without pre-heating it.

The NGR Cutter-Feeder-Extruder can reportedly recycle most of the commonly used bioplastics, such as starch or PLAbased products. The screws, vacuum vent and melt filter can all be tailored to the special requirements of bioplastics, for example low heating of the material or the removing of printing inks.

This method is also sensitive towards monitoring slight changes in the molecular mass distribution resulting from the inevitable heat stress in any polymer processing step. further information: www.ngr.at

From the kitchen to the lab: how waste cooking oil could make bioplastics cheaper Bioplastics that are naturally synthesised by microbes could be made commercially viable by using waste cooking oil as a starting material. This would reduce environmental contamination and also give high-quality plastics suitable for medical implants, according to scientists presenting their work at the Society for General Microbiology’s Autumn Conference at the University of Warwick.

The Polyhydroxyalkanoate (PHA) family of polyesters is synthesised by a wide variety of bacteria as an energy source when their carbon supply is plentiful. Poly 3-hydroxybutyrate (PHB) is the most commonly produced polymer in the PHA family. Currently, growing bacteria in large fermenters to produce high quantities of this bioplastic is expensive because glucose is used as a starting material.

Work by a research team at the University of Wolverhampton suggests that using waste cooking oil as a starting material reduces production costs of the plastic. “Our bioplastic-producing bacterium, Ralstonia eutropha H16, grew much better in oil over 48 hours and

consequently produced three times more PHB than when it was grown in glucose,” explained Victor Irorere, who carried out the research. “Electrospinning experiments, performed in collaboration with researchers from the University of Birmingham, showed that nanofibres of the plastic produced from oils were also less crystalline, which means the plastic is more suited to medical applications.”

Previous research has shown that PHB is an attractive polymer for use as a microcapsule for effective drug delivery in cancer therapy and also as medical implants, due to its biodegradability and non-toxic properties. Improved quality of PHB combined with low production costs would enable it to be used more widely.

The disposal of used plastics - which are largely non-biodegradable - is a major environmental issue. “The use of biodegradable plastics such as PHB is encouraged to help reduce environmental contamination. Unfortunately the cost of glucose as a starting material has seriously hampered the commercialisation of bioplastics,” said Dr Iza Radecka, who is leading the research. “Using waste cooking oil is a double benefit for the environment as it enables the production of bioplastics but also reduces

Research suggests bioplastics that are naturally synthesised by microbes could be made commercially viable by using waste cooking oil as a starting material

environmental contamination caused by disposal of waste oil.”

The next challenge for the group is to do appropriate scale-up experiments, to enable the manufacture of bioplastics on an industrial level. further information: www.sgm.ac.uk

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engineering materials

Excellence in Nylon Distribution

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news University professor develops plastic that “bleeds and heals” It’s the stuff of dreams that became a reality in a University of Southern Mississippi laboratory.

Inspired by his own dream of a technology now considered revolutionary in the world of plastics research, polymer science professor, Marek Urban, developed a unique type of plastic material that turns red or “bleeds” when damaged.

When the damage occurs, or when stressors mount that portend damage to the material, the molecule links that span along chains of chemicals within the material split and release a colour simulating bleeding. After exposure to sunlight or change in temperature, the material begins repairing itself in much the same way human skin does.

“I dreamed of developing this after thinking about how human skin repairs itself when damaged, and how blood coming from the injury works as a sign of that damage,” Urban said.

“Sometimes, damage to material may not be visible to the human eye, but with the release of the colours that mimic bleeding we have a warning of damage.”

The material has the potential to be developed into self-repairing surfaces in a wide variety of commonly used products, including mobile phones, laptops and military weapons.

Urban is enthusiastic that further research, and with the assistance of graduate students and staff in his Urban Research Group, he can extend the material

Edible films mean now you can have your packaging and eat it MonoSol, specialists in water-soluble, polymer-based films, has developed a new film packaging technology that dissolves when water is added.

The packaging system is a water soluble, edible pouch engineered from MonoSol’s Vivos films. The pouch disappears and releases its contents when exposed to hot or cold liquids, with the dissolved film said to be safe to be consumed along with the food.

MonoSol states the patent pending edible film formulation is composed of a proprietary blend of food grade

ingredients. The film is transparent and reportedly has no smell or taste when consumed. It is said to offer good oxygen barrier properties and is robust enough to enable real-world usage with various foods and forming of bags/pouches using existing converting technologies.

