BP&R Oct/Nov 2014

BRITISH PLASTICS

AND RUBBER

bp&r OCT/NOV 2014

Moulding the Trends

Interplas: The Review

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COMMENT

bp&r BRITISH PLASTICS &RUBBER

WWW.BRITISHPLASTICS.CO.UK EDITORIAL

group Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com

SALES

Riding the trade show roundabout

Group Advertising Manager: Lisa Montgomery T: +44(0)1244 680222 E: lisa@rapidnews.com

he past month has been a blur moulding machinery manufacturers, of trade shows, exhibitions and who virtually all reported that the UK events as trade show silly season had proved “a positive surprise” in hits plastics. Despite the whirlwind, the terms of machine sales, projects and overriding positivity from collaborations, when I spoke two of Europe’s flagship to representatives during The upbeat reports fairs indicates that the from these two shows Fakuma, one of Germany’s industry will exit 2014 on alone signify that the largest plastic industry a strong footing that looks exhibitions, held just over a appetite for plastics set to continue into the week after Interplas finished. is only getting New Year.

Reports from Fakuma stronger as markets After a three-year build were equally positive, with strengthen and up and much industry the show’s organisers economies recover, interest, Interplas did indicating that visitor which should pave the numbers for the 2014 edition not fail to deliver as the way for some equally had been “record breaking”, UK’s leading plastics successful events in with the sold-out show floor industry exhibition, with the coming year. organisers reporting a providing “a marketplace 10 percent growth in for innovative solutions attendees against the covering all aspects of figures from the show’s last outing in injection moulding, thermoforming and 2011. The positivity in Hall 4 of the extrusion,” and a “trend barometer” NEC, Birmingham, was apparent, with for the industry. These trends included a number of companies reporting integrated functions, such as automation new projects, high-level research and and decoration for improved energy development activity and forwardand resource efficiency; increased use thinking innovations and collaborations of 3D printing; metal replacement and that represent the buoyancy of the UK composite material developments. plastics industry.

The upbeat reports from these two International attendance at Interplas shows alone signify that the appetite also increased in 2014, with visitors for plastics is only getting stronger as from 56 countries travelling to the event, markets strengthen and economies underlining the importance of the UK recover, which should pave the way for plastics sector on the world stage. The some equally successful events in the surge in manufacturing activity was not coming year. least felt by the industry’s major injection

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COVER STORY

THE BIG STORY Rising order books, recent investment and new recycled ranges Knutsford-based materials distributor and thermoplastic compounder, ALBIS UK, has reported a successful and somewhat busy 2014, which has seen it invest in its manufacturing facilities, expand its range of recycled-content products, as well as finding time to attend some of Europe’s biggest trade fairs.

I

n response to rising order books, the UK subsidiary of ALBIS Plastics GmbH has completed a project to expand compounding manufacturing capacity at its site in Cheshire. The investment of €250000 upgrades the output of one of the existing ZSK70 compounding lines and will increase overall site capacity by more than 10 percent.

“This investment reflects confidence in ALBIS UK, as well as the wider plastic processing industry and will help to improve flexibility and response times for our customers,” commented Ian Mills, Managing Director of ALBIS UK. A voltage optimisation project is underway with the first of three site transformers replaced, helping the company meet its environmental obligations through the Climate Change Agreement (CCA). Energy consumption at the site has already been reduced almost 35 percent since 2007, whilst increasing output and this latest project will enable further reductions.

In addition, a number of smaller investments have been completed including the €30000 purchase of an XRF Analyser.

This strengthens ALBIS UK’s laboratory resource enabling onsite testing to ensure products containing recycled materials comply fully with ‘The Restriction of the Use of Certain Hazardous Substances’ (RoHS) in Electrical and Electronic Equipment (EEE) Directive (2011/65/ EU). “This is a vital part of the ALBIS compliance programme to give our customers full confidence in the compounds we manufacture and supply,” added Mills.

These compounds now come from an expanded range, as ALBIS continues to add to its portfolio of recycled content sold under the ‘ALTECH’ name, one of many own-brand product lines sold alongside some of the industry’s biggest brands.

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ALBIS UK has found the atmosphere and activity levels at recent trade shows to be “excellent”

ALBIS used recent trade shows such as Interplas UK to demonstrate its portfolio of products for a number of markets

The company has recently added a new, easier flowing PA66 compound to its range, said to be particularly suitable for parts with a long flow length and is based entirely on recycled nylon 66.

Additionally, ‘ALTECH PP NXT’ continues to be selected for projects where lighter weight, dimensional stability and easy processing are key requirements. It has found use in a wide range of applications including the automotive, domestic appliance and power tool markets. “We are seeing an increasingly strong interest in this product,” said Mills. “This is because of the many benefits it provides in processing and the fact it is often an easy fit for existing tooling.” ALTECH PP NXT is available in 30 percent glass- and mineral-filled and also 35 percent and 50 percent glass-filled versions.

ALBIS has been able to introduce the new grades to customers during its recent appearances at key European trade shows, namely Interplas UK and Fakuma in Germany, something which Mills says has been very beneficial for the company.

“The atmosphere and activity levels at these shows have been excellent and demonstrate the continued vibrancy of the plastics industry across Europe,” he commented. “ALBIS is increasingly challenged by its customers to support them across both their European and worldwide operations and by its presence at these trade shows, as well as the company’s increasing global footprint, it can effectively respond to these challenges.”

The company will next exhibit at Compamed in Dusseldorf, Germany, a show dedicated to the medical plastics market.

ALBIS says shows such as this provide its newly created industry business teams to provide expert advice tailored to a particular market, including healthcare, automotive, electrical and electronic and packaging.

“This approach offers customers the ability to ensure the right product is selected for their application ensuring the necessary regulatory, compliance and sustainability requirements specific to their sector are met,” explained Mills.

“It increasingly means ALBIS is completely aligned with the customers’ requirements and with increasing regulation of some markets this specific knowledge is vital to ensure the right materials are selected and the appropriate support provided.”

FURTHER INFORMATION www.albis.com

Images © Copyright of Graham Makepeace-Warne

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bp&r BRITISH PLASTICS &RUBBER

contents OCTOBER/NOVEMBER 2014

ON THE COVER Rising order books, recent investment and new recycled ranges Knutsford-based materials distributor and thermoplastic compounder, ALBIS UK, has reported a successful and somewhat busy 2014, which has seen it invest in its manufacturing facilities, expand its range of recycled-content products, as well as finding time to attend some of Europe’s biggest trade fairs.