According to MonoSol, the benefit to consumers will be “on-the-go convenience, in addition to portion control and sustainability in terms of not having to throw away the package.” Specific examples for the use of the edible film system include fruit drinks, work out supplements, instant teas and coffees, soups, hot chocolate, pasta, cooking aids, dyes, enzymes, vitamin fortifiers and yeasts to mention a few.

to usage in cars, planes and spacecraft, as well as large infrastructure. The development of similar material that can also withstand high temperatures is on the drawing board.

“I believe there are endless possibilities, and we continue our research in hopes of capturing those possibilities that can further enhance our quality of life through the products we access daily,” Urban said. further information: www.usm.edu aterial stic m leeding and la p e h T e b tes th simula f human skin o healing

MonoSol’s Vivos films are said to be edible when dissolved in water

further information: www.monosol.com

www.ultrapolymers.co.uk a Spirit of Partnership

Scientists to develop material to extend shelf life of beer in plastic bottles Scientists at Crann, the Science Foundation Ireland (SFI)-funded nanoscience institute based at Trinity College Dublin, have partnered with brewing company, SABMiller, on a project to increase the shelf life of bottled beer in plastic bottles. The new deal will see SABMiller invest in the project over a twoyear period.

Professor Jonathan Coleman and his team at Crann are using nanoscience research methods to develop a new material that will prolong the shelf life of beer in plastic bottles. Current plastic bottles have a relatively short shelf life, as both oxygen and carbon dioxide can permeate the plastic and diminish the flavour.

The new material, when added to plastic bottles, will reportedly make them extremely impervious, meaning that oxygen cannot enter and that the carbon dioxide cannot escape, thus preserving the taste and ‘fizz’.

The team will exfoliate nano-sheets of boron nitride, each with a thickness of approximately 50,000 times thinner than one human hair. These nano-sheets will be mixed with plastic, which will result in a material that is extremely impervious to gas molecules. The molecules will be unable to diffuse through the material and shelf life will be increased.

As well as increasing the shelf life of the beer itself, less material is required in production, reducing cost and environmental impact.

Dr. Diarmuid O’Brien, Executive Director, Crann, said: “This partnership with SABMiller highlights the applicability of nanoscience and its relevance to everyday products.

“We are delighted to partner on this exciting project and look forward to its results.”

Beer in plastic bottles should taste better with a drop of science, according to Crann researchers

further information: www.crann.tcd.ie

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RECLAMATION & RECYCLING

100% Recycled Nylon 100% Prime Properties

BP&R talks all things green with Shadow Environment Minister Gavin Shuker MP, Labour’s Shadow Waste and Resources Minister, called for a Plan B for resources whilst speaking at the RWM 2012 conference.

In his speech, Mr Shuker called on DEFRA to take a more ambitious approach to waste policy, including adopting a higher recycling target and bringing England into line with the devolved administrations in Wales and Scotland, as well making the creation of new green jobs in the UK a priority.

Leanne Taylor sat down with the Shadow Minister to find out more.

LT: How will Government support for the UK recycling industry encourage investors?

GS: I went to see EcoPlastics a few of weeks ago and I was really impressed by what can be done when big manufacturers choose to show a bit of confidence in the plastics industry. What I’m focusing on is how Government can create the conditions where there is investor certainty. I think at the minute the certainty isn’t there at the measure that it

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needs to be. If you get the investor certainty right, this industry will attract private investors who can put their money anywhere they like to drive up standards as well as to reprocess more, and we know we need to do that more in plastics.

LT: How important is it to keep the reprocessing of plastics waste in the UK? GS: I am concerned that we are exporting jobs and growth to other nations. There is an economic argument, which is to say surely Government should create a level playing field to make sure that we keep high quality feedstocks here in the UK. There’s also an ethical argument, which is that very often these materials can go poorly sorted because enforcement isn’t right. So I’ve announced that we will look to see what we can do on enforcement, and around the exports regime to make sure we have a level playing field. It’s not about protectionism, but it is about making sure we maximise the opportunities here in this country.

In terms of those opportunities, how important is resource security?

GS: I’ve spent the last year visiting businesses with really innovative products

Gavin Shuker, MP

and processes when it comes to recycling and materials but I’ve also seen the chilling effects of, for example, George Osborne saying when it comes to transitioning our economy to new green growth, we don’t want to go any faster or any slower than any of the other countries in Europe. Well, advanced nations around the world are realising that resource security is vital to their long-term and their short-term growth. There is massive potential in the waste and resources sector to create growth and jobs. But if government at the highest levels doesn’t present a united

www.ultrapolymers.co.uk

front and provide clear leadership we’ll miss out on that prize.