See page 4

3 EDITOR’S LETTER

FEATURE 28-30

Injection Moulding

Moulding the trends

FEATURE 32-34

Plastic Electronics

Collaboration sees “industryfirst” transparent conductive polycarbonate film

08

NEWS FROM THE FRONT LINE

12

RECLAMATION AND RECYCLING 36 MATERIALS

45

SOFTWARE

47

BUYERS’ GUIDE

48

Purging Compounds New purging compound for clean colour and material changes

FEATURE 14-17

FEATURE 42-43

Robots pave the way for automation in injection moulding

INDUSTRY NEWS

FEATURE 40-41

Riding the trade show roundabout

AUTOMATION AND ROBOTICS

REGULARS

Process Control and Monitoring A precise look inside the cavity for zero rejects

FEATURE 18-20

Feature In-Mould Labelling “IML has a great potential for growth on a worldwide scale”

FEATURE 22-26

Interplas: The Review Serious selling and high spirits during three-day show

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INDUSTRY NEWS

Private equity FIrms consider Bayer MaterialScience business

A

ccording to Reuters, Advent; Carlyle; Cinven and KKR are amongst those interested in the MaterialScience business, which Bayer confirmed in September it was planning to float through a stock market listing Reports from news in order to concentrate agency, Reuters, on its drug and crop are suggesting science offerings. that private equity Reuters said none fiFIrms are eyeing of the companies had up Bayer’s plastics issued a comment on division, thought the story. to be worth Bayer intends €10 billion. to float the MaterialScience business on the Frankfurt stock market as a separate company within the next 12 to 18 months. A major reason for this move, said the company’s CEO, Dr. Marijn Dekkers, is to give MaterialScience direct access to capital for its future development, access that can no longer be adequately ensured within the Bayer Group due to the substantial investment needs of the Life Science businesses for both organic and external growth.

“We firmly believe that MaterialScience will use its separate status to deploy its existing strength even more rapidly, effectively and flexibly in the global competitive arena,” Dekkers said in a statement when the news was announced.

A strategy and corporate culture aligned to technological and cost leadership, coupled with the ability to make its own investment and portfolio decisions, would give MaterialScience the best development prospects in a highly competitive market, said Dekkers.

That, he believes, includes direct capital market access so that it would not have to compete with the Life Science businesses

News reports have suggested that there is several private equity firms looking at Bayer’s MaterialScience division.

Credit: Bayer

for investment funding in the future.

Following the intended flotation, MaterialScience will be Europe’s fourthlargest chemical company; it had global sales in 2013 of more than EUR 11 billion (pro forma figure). The new company is planned to have a global workforce of roughly 16,800, including about 6,500 in

Stronger supply chains could boost economy and strengthen plastics, says CBI Targeted action to revitalise domestic supply chains could inject £30 billion into the economy by 2025, creating more than half a million jobs across the UK and strengthening key manufacturing industries, including plastics, according to a new CBI report.

‘Pulling Together’ recommends ways to kick start the UK’s supply chains, and solutions to reinvigorate Britain’s industrial strategy. Based on new research carried out by A.T. Kearney, the global management consultancy firm, the report reveals underinvestment in research and development (R&D), a growing skills crisis and weakened foundation industries that The CBI says targeted action to revitalise the UK’s domestic supply chains could be beneficial to a number of industries, including plastics

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Germany. It will have a new name and a separate identity and be headquartered in Leverkusen.

FURTHER INFORMATION: www.materialscience.bayer.coM

are key to advanced manufacturing - such as plastics, metals and chemicals.

To tackle these issues, the CBI is urging the Government and business to act together to strengthen supply chains, focusing on innovation, better quality products, and excellent customer service.

“We need to see a bold strategy that breathes new life into our supply chains, and makes the UK the destination of choice for manufacturing high value products. This could provide a £30bn boost to the economy, and create half a million extra jobs,” commented Katja Hall, CBI Deputy Director-General.

“The scale of the challenge is sizeable - our competitors are powering ahead, with France outstripping our research and development (R&D) investment by 40 percent. At the same time, only three percent of our graduates end up in engineering or technology jobs.”

Hall said the UK needs policies that focus on creating long-term value, from increasing R&D spending to establishing a UK-wide materials strategy, in order to enable industry to “play to its strengths and compete effectively on the world stage.”

FURTHER INFORMATION: www.cbi.org.uk

William ‘Tiny’ Jordan

Don’t risk FIne for displaying old health and safety poster Large numbers of businesses throughout the UK are breaking the law and risk being fined after new legislation introduced earlier this year requires all workplaces to display a new and updated Health and Safety Law Poster.

However, many workplaces are unaware of the changes, which were introduced on 5th April 2014, and are still displaying the old poster which was first introduced and became a legal requirement in all workplaces in 1999.

Obituary: Summit Systems Ltd announces passing of William Stanley Jordan Summit Systems Ltd has announced the death of William Stanley Jordan on September 16th, 2014, father of company owner, Mike Jordan.

Known as ‘Tiny’ to his friends and family, Jordan had a long history in the plastics industry with his company, Peerless Plastics, after recognising the importance of the plastics moulding market which was emerging in the mid 60’s.

Summit Systems issued a statement saying: “Tiny was a loving and huge character who will be sadly missed by all.”

“ Sumitomo (SHI) Demag – Combining Technologies Efficiently“

The new version of the HSE poster that all businesses should be displaying by law

Under the Health and Safety Information for Employees Regulations (HSIER), employers are required to display the approved poster in a prominent position in all workplaces. In addition, employers should provide staff who work remotely or off-site with a copy of the HSE’s health and safety law leaflet or pocket card, which can be downloaded from the organisation’s website.

FURTHER INFORMATION: www.hse.gov.uk

Sumitomo (SHI) Demag Plastics Machinery (UK) Ltd Accent House · Triangle Business Park Stoke Mandeville · Bucks · HP22 5BL T: +44 (0)1296 739500 F: +44 (0)1296 739501 E: sales.uk@dpg.com www.sumitomo-demag.co.uk

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INDUSTRY NEWS

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NEWS Umbrella brand forms over multiple acquisitions A new plastics company with operations across three countries (resulting from a string of strategic acquisitions) has been launched, outlining an ambitious growth plan over the next few years.

One51plc has created a new brand called ‘OnePlastics Group’ that will see seven businesses come together under one brand umbrella with a view to offering plastic products in a variety of sectors.

OnePlastics Group said in an official statement that it plans to grow its client base organically by “delivering innovative solutions and by acquiring strategic targets”, which include the recent purchase of Straight plc – a UK-based wheeled bin and recycling container manufacturer.

Conor Sugrue, Commercial Director of OnePlastics Group, said the new OnePlastics Group brand will be driven by investment within the portfolio of businesses and the launch of new products.

“The launch of OnePlastics Group is a unique and innovative step and we have very ambitious plans for this new brand,” Sugrue said.

“The plastics division within One51plc group has been enjoying strong growth in recent years and the creation of the OnePlastics Group brand as a separate entity will give us a strong platform to realise our vision of becoming a leading manufacturer of plastics products in each of the sectors in which we operate.

“Bringing all the businesses together with all their different capabilities makes sense from a strategic level and also gives our customers access to a very strong offering in terms of price, service and innovation.

“As part of our growth policy we will continue to invest in the businesses within OnePlastics Group. This will allow us to maintain the highest quality standards, employ talented staff and continue leading the market with new products.”