LT: Do you think that current recycling targets are achievable?

GS: I think the targets are very challenging from where we are right now. I hope that the industry will be able to step up, but I equally think that the action of this Government is undermining investor certainty in new green technologies. It makes it far less likely that we will meet these obligations.

LT: Would the Labour party look at realigning England’s recycling targets with those of Wales and Scotland, if Mr Shuker called on DEFRA elected in to take a more am 2015? bitious approach to wast GS: I think it’s e policy

01925 750320

important to review the targets that have been set as we see progress being made.

So I don’t want to give up on ambitious targets, I think that’s really important. The question is how do we get certainty so that investors will put in place the infrastructure we need to handle that recycling. I think it’s important to review this and if Labour come into power in 2015 we’ve got a very short window of time so I’m not going to constrain myself in terms of those targets. Ambitious targets is right, but then let’s not have a government that’s then undermining confidence and then blaming the industry for not meeting them.

LT: Looking at domestic recycling, what do you think is the best way of educating the consumer?

GS: I think there are two issues here.

Firstly – recycling isn’t just a physical process – there is a human interaction there as well. That’s why I’m really concerned about the deep cuts to local Government right now and the attack on so called ‘non-jobs’ in that sector, such as people that actually inform local residents how to recycle. It’s driving down quality and it’s driving up costs. A lot of people

a Spirit of Partnership

are uncertain about what they can throw away. So the only route through, therefore, is to have clear and ambitious targets, to work back from that point, to educate people, but most of all to provide certainty because the consumer hears mixed messages and it makes it much harder to get compliance.

LT: How can we encourage more young people into the waste and resources industry?

GS: Waste and resources increasingly presents the opportunity not just to create new jobs, but regional jobs, jobs at every skill level and jobs for both men and women. But it requires Government to be on the pitch to do it. So one of the things that we’ve committed to doing is reducing university tuition fees because I believe fundamentally that we need to attract a new generation of young people into waste, resources and design. Kids in my constituency are put off from picking up those skills but we are going to need those skills. How do we create an economy that works for working people? This is something we need to look at, as right now I just don’t think we’ve got the mix right.

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industry

news Mediplas is just what the doctor ordered A newly launched UK show, dedicated to the medical plastics device industry has been hailed as a success by its organisers, Rapid News Communications Group.

Held 25th-26th September at the NEC, Birmingham, alongside the TCT Live, MM, MEMS and NANO Live shows, the combined events made up one of the largest gatherings of engineering professionals in the UK during 2012. As testament to this, the organisers have reported that visitor numbers have once again hit record levels for the three shows with just over 4600 attendees through the doors.

Although a debut show, Mediplas boasted an impressive set of visitors from across the machinery, materials, deisgn and prototyping sectors, such as Air Safety Ltd, BASF, Gabriel-Chemie, Lyondellbasell, Total Petrochemicals UK and Unilever, plus many more.

Exhibitors across all of the shows

Mediplas made a successful debut at the NEC, Birmingham

reported significant lead levels and in many cases orders were taken on stand.

Many companies have already reserved their space for 2013, which underlines the success and signals continued support for next year.

The free of charge seminar sessions held at the shows also played a significant part in making it worthwhile visit for attendees. Each conference and seminar had a compelling mix of both industrial and academic speakers ensuring balanced and informative presentations

for visitors.

The combination of first class suppliers on the show floor and free of charge seminar sessions, paid for car parking and free visitor Wi-Fi proved a winning formula for visitors and the stage is now set for further growth in 2013.

Mediplas will take place next year on 25-26 September 2013 at the NEC, Birmingham, UK. further information: www.mediplasuk.com

FROM THE FRONT LINE This month, Philip Law, Public and Industrial Affairs Director at the BPF, talks politics, presentations and PVC.

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George Osborne startled the Conservative Party Conference 2012 by announcing the exchange of employment rights for company shares. This will certainly appeal to some companies but could not apply to all types of business.

It’s still a concept and needs to be worked through. He also announced a planned generous tax regime for shale gas exploration. This development is certainly excellent news. For plastics it won’t just mean an energy source energy, it will mean a feedstock for material production. The availability of shale gas to UK industry could be a massive boost to global competitiveness for UK manufacturing. Osborne announced £1 billion of new science investment, which on the face of it is good news, but it’s unclear if this is really new money. There have been cuts in Government R&D spending across the board and this could just possibly amount to an element of catching up.

To a very different event, the BPF’s

Rotational Moulding Group was represented in full force at the recent ARMO (Affiliation of Rotational Moulding Organisations) in Lyon on the 1st and 2nd of October. The conference is the largest internationally recognised event in the rotational moulding industry, with over 450 delegates present. Over 20 UK companies were there - moulders, material suppliers, machinery manufacturers, ancillary equipment suppliers and service providers. At the conference Mark Kearns of Queens University Belfast delivered a wellinformed presentation on the ‘Future Proofing of the Rotational Moulding Process’. Martin Spencer of Rototek, Dr Gavin McDowell and Dr Nick Henwood of 493K and Karen Drinkwater, Chairman of the BPF Rotational Moulders Group, also made presentations.

A further key event was the BPF Vinyls Group annual seminar in Manchester on October 2nd. This marked the launch of a new animated video, which looks at the savings achieved by choosing PVC products. By using real life examples from UK Local Authorities the video shows viewers how, at a time of economic austerity, using PVC products can not only

save money but can also help to meet targets to develop better housing with improved comfort and insulation. In addition, with the Industry’s continued commitment to sustainable development through the VinylPlus initiative (www.vinylplus.eu), specifiers are assured that choosing PVC products has no greater environmental impact than the alternatives. The video includes details of two local authority case studies. A study conducted for Stockton-on-Tees Council found that it was possible to install twice as many PVC windows as timber windows for the same price. Another study, conducted by Green Party-lead Brighton and Hove Council, found that by using PVC products in the district, instead of alternatives, the Council saves £36 million over a period of five years.

Returning to George Osborne, if he wants to see how public authorities can pursue austerity by getting better value for money then he should key into http://bit.ly/bankonPVC. Better still, he could circulate it around government departments.

Further information: www.bpf.co.uk

party

as SMEs are focus of party conferences — let’s hope for some results…

This month’s view from Smart Currency Support for small and medium-sized enterprises (SMEs) has featured heavily during this year’s party conference season, with political parties announcing initiatives aimed at helping SMEs deliver growth back to the UK economy and increase their export business. The highlight has been plans for a £1-billion business bank, intended to give firms access to major long-term investment finance, announced by Vince Cable at the Lib Dems’ conference.

This is in response to concerns that banks remain unwilling to lend to businesses in the UK. Then, as part of its plans to double UK exports by 2020, the Government announced the allocation of £13-million to UK Trade and Investment to help UK SMEs secure trade opportunities abroad.

The British Chambers of Commerce (BCC) has offered its penny’s worth too, calling for the introduction of a £100-million Growth Voucher scheme, giving SMEs with a clear growth plan access to training worth £5,000, including advice on exporting.

BCC research has shown that more than one in five businesses believe they lack the in-house skills, managerial capacity and /or knowledge to export. John Longworth, Director General of the British Chambers of Commerce recently highlighted the need for businesses to focus on export at a time when our domestic economy is flat, adding there has been a shift towards exporting to the rest of the world and away from the European Union. As with so many government initiatives, these recent ones won’t be perfect, and some will not deliver, but let’s hope one – or some - will be implemented and start to have some positive effects.

UK plastics firms need to implement a strong currency strategy, something that Smart Currency can offer. further information: www.smartcurrencybusiness.com/bpr

software directory manufacturing management directory ENTERPRISE RESOURCE PLANNING Solarsoft Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Solarsoft Business Systems MEI Division (Europe) T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Modules: Production Monitoring, “Drag and Drop”, Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts, Trace-ability, Operator Visual Aids, Process Parameter Profiling, Email/Tannoy Alerts, Stand-alone, “Drag and Drop” Scheduler, Standalone, SPC “Machine Analyzer”, Machine Energy, Monitoring, KPI Dash-boards, Visual Manufacturing (Large LED/LCD Displays), Automatic Data Import/Export Functions (for Integration to Manufacturing Systems &Other Software Packages).

Solarsoft iVP ERP SAAS Manufacturing Software (for Plastics’ Processors) Solarsoft Business Systems T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Solarsoft’s iVP ERP (SAAS) software for the plastics’ converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution. It seamlessly integrates with Solarsoft-Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’ industry.

REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

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

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

Affordable and flexible MES system for the plastics/rubber industry. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts.