OnePlastics Group currently operates with a combined turnover of around €150million and will employ 450 people servicing a range of blue

chip multinationals. It will design and manufacture a range of products across a number of key markets and sectors and will also offer full contract manufacturing and related services.

The seven businesses that comprise OnePlastics Group include MGB Plastics, Straight, AAC Plastics and Protech Performance Containers in the UK. Protech Performance Plastics and Thormac Engineering in Ireland and Protech Plastics China in Shanghai complete the portfolio. It has also created a new support office in Boston, USA. One51 operates a portfolio of businesses in specialised sectors including environmental services, renewable energy and injection moulding plastics.

FURTHER INFORMATION: www.one51.com

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INDUSTRY NEWS

NEWS Faerch Plast launches world’s FIrst ovenable CPET skin packs for meat and poultry Food packaging specialist, Faerch Plast, has launched what it says is the “world’s first” ovenable CPET skin pack.

The company’s latest innovation is an “ultra-hygienic” way of allowing consumers to place uncooked meat and poultry products directly in to the oven or microwave without removing any of the immediate packaging or touching the raw food.

The company worked with UK and Ireland-based companies, ABP and Bemis Flexible Packaging, to develop a lightweight ovenable pack using Bemis’ SkinCOOK technology, that is said to have significant barrier and strength properties and delivers

The new packs are said to be the “world’s first” ovenable CPET skin pack

major benefits for processor, retailer and consumer.

“These ovenable skin packs are truly revolutionary. With the special SkinCOOK topweb from Bemis Flexible Packaging, they can be cooked from chilled or frozen without being unwrapped in any way,” commented Joe Iannidinardo, Managing Director at Faerch Plast UK. “The packs also offer enhanced consumer appeal, shelf space efficiency and maximum protection to products during transit and in store. Cooking time is reduced

by up to 20 percent for a conventional oven and 40 percent for microwave and there are no unsightly meat juices on show. Plus there is significant shelf life improvement which helps reduce food waste.”

CPET eliminates negative effects on food flavour and aroma, giving consumers wellprotected, more versatile and better tasting meals.

FURTHER INFORMATION: www.faerchplast.com

FROM THE FRONT LINE This month, Philip Law, Director-General of the British Plastics Federation, puts plastics on the table with food for thought on the themes highlighted at the association’s annual dinner.

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The last week has been dominated by our BPF 81st Annual Dinner, which this year attracted 469 guests, one of the largest held in the history of the BPF. Our President, Mike Boswell, gave a stirring speech. He illustrated contemporary attitudes of plastics by a story about his young son Robbie. Robbie was playing with a ‘Super Mario Cart’ when it disappeared under Mike’s car with poor old Mario left decapitated. Robbie attempted to console Mike with the words “don’t worry Daddy; it’s ONLY plastic.”

Mike announced the initiation in the coming month of a BPF political contact programme where we will be issuing a document containing an elaboration of his Presidential themes, asking the membership to use it to establish contact with their local Member of Parliament. The document contains important messages on the skills shortages in the industry, the need for stable energy supply, and greater diversity in the banking sector together with ongoing support for the construction sector, traditionally a locomotive of the manufacturing economy as a whole.

Mike took the opportunity to thank former BPF Director-General, Peter Davis, for promoting the BPF in the political world with such effect for some 16 years and also former Finance and Administration

Director, Alan Davey, for his aggressive stewardship of the BPF Finances.

Mike told the audience that, as a new step, the BPF was creating a ring-fenced fund to finance educational projects of benefit to the BPF membership. This is to be administered from 2015 by the BPF’s Strategy and Finance Committee.

The BPF’s Gold Medal this year was awarded to Gabriel-Chemie UK’s Greg Hammond. Greg has been the major force behind the creation of the BPF’s Masterbatch and Technical Compounders Group. He has been its Chairman for over eight years and has inspired several seminars on colour in plastics. Greg’s dedication to the industry and profession is hard to rival.

Our guest speaker Matthew Parris, provided a humorous account of his chequered career at the Foreign Office, as an MP and as a political sketch writer.

He concluded with a chastening message that at no point in his life has he witnessed such scepticism of not only the behaviour of political leaders, but also business leaders; all established authority in every field is being challenged as never before.

This, of course, rings loud bells because a principal cause of many of the debates in which the BPF finds itself entangled

Winner of the BPF Gold Medal, Greg Hammond (left), with President, Mike Boswell

gather pace because of the shaken faith in traditional authority. We have Governments taking outrageous positions on particular chemicals, ignoring the measured scientific judgements of their advisors. We are also finding some alarming cases of head teachers, whose judgement should be more balanced, giving serious airtime to campaigning groups with anti-plastics messages in schools; a point I recently made in a letter to Education Secretary, Nicky Morgan MP. Our Dinner was a great success, with plenty of food for thought. For me it was a particularly significant event because it’s one thing saying that the plastics industry is very large but to actually see, physically present, in a large forum the serried ranks of several hundred business directors from the UK plastics industry, delivers a real message of dynamism and influence.

FURTHER INFORMATION: www.bpf.co.uk

AUTOMATION AND ROBOTICS

NEWS

ATM concept combines a 6-axis robot, ultrasonic technology and quickchange fixtures to allow processing of multiple part types

Putting a buzz into automotive trim assembly Leicestershire-based ATM Automation has developed a new concept combining the use of robotics and ultrasonic technology for staking applications on automotive interior trim components.

The development is in the form of a fully integrated, stand alone work cell, which incorporates a 6-axis robot, two-position turntable, interchangeable fixtures and ultrasonic technology which is mounted to the robot. “This combination provides a highly flexible and powerful solution to a wide range of staking and assembly operations on automotive components.

The inherent flexibility of the 6-axis robot, combined with the broad capabilities of the ultrasonic technology has allowed ATM to apply the concept to a range of applications, such as the assembly of interior door trim components for high quality, lower volume vehicles,� commented ATM’s Sabir Hirji.

ATM has also used the combination of robot and ultrasonics to cut apertures in rigid polymers

The cell is designed to allow rapid changeover using quick-change coded fixtures, that allow automatic selection of the robot programme and processing parameters, making it possible to produce complete vehicle sets within the system with minimum operator intervention. The flexibility of the robot also enables the number of stake points, their positions and orientation to be changed as required to take account of customer specified

options or indeed new product variants.

Although the concept was initially developed as a flexible method of staking and joining parts, ATM says it has also applied the same principles and technology to the removal of excess material following over-moulding operations on automotive components such as roof linings and A, B, C and D pillars. The broad capability of the ultrasonic technology has also allowed further developments, including the cutting of apertures in rigid polymer components.

FURTHER INFORMATION: www.atmautomation.com

AUTOMATION AND ROBOTICS

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COMMENT Robots pave the way for automation in injection moulding Parts of Europe, including the UK, have been slower to automate than others.