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

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

Affordable systems available for all size of processor.

Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.

A listing in the Software Directory costs £140 per programme per year.

Call Lisa on 01829 770037 for details.

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BP&R buyer’s guide services acquisition

WANTED

Injection Moulding businesses Are you looking to retire and/or sell out of your injection moulding business? We may well be interested, if you are not tied in to a long lease. If you're located in the West Midlands, we may well want to take on your key employees as part of the deal.

If interested, please contact, in confidence: Greg McDonald Goodfish Limited greg@goodfishltd.com (01543) 505 323

Contract cleaning Injection Moulding Extrusion • • • • • •

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

extrusion flow analysis Fleming Polymer Testing & Consultancy Unit 326, Hartlebury Trading Estate, Kidderminster, Worcestershire, DY10 4JB T: 01299 253300 E: enquiries@flemingptc.co.uk W: www.flemingptc.co.uk Compuplast bureau service & distributor

printers

tool making

printers of plastic mouldings

design and manufacture of blow moulds

TAMPO.SCREEN.FOIL Contour Marking Co Ltd Albert House, Gledrid Industrial Park, Gledrid, Chirk, Wrexham LL14 5DG T: 01691 770093 F: 01691 770023 E: sales@contourmarking.com W: www.contourmarking.com

Beaubury Precision Moulds Ltd 4 Telford Close, Aylesbury, Buckinghamshire HP19 8DS T: 01296 434311 F: 01296 433276 E: blowmoulds@ beaubury.co.uk W: www.beaubury.co.uk

mouldmaking pad

conductive plastics and coatings TBA Electro Conductive Products Ltd Unit 3 Transpennine Trading Estate Gorrells Way, Rochdale, OL11 2PX

T: 01706 647718 F: 01706 646170 E: info@tbaecp.co.uk W: www.tbaecp.co.uk

fastenings and fixings

Total Print Ltd Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com

testing/ consultancy Gammadot Rheology Testing & Consultancy Services Unit 5C, Leaton Industrial Estate, Bomere Heath, Shrewsbury, Shropshire, SY4 3AP T: 01939 291677 E: enquiries@gammadot.com W: www.gammadot.com Providing independant testing solutions to all your quality control, failure analysis & flow simulation data needs Fleming Polymer Testing & Consultancy Unit 326, Hartlebury Trading Estate, Kidderminster, Worcestershire, DY10 4JB T: 01299 253300 E: enquiries@flemingptc.co.uk W: www.flemingptc.co.uk Rheometry,TGA,DSC,MFI/MVR Impact

injection moulding mould release masterbatch

materials polymer distributors

mouldflow analysis

colour masterbatch

equipment

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www.britishplastics.co.uk

COMPOUNDING we have a comprehensive directory of suppliers, products and services. is your company listed? should it be? let us know.

Contact Lisa montgomery on 01829 770037

AEROSOLS

Eclipse Colours Ltd Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service.

1 mm Easysperse MicroPellets to 4 mm MaxiPellets.

Standards second to none.

thermocouples

ancillary

co-extrusion die heads and systems Ridgeway Co-Extrusion Technology Ltd

assembly hot plate welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransonplasticsjoin.com Machine Techniques Ltd Units 3-5, Sutton Court, Bath Street, Market Harborough, Leicestershire LE16 9EW T: 01858 434059 F: 01858 433638 E: davidchatterton@ymail.com W: www.mactec.co.uk

pulse staking H.T.E. Engineering Services Ltd 75, Dunboyne Business Park, Dunboyne, Co. Meath, Ireland T: +353 (0) 1 8013261 F: +353 (0) 1 8013262 M: +44 (0) 7435 967632 E: patrick@hte.ie W: www.hte.ie

Telsonic UK Ltd Units 14 & 15 Birch Copse, Technology Road, Poole, Dorset, BH17 7FH T: 01202 697340 F: 01202 693674 E: sales@telsonic.co.uk W: www.telsonic.co.uk Blog: www.telsonicuk. wordpress.com

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

chillers/temperature controllers

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

dryers/ dehumidifiers

Unit 22, W & G Estate, Challow, nr Wantage, Oxfordshire OX12 9TF T: 01235 760435 F: 01235 763021 E: frankh@ridgewaycoex.co.uk W: www.ridgewaycoex.co.uk Optimised monolayer die heads, coating die heads up to 4 layers, multi-layer die heads up to 7 layers, for pipe/tube sizes from 1 mm O/D up to 200 mm O/D; multiple tube die heads for mono and multi-layer products; multi-layer, multi-parison blow moulding die heads up to 7 layers; multi-layer sheet and profile dies up to 5 layers. R & D and product development projects; line conversions; turnkey system installations.