Like many processes, In IM, this was, injection moulding at least in (IM) can beneFIt part, because hugely from in the early automation involving 2000s, many robotics. But what in the supply precisely is the chain pursued impact of this type the trend of of automation? How offshoring work – are the technologies particularly to the and applications Far East.

“More advancing, and why is recently, there’s demand in this area increasing? In the been a gradual following article, shift back technical experts in attitude,” at Sepro Robotique explained and Sumitomo Demag Technical Sales discuss. Manager at Sumitomo Demag, Dave Raine. “Many businesses now appreciate that, wherever production is located, there is a cost to getting higher quality products. On the flipside, UK moulding companies have had to automate their processes as much as possible in order to reduce costs and ensure competitiveness. Over the past two years, especially, we’ve seen a massive increase in interest.”

In fact, figures from the British Automation and Robotics Association (BARA) show that sales of robotic systems into the plastics sector as a whole grew by a healthy 69 percent between 2012 and 2013*.

Like all sectors, plastics suffered as a result of the 2008 crisis. However, according to Sepro Robotique, an IM robotics specialist, last year was the best for UK sales since 2000. With the French-based robotics company expanding internationally, it was also a record year for Sepro as a whole.

“In general terms, we’ve experienced steady growth over the past two decades,” said MD of Sepro in the UK, Paul Goodhew.

“Europe was lagging well behind, but more people have come to realise that they need to embrace automation to stay ahead of their competition.”

Raine put the initial outlays into context, stating: “Including a robot in an IM machine can cost an additional £25,000 or so, but what you get is available 24-hours a day. Not everyone is ready to make that investment, but those who do invest are – depending on the operation – likely to see payback in less than a year.”

Images 1 and 2: A prime area for automation using robotics is in-mould labelling (IML), which has really taken off in packaging applications over recent years

conscious of their on-shelf impact. In addition, IML is increasingly being used to double up the barrier layer in packs for food products requiring a longer shelf life.

Extending well beyond labels, in-mould insertion is common practice when creating automotive parts, highlighted Goodhew, especially fabric insertion, which is a major feature of many IM installations. Other examples in motor industry applications involve the exposure of moulded bumpers to a gas flame in preparation for downstream spraying, he added.

IM automation during the production process The simplest robot applications involve sequencing with the moulding cycle to remove finished parts from the machine and placing them on a table. Another common task involves stripping sprues and waste from around the mould and placing them in a granulator for recycling.

“A slightly more sophisticated system might take two left-hand parts and two right-hand parts from the mould, such as ventilation grilles for a car, and place them in the correct boxes,” explained Raine.

Another prime area for automation using robotics is in-mould labelling (IML), which has really taken off in packaging applications over recent years, both in the UK and the rest of Europe. Speed is all-important in this role, and Sepro offers a series of high-speed side-entry robots, incorporating the label dispensing and placing technology of fellow French company, Machines Pagès.

“On a two or four-cavity mould for a tub or lid, you might have a cycle time of between 3.5 seconds and five seconds.

The robot enters through the side of the machine, one tool picking off the finished part, another inserting a label. Operators would be looking for a typical in-out time of less than half a second,” Raine added.

IML offers clear operational efficiencies and improved graphics quality for brands

Options for optical Beyond these specific functions, says Sumitomo Demag, full automation using robotics and vision (when required) can generate a sequence of diverse operations, adding important quality control functions to a production role.

“For example, a cell we are building right now requires the positioning of two very delicate inserts into the mould,” said Raine. “The same robot head rotates to take the finished part from the mould.”

This is just the start of things. “A tiny camera is inserted inside the part, taking pictures at a right-angle,” he added. This is in order to verify quality and keep a traceability record. “Each part then goes to a laser marking station for coding and is cleaned before being placed in a blister pack and indexed out of the system.” Each unique code is tied to the part’s quality control data.

Within the cell, the master computer is connected to the robot, the camera and the laser marking system. Any defect is detected by the software, and the part is placed to one side for manual inspection.

“This type of integrated system goes well beyond simply automating a manual process,” Raine explained. “It’s actually the only way of guaranteeing repeatability and quality to the levels required by the customer.”

Speed, yield, repeatability, reliability, multi-tasking and long-term cost saving are all reasons why end users might opt for a robotic solution. Space-efficiency is another, and in some situations this ability to keep an operation compact is of particular value.

Hygienic cells can widen business scope “More and more customers are looking at cleanroom-standard manufacturing as an opportunity, without going to the expense of creating a full cleanroom,” added Raine. By applying automation, even attaching the robot to the frame of the IM machine, functions from handling to packing can be performed within a compact, enclosed cell. This allows a manufacturer to diversify into highermargin, hygiene-sensitive markets, such as medical and healthcare products. “Once you have the filter and laminar airflow, the robot is sitting in a cell that’s cleaner than the average operating theatre,” he said.

A specialist robotics engineer can supply everything from the simplest 3-axis Cartesian-style system, to the highlyflexible 6-axis articulated arm robot.

According to Raine, the higher cost of a system incorporating a 6-axis robot, for example, is only partly attributed to the price of the equipment itself. Around one third of the installation cost is likely to come down to the systems integration expertise that is required to ensure it is a perfect fit with the wider IM operation.

“Historically, the 6-axis robot has been more difficult to programme than other robot types, making end users rather more wary of them,” said Raine. “However, in recent years robotics specialists have invested a lot of energy to ensure they are easy to program.”

Goodhew added: “With a 3-axis robot, it is easier to predict the trajectory of a particular movement, and so avoid a potential collision. With a 6-axis robot, you have so many flexible joints, or pivots, on the arm, there are endless possible permutations of how the head can get from A to B. The trick is in simplifying the software and programming so as to avoid the risk of collision.”

Price drop in real terms All these improvements and better tailoring to specific end uses have made it easier for IM customers to justify investment in automation. So too has the downward trend when it comes to costs. “Over the past 20 years, size-forsize, the price of a 3-axis system has stayed effectively the same. In some cases, it could be 10 percent or less,” said Goodhew. Factoring in inflation, this represents a dramatic price reduction in real terms. “There has been a similar drop in the cost of 6-axis systems,” he stated.

In fact, greater affordability of 6-axis robots means that the cost differential between 6-axis and 3-axis options has also been eroded.

Nonetheless, a customer’s willingness to invest in automation will often come down to issues of perception and knowledge of a system’s capabilities.

Some 20 percent of IM machines sold by Sumitomo Demag in the UK during 2013 had some sort of robotic feature.

Many injection moulding machines are being sold with automation, says Raine.

Here a Sepro robot is mounted on a Sumitomo Demag machine

Sumitomo Demag and Sepro are one of many partnerships formed by machinery suppliers and automation companies, as the industry leans towards increased use of flexible systems.

FURTHER INFORMATION: www.sepro-robotique.com http://uk.sumitomo-shi-demag.eu

* British Automation and Robotics Association (BARA) 2013 Full Year Report

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In-Mould Labelling

NEWS

A selection of products using Verstraete’s labels

Verstraete: “IML has a great potential for growth on a worldwide scale” The CEO of an In-Mould Label (IML) producer says that the technology has the potential for growth on a worldwide scale as highly decorated plastic packaging is adopted by a growing number of middle-class consumers in developing markets.

Koen Verstraete, CEO of Belgium-based Verstraete IML, says he believes that a growing middle class population in Africa, Latin America and South-East Asia is only the “starting point” for IML becoming a global packaging decoration technology as marketing managers look for ways to differentiate their products in an increasingly competitive market.

“The European market has already picked up on multiple IML innovations. As the ‘orange peel’ and ‘glossy’ look have become a market standard, brand owners look more and more to differentiate themselves through ’look and feel’ innovations. As for other continents, we see a shift from other decoration techniques to in mould labelling,” explained Verstraete.

“During the past two years, we have built our own worldwide network of IML experts, assisting our industry partners, customers and all newcomers in IML projects. We have opened our own offices in Boston, Sao Paulo, Beirut, St-Petersburg and Bangkok. IML has a great potential for growth on a worldwide scale.”

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The company has launched several IML innovations in the past year, of which it says its ‘DoubleSided’ and ‘Metallic IML’ lines are most popular.

“Important brand owners showed much interest as they are continuously looking for new packaging decorations,” said Verstraete.

The DoubleSided IML The Jotun paint pot uses labels are printed on both the Metallic IML labels sides, creating additional space for information such as product use suggestions, contents or mandatory nutritional or storage information. The Metallic IML labels focus on giving the packaging a premium metallic look by the use of cold foil.

“The paint, cosmetics, storage box and high-end food markets have shown much interest,” said Verstraete. “Various brand owners appreciate the extra branding and diversification opportunities offered by metallic IML. The transition from metal to plastic packaging using metallic IML is a guaranteed cost-efficient solution. Paint producer, Jotun, distinguishes its paint on shelf by using this innovative IML label, taking the benefits of plastic, although keeping the metal look.”

To cope with the worldwide demand for IML labels, Verstraete is investing largely in expanding its production capacity over the coming 12 months. The company recently hired an additional 40 employees, which it is in the process of training.

FURTHER INFORMATION: www.verstraete-iml.com

A new name in IML unveiled at Fakuma 2014 IML Xperts, a service provider and turnkey supplier for complete IML systems, exhibited for the first time at Fakuma 2014, where it unveiled its ‘3D Full Cover IML’ for manufacturing fully decorated containers made with cost-effective standard equipment.

With the new development of 3D IML Xperts is working Full Cover IML, the company says alongside Waldorf Technik it is “considerably expanding” the and Roth Werkzeugbau for complete IML systems spectrum of carton geometries and decoration options available using the IML process. A production line for 3D Full Cover IML was presented at Fakuma in conjunction with Weidenhammer Packaging, a supplier of containers.

What makes the system special, said IML Xperts, is the fact that these new types of containers can now be efficiently produced in an industrial environment immediately, due to the combination of standard IML automation (manufactured by Waldorf Technik) and standard IML tool technology (manufactured by Roth Werkzeugbau), complemented by expertise in the design of labels and in process parameters.

“The manufacturing costs for 3D Full Cover IML are no higher than for conventional IML cartons, but the attractiveness for the consumer is significantly higher,” explained Holger Kast from Waldorf Technik.

“Higher sales, better profits, that is the direct result for the food manufacturer and the supplier of containers,” With the equipment required reduced to standard components, the investment for 3D Full Cover IML is lower than previously available from individual niche suppliers, says the company.

The entire process from product design, via test quantities all the way to the commissioning of production systems including professional project management, is offered by IML Xperts as a package.

FURTHER INFORMATION: www.iml-xperts.de

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In-Mould Labelling

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NEWS New distance sensor and feedback system for label production launched Meech International has launched a new distance sensor and feedback system, the latest additions to the company’s Hyperion range of static control systems.

Compatible with the 971IPS and 929IPS bars, the add-ons are designed to help monitor and control static with greater precision in a variety of applications, including labelling and packaging.

Rapid, space-saving IML automation system demonstrated at Fakuma During Fakuma 2014 Beck Automation, a Swiss provider of automation solutions for IML labels in injection moulding technology, presented a system that it designed to be extremely space saving, fast and precise.

On Engel’s stand at the show, a manufacturing cell consisting of a fully electric e-motion 440/160 injection moulding machine, a two-cavity injection mould by Glaroform and an integrated inspection system from Omron showcased the system, which was producing a 500ml oval-shaped, thin-wall food container with an average thickness of 0.4 mm and a part weight of approx. 11 g.

“This IML system is compact and yet very easily accessible, meaning userfriendly,” explained Daniel Merki, Sales Manager at Beck. “As IML is a highly dynamic process, profitability is derived from the level of all system components.

In an initial step the labels are drawn in from the label hopper. In a second step, the labels are placed on the cores and held with vacuum. The automated cores move into the cavities to transfer the labels. In this stage the labels are blown against the vacuum, electrostatically charged and thus placed and held in the cavities so they are form fitting. This makes the level of process design and quality of the label key factors in process stability, reproducibility, unit quality and

The new Meech distance sensor launched recently

“The launch of these two new enhancements mark an important step forwards for Meech’s Hyperion range of static control solutions,” commented Matt Fyffe, VP/General Manager at Meech USA. “These new additions allow us to demonstrate how our ever-evolving range of static control technologies are able to meet the needs and demands of the labelling sector.”

The Distance Sensor is to be used in combination with Meech’s 971IPS static elimination bar, which is employed for long-range ionisation. The enhancement’s

Image 1+2: Labels by Viappiani (image source: Viappiani)

economic efficiency.”

The high-speed application (total cycle: 2.9 seconds, intervention time 0.9 seconds) is equipped with the latest in control and drive technology and operated via a touch screen, with the quality of the process monitored by a FZ3 camera system from Omron in Japan.

“The structure and number of camera inspection modules depend, among other aspects, on the control requirements of the packaging unit, cycle speed and the number of cavities,” continued Merki. It is the job of the Omron FZ3 vision system to identify defective parts, with the specific number of cameras needed defined by various factors relating to shape, size and quality.

The labels used for the container produced at Fakuma consist of a 60µ EUP orange peel film made of a material

main function is to enable a change in frequency when the distance to the static surface is either increased or decreased.

This means that the sensor will adjust the neutralisation according to the varying distance of the static surface.

The new feedback-enabled systems aim to provide high accuracy static control in production environments with the ability to output the voltage level for remote monitoring.

FURTHER INFORMATION: www.meech.com

IML high-performance cell by Beck Automation

Camera inspection system for more supply stability: It is the job of the Omron FZ3 vision system to identify defective parts.

called Treofan by Viappiani Printing Segrate (Italy). The rounded oval shape of the food container requires labels that are both stamped out with a high degree of precision, as well as complying with the short cycle time due to a good electrostatic charge.