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

BS EN ISO9001:2008

hot runner systems hot runner controllers

GATE CUTTERS

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

infra red systems extrusion systems

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

granulators 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

spin welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com

extruders and downstream equipment

heating equipment

injection moulding

Cooper Plastics Machinery

ultrasonic plastics assembly systems Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com

ultrasonic welding InControl Ultrasonics Ltd (FFR Ultrasonics Ltd) The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 816507 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

To advertise in this space contact lisa montgomery 01829 770037

CNC ASSEMBLY MACHINES Cannon Shelley UK agents for Belotti 5 axis CNC machines T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.belotti.com W: www.shelley.biz

Unit 12, Harmill Industrial Estate, Grovebury Road, Leighton Buzzard, Bedfordshire LU7 4FF T: 01525 850610 F: 01525 218008 E: cooperplastics@ googlemail.com W: www.cooperplastics.co.uk Extruders, water baths, hauloffs, fly knife cutters, conveyors/ tip tables, in-line punches, coilers etc. New and used.

Repairs, servicing or rebuilds.

UK agent for Lyons Electronics

In Partnership with PC Moulding & Automation

www.pmmuk.net Tel: +44 (0) 1296 658 638 World Class Robotics from Max Robot

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.

45 bp&r

BP&R buyer’s guide materials handling and storage gravimetric/volumetric blending Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motancolortronic.co.uk W: www.motan-colortronic.co.uk PLASTICOLOR B A Thorne (Machinery) Ltd19A Imex Business Centre, Oxleasow Road, East Moons Moat, Redditch, Worcestershire B98 0RE T: 01527 584714 F: 01527 584784 E: bat@bathorne.co.uk W: www.bathorne .co.uk

mixing, feeding, drying 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

screen changers Industrial Plastics Ltd Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk

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

nozzles & nozzle tips

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

secondhand and reconditioned

screws and barrels

ANGLO PLASTICS LTD Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com DM Machinery Ltd Used Injection Moulding Machine Stockists 40 Thorne Lane, Wakefield West Yorkshire, WF1 5RR T: 01924 290206 E: sales@dmmachinery.co.uk W: www.dmmachinery.co.uk Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com Rawmec (EEC) Ltd Rawmec Industrial Park, Plumpton Road, Hoddesdon, Herts EN11 0EE T: 01992 471796 F: 01992 471797 E: rawmec@btconnect.com W: www.rawmec.com TransXL International Ltd Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

hardness - IRHD and shore MAPRA Technik Co — BAREISS Unit D13 The Seedbed Centre, Langston Road, Loughton, Essex IG10 3TQ T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

inspection & measurement MAPRA Technik Co – MARCEL AUBERT – DOSS – KAFER Unit D13 The Seedbed Centre, Langston Road, Loughton, Essex IG10 3TQ T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

thermoforming equipment

static control Arrowquint Ltd

printing machines

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

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

silk screen and pad

testing equipment

www.pmmuk.net Tel: +44 (0) 1296 658 638 World Class Ancillaries from FASI

hopper dryers

46 bp&r

Mascoprint Developments Ltd Stags End Cottage Barn, Gaddesden Row, Hemel Hempstead, Hertfordshire HP2 6HN T: 01582 791190 F: 01582 791199 E: info@mascoprint.co.uk W: www.mascoprint.co.uk

pad

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

Cannon Shelley Sales and service for thermoforming equipment T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.shelley.biz

WATER FITTINGS

varriabilitty Working with Husky to reduce variability improves your bottom line

Vaariability costs you money. It doesn’t matter where you are in the world or what you are manufacturing, variability adds risk to your operation. Husky hot runners and controllers are designed to help minimize variability in your injection molding process.

Reducing variability ensures more reliable product per fo ormance, allowing you to consistently produce and ship higher quality parts.

By implementing new Husky hot runner technology to a critical component, one customer was able to reduce scrap by 25%.

Husky helps you reduce variability in your injection molding process, so you can focus o on what matters most—satisfied customers and a healthy bottom line.

Scan the QR code or visit www.husky.ca/hot-runner-solutions to learn more about the benefits of Husky hot runners and controllers