FURTHER INFORMATION: www.beck-automation.com

INTERPLAS: SHOW REVIEW

www.quick-mould-change.com

A panoramic view of the halls before opening

Serious selling and high spirits during three-day show

V

Words: Leanne Taylor

isitor numbers and footfall was up, with the organisers saying the show an attracted over 10,400 attendees (pending BPA audit) for its 2014 edition, a number that represents growth of 10 percent Busy aisles at Interplas 2014 The three days of against 2011 figures along with increased exhibitor numbers and an Interplas saw buzzing expanded show floor. halls and high spirits constant enquiries from potential new customers. There is International attendance at certainly more optimism about the industry now.” as well as some Interplas also increased in 2014, Over at Resin Trade, the company said the public reaction to with visitors from 56 countries major stand sales, travelling to the NEC, Birmingham, its new marketing campaign had been positive and pleasing, with testament to the underlining the importance of the the stand “constantly busy” with enquiries throughout the course of the show.

UK plastics sector on the world positivity felt in “We wanted a modern representation of an industry that itself stage. the industry. is becoming more modern,” explained Alex Nunn, Marketing “Interplas has continued its resurgence under our management, Manager at Resin Trade.

“We’ve been inundated with enquiries at the and 2014 represents a second consecutive edition show that are for forward-thinking projects that with solid growth on all the key metrics of number “This is the best are more focused on 10 years into the future of visitors, exhibitors and space sold,” commented Interplas I’ve than stuck 10 years in the past. We want to Duncan Wood, COO and Event Director for the show.

“The key to the continued resurgence of Interplas been to in years. reflect that modernity with our branding and Interplas was the perfect place to introduce it.” under the management of Rapid News is the level People are here Manufacturer of antimicrobial and detectable of business created and executed at the event. The because they solutions, SteriTouch, exhibited for the first time post-show feedback this year, has been unequivocally at Interplas in 2014 and says it is already looking positive in this area.” want to be” forward to the next show.

Testament to this, Romi Machines UK announced “Interplas exceeded all of our expectations,” it had sold some 14 machines on the first day of said Joanna Wilson of SteriTouch. “The atmosphere was great, Interplas alone, Richard Hird of Premier Moulding Machinery said and we were kept constantly busy with enquiries for the full that the company had sold four machines and PMS UK sold its three days, with interest from a real variety of companies with Borsche BS150 moulding machine straight off its stand. antimicrobial and detectable requirements for a broad list of Also selling directly off his stand was Kevin Horne, Managing applications, from food packaging to flooring.”

Director of Renmar UK, whose three AEC gravimetric blenders Finally, those providing services and consultancy also said were being taken straight from the NEC to UK manufacturer, Chess interest was high. “We have nearly filled our enquiries book and Plastics, in Droitwich. have had loads of good leads,” said Alex Miles of the British “We’ve had a really good show – the footfall has been excellent Plastics Federation. and it’s the first time I’ve sold the machinery on display straight off Over at BBE recruitment, Nigel Hyde said having not exhibited the stand,” Horne told BP&R. at the show since 1999, the company was “very impressed” with “We’ve invested a lot in our stand this year. Three years ago we couldn’t have justified the cost, as people were coming to look attendance and said they’d had a successful show.

PlastikCity was also feeling the buzz, adding that it felt its and not buy. Now, however, people are coming ready to purchase stand was “one of the busiest at the show,” and said that the machinery and equipment, they are looking at the technology on numbers in attendance, as well as the high spirits of visitors, was the stand and asking about lead times and when we can deliver.” “a clear indication of the positive state of our industry.”

Materials exhibitors were also full of positive news, with Interplas will return to the NEC in Birmingham from 26th – Plastribution’s Duncan Scott stating that the show had resulted in 28th September 2017. several new customer projects and lots of detailed enquiries.

“This is the best Interplas I’ve been to in years. People are bp&r FURTHER INFORMATION here because they want to be,” commented Scott. “We’ve had www.interplasuk.com

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

“Plastics have an important and vital role in the UK economy”– says Shadow Minister at Interplas

I

ain Wright MP, Shadow Minister for Industry, said plastics have “an important and vital role in the British economy,” during his keynote address at Interplas 2014.

Speaking at the show, the Labour MP, who recently met with representatives of the British Plastics Federation and was briefed about business conditions, said that the industry represented one of the biggest success stories in UK manufacturing.

“In the 12 months to July 2014 plastic products contributed more to manufacturing growth than any other sector,” said Wright.

“Your industry has successful clusters around the country, not only in the North East where we have one of the largest clusters, but also in the North West too. And those clusters around the different nations and regions of the United Kingdom, based upon manufacturing, innovation and exports, could provide a real rebalanced and sustainable economic recovery.

“All credit must be given to you, your colleagues and everyone involved in your industry for your hard work, dedication, enterprise and resilience in ensuring that plastics, in the UK, are in such good shape,” he told the audience.

Wright said that there now needed to be an active industrial strategy that tackled both skills and finance in order to extend the lead that the UK has in plastics manufacturing.

Iain Wright MP speaking at Interplas

Wright started a day of presentations focusing on the UK’s resurgent automotive industry; including a selection on the opportunities for plastics companies within the UK’s automotive supply chain, light weighting, materials innovation and recycling as well as design and selection.

In the afternoon keynote, Luke Hampton, Supply Chain Development Manager at the Society of Motor Manufacturers and Traders (SMMT), discussed some of the key reasons why the UK automotive industry is excelling at the moment, and how plastics manufacturers can break into, develop and capitalise on the opportunities seen within it.

“Some of the biggest automotive companies see the UK industry as ‘the place’ to manufacture,” Hampton said. “There is massive opportunity coming for suppliers up and down the supply chain.”

FURTHER INFORMATION www.interplasuk.com

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INTERPLAS: SHOW REVIEW

www.quick-mould-change.com

COMMENT Strong show signIFIes a solid market In his regular column, Nigel Flowers, Chairman of the PMMDA, reflects on show success signifying and a solid market, as well as calling for participants in a new working group for EN Standard development.

W

ith the dust now settled on Interplas 2014, it appears to have generated a number of positive leads for members year. This boost to follow up on, reflecting the revived optimism in suggests that UK the plastics industry. I was struck by how busy the aisles and manufacturing is stands were; I do hope that all our members benefitted from the well positioned abundant opportunities to network and showcase their expertise. for a bumper In talking to colleagues throughout and after the show, the 2015. Looking feedback from the majority of exhibitors has been extremely at the PMMDA market positive, with good quality enquiries. survey for the first six months of 2014, while the overall Representatives from Sandretto said are at a record 10-year high, the adoption of “It’s certainly numbers “there was an exciting buzz about the electric technology has stagnated at around 20 percent. good to see the This is surprising given the investment many suppliers show which was very encouraging”, with Arburg adding “it was particularly market buzzing are making in their eIMM ranges, combined with the satisfying to secure high value orders inherent benefits of energy consumption, precision and again.” across a number of sectors during the repeatability. show.”

Finally, I would like to ask for your help. The PMMDA The ancillary equipment segment has been involved with EN standard development for was not overlooked, with Renmar saying it had “a really good many years, with UK representation on 11 of the 15 working show” with “excellent footfall.” From Sumitomo (SHI) Demag’s groups. In 2015 we are kicking-off a new working group to revise perspective, these comments really encapsulate the mood EN1612: Reaction Moulding machines. For anyone involved throughout the arena. It’s certainly good to see the market in production or use of these machines, I would welcome your buzzing again. input. If you’d like to be involved in the development of the next A successful show is usually a solid indicator about the state standard, please do get in touch: nigel.flowers@dpg.com of the market. As I reported in my last column, the UK injection moulding machine market is expected to top 550 machines this FURTHER INFORMATION www.pmmda.org.uk

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27.10.2014 15:52:41

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

Announced at Interplas: M&H Plastics’ Braille Tubes wins Bottlemakers Award 2014 M+H Plastics has won this year’s Bottlemakers award for its innovative new method of printing Braille characters directly onto plastic packaging.

A high-build varnish is used to print the dots directly onto the product using extremely accurate measures, ensuring the height of the Braille alphabet remains uniform throughout the packaging run.

“We are really pleased to have won this award,” Michael Pye, Decoration Manager at M&H, told BP&R when receiving the award at Interplas. “The Braille packaging has had good feedback from users so far and we are constantly developing it.”

Printing directly onto the product has significant benefits over labels which can be easily damaged or peel off, as well as being less likely to rub off or be damaged by liquid. Although developed for Braille, this process can also be used in traditional screen printing; allowing customers to highlight specific design features by utilising an embossed effect.

Samples of the Braille printing have been analysed by the Royal National Institute of Blind People (RNIB) and and measured against the Marburg and RNIB standards. The RNIB has validated the samples; readability was found to be good as the 0.30mm dot height is above average. This new technique complies with BS EN 15823 as an approved labelling system.

The judges announced that two RPC designs, the Tetrosyl ‘Demon Foam’ container and the ‘Extended Shelf Life Pack’ for Ragú, were both nominated for the ‘Highly Commended’ Certificate.

The Tetrosyl Demon Foam Container, a bespoke product for car shampoo with an integrated ‘foam gun’, features a profiled recess at the rear, deep enough to retain the gun flush with the container surface.

Moulded-in clips hold the gun in place and a second recess on the front provides pack strength and allows the gun’s operating switch to be accommodated.

The Extended Shelf Life Pack for Ragú offers glass-like transparency but with the added in-home safety of a non-shatter container. Further consumer benefits include easy re-closability thanks to the twist-off/screw-on lid and the pot being microwave, dishwasher and freezer safe.

FURTHER INFORMATION www.horners.org.uk

The winning Braille tubes from M&H

Announced at Interplas: Hydrophllic polymer for dental application wins Horners Award The highly innovative ‘self-sealing’ obturation points, Propoints, have been announced as the winner of the Horners Award for Plastics Design and Innovation 2014.

Propoints, a joint project by DRFP Ltd and Endo Technologies, are ‘self-sealing’ obturation points, designed for use in dental root canal treatment to replace existing materials and some techniques, which can cause damage to the tooth and increase the chances of reinfection.

“They are designed specifically to fit into the root canal and there is different file sizes that the dentists use so they get a very accurate fit,” Grant Riley, Production Engineer for R&D at DRFP Limited, told BP&R when collecting the award at Interplas.

“The main technology behind Propoints is a hydrophllic polymer, which ensures that the product swells in the tooth and fills all of the cavities to stop any infection, which is an improvement on the current techniques, which actually shrink a little bit.”

Propoints are a single-cone obturator, and so only one Propoint is required per tooth, unlike multi-cone lateral compaction techniques which a) create potential voids within the canal increasing chances of reinfection and b) result in lateral compaction which can potentially cause root fracture through the forces exerted.

Propoints solves these problems through single cone technology and exact fit engineered sizes, no compaction is required and its expansive qualities eradicates voids in the canal. In addition, Propoints as a plastic, unlike GP (a resin

The Propoints

based material most commonly used,) do not degrade over time; reducing the chances of retreatment.

Propoints are made up of a central plastic core surrounded by hydrophilic plastic polymer and were specifically developed for the root canal environment and drew upon contact lens technology.

They use polymer plastic technology to absorb moisture already in the canal to expand and create a seal. Propoints are a ‘smart’ plastic polymer, as they only expand where there is room to do so and up to a maximum of 20 percent.

Propoints are ‘clean’, manufactured in a clean-room and individually blister packed, preventing cross-contamination unlike conventional obturation points.

Propoints provide dentists with a fast, safe, bio-compatible, specifically-designed and innovative product which requires no additional equipment or techniques. They are CE marked and FDA approved.

The judges also nominated the Powerhoop, developed by Innertrak, for the Horners’ Runner Up award. This is a specialised fitness hoop, verified by Canada’s University of Waterloo Spine Biomechanics Laboratory, to reduce the waist size, tone and improve core strength.

FURTHER INFORMATION www.horners.org.uk

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INTERPLAS: SHOW REVIEW

www.quick-mould-change.com

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NEWS Announced at Interplas: G&A Moulding Technology acquired by RJG G&A Moulding Technology and RJG announced at Interplas that they plan to join forces in an acquisition effective from January 1, 2015.

G&A is likely to become “a division” of RJG, however, the company will retain its entire staff and will operate with a “business as usual” policy.

“There could not be a better synergy between the two companies,” John Goff, CEO of G&A told BP&R. “We share the same ethics and approach and the knowledge of both companies complement each other perfectly.” As an independent division of RJG, G&A will continue to provide support, training and advisory services to the UK market.

RJG says the acquisition will strengthen its existing global footprint and result in an organisation with unmatched capabilities to assist customers with consulting, training, and process optimisation services worldwide.

Since 1998, G&A has been a highly reputable and successful company serving many industries within the field of injection moulding in the UK, Europe, and worldwide.

“John and his team have a proven reputation as a premier consulting and training organisation that delivers superior value to their clients,” stated Rod Groleau, Chairman and Founder of RJG.

G&A is likely to become a division of RJG

“Advanced training of injection moulders is a key component of our mission and something we do with great pride and commitment. We are excited to be adding G&A’s capabilities to our team and to be adding a training facility in the UK for delivering RJG’s world renowned ‘Master Moulder’ training classes,” added Dale Westerman, President & CEO of RJG, Inc. FURTHER INFORMATION: www.rjginc.com www.gandamoulding.co.uk

Comment: Training and skills in demand at Interplas This month, Steve Shaw, Executive Director at RAPRA, reflects on a successful Interplas and looks at the need for skills and training highlighted by the enquiries received.

W

hat better occasion for RAPRA to identify the main developments and needs in the plastic industry than at the number one show for the plastics processing community, Interplas.

During the course of the show a steady stream of visitors to the RAPRA stand highlighted the desire within the industry for skills and knowledge development, with over 50 percent of the total enquiries relating to training.

We were encouraged by the amount of detailed enquiries from major companies we received, showing that there is a definite thirst for new opportunities and projects. We were also very pleased with the number of new companies looking to explore business prospects as well as partnering to expand our current technical support network.

Visitors and exhibitors benefited from our “More Profits from Plastics” presentations, delivered by our keynote speaker, Simon Canfer of the STFC and followed by Gary Howe at IPolytech, Bethan Dean at Exova Warringtonfire and John Goff from G&A Moulding Technologies, all experienced and dedicated experts in their area of operations.

The range of exhibitors was impressive, with some of the world’s best-known names in the industry featuring. The advances in the world of injection moulding were to be marvelled at, from energy efficiency to speed and precision. The upward trend for automation was evident, with the robots incorporated into some of the cells providing a hypnotic display.

The mood of the show was upbeat, showing a growing confidence in the UK market. We encourage companies of all sizes working within the plastics industry to develop new territories for an even more sustainable industry and offer additional support to encourage avant-gardism of plastics uses in their technical advances.

FURTHER INFORMATION: www.rapra.org

Tel: 01952 671918

Email: connectors.uk@staubli.com

years | tie-bar-less

See The Possibilities Only those who have a clear view can see new ways. That’s why we at ENGEL are always open to new ideas. We welcome inventive thinking in the plastics industry – in the shape of injection moulding technology that gives your imagination free rein. It’s been 25 years since the launch of the ENGEL victory, the injection moulding machine with the revolutionary tie-bar-less design that allows limitless innovation. Free yourself from the conventional, and do the impossible.

Visit our website for more information on tie-bar-less projects.

www.engelglobal.com

INJECTION MOULDING

Engineering Passion

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REPORT

www.kraussmaffei.com Over the course of the last few months, major machinery manufacturers have exhibited at some of Europe’s biggest trade shows, showcasing their latest technology, developments and upgrades. In the following article, Leanne Taylor looks at those reporting a successful 2014, highlights the key markets, trends and competition, as well as looking ahead to what’s in store for 2015.

Moulding the Trends WORDS: LEANNE TAYLOR Engel reports a steady sales high and says innovation will drive further growth Engel has reported it has sustained the high levels of growth it saw in 2012/13 with a projected seven percent increase in turonover when its current financial year ends next year.

Speaking at Fakuma in Germany, Engel CEO, Dr Peter Neumann, said that the company has generated some €935 million Euros in sales revenues so far worldwide in 2014, but remained tight-lipped about his feelings on potentially breaking the €1 billion mark by the end of March 2015.

“We will have to wait and see,” said Neumann. “Our financial year concludes on 31st March, so we will look at the figures and make an announcement only then. For now, we are satisfied with the projection of a seven percent increase.”

Neumann reported that the order situation “was good” and that despite political conflicts weakening individual regions such as Russia, the growth of formerly weak markets is compensating the decline.

China, the USA and Mexico continue to be the company’s fastest growing markets and Neumann told BP&R that the UK market had performed “very positively.”

“The UK has been a very positive surprise in Europe,” he explained. “There have been a number of projects for us with the

Engel launched the new Engel e-pic robot at Fakuma

major automotive manufacturers that have returned to the country.”

Engel said that automotive is an area driving sales for the company due to the rise of investment in innovation, with lightweight design one of the most important drivers.

“We have only seen the beginning of lightweight automotive engineering,” said Neumann. “In the field of fibre composite engineering in particular, we can look forward to strong growth in the injection moulding industry in the next few years.”

The company reported that the demand for complete production systems, as opposed to individual machines, is driving innovation due to the complexity of the integration required, as well as driving sales.

“The requirements are becoming increasingly complex,” as Dr Stefan Engleder, the CTO of Engel, commented. “Low unit costs, maximum productivity and sustainability can only be combined if all components of a manufacturing cell optimally mesh.”

Process integration and automation were reflected in the company’s exhibits at Fakuma, with the company premiering the new ‘Engel e-pic’ at the show, an efficient pick-and-place robot for small moulded parts and sprues.

The company also focused on 25 years of tie-bar-less innovation, as well as its ‘flomo’ system for process control.

Arburg highlights UK market as positive example of growth At Fakuma 2014 Arburg said that it was enjoying “particularly positive” results from its UK subsidiary thanks to the continued re-shoring of production to the country.

Speaking at the trade show in Friedrichshafen, Managing Partner, Michael Hehl, said that the UK contributed to what was shaping up Arb urg’s stand at Fakuma was to be an “extremely positive” year consistently busy that has seen continued expansion of production sites and sales figures expected to top €500 million.

“We do not like to speculate on figures,” said Hehl. “However, what I will say is that it is likely to be a bit above €500 million; it will be a figure worth mentioning.”

In terms of projections for an equally successful year in 2015, Head of Sales, Helmut Heinson, said he expected to see positive developments in China and the USA, with a slightly slower development in Europe than in the current year.

Although he was cautious to speculate on forecasts, said he imagined sales would stay fairly level, with “no serious deterioration.”

Arburg spoke at length about its development of the Freeformer, which as of Fakuma is on general sale to customers in Germany, with delivery of the machines due in March next year.

The Zhafir Zeres machine

Haitian and ZhaFIr get to the ‘point’ with application-focused technologies During Fakuma, Haitian and Zhafir introduced their latest products especially for the European market.

Both the Zhafir Zeres and Haitian Jupiter II Series are designed with a strong focus on application and are equipped strictly for performance in the production of standard parts.

“Haitiain aims to serve machines for the production of standard applications,” Uwe Baer, General Manager of Haitian Europe, told BP&R at the show. “Our ‘Technology to the Point’ slogan emphasises this, as we don’t have ‘over-equipped’ machines, simply those that are perfectly suited to what they do, which is fulfilling the core functions of modern injection moulding technology.”

Both Haitian and Zhafir say they intend to give processors machines with high dynamics, speed and precision, short setup times, great flexibility and savings on resources.

In the first six months of the year, more than 14,000 machines have been sold and delivered. In the process, the proportion of electric machines has risen considerably; the fully electric Zhafir Venus II Premium Series achieved an increase of 49.7 percent in turnover with a sharp growth in export trade.

Professor Dipl.-Ing. Helmar Franz, Board Member and CSO of Haitian International, confirmed this: “Also this year we can again

see growth in the electric machine sector.

I’m glad to say that more than 800 Venus II Series machines are already on the order books in 2014, increasingly from abroad.

More than 40 percent of our electric machines are exported. And it is on the rise.”

With the new Zeres Series, Zhafir says it is expanding the versatility of applications for the electric series, ensuring noticeably greater flexibility by adopting the dynamics and precision of the successful Venus II Series, as well as offering integrated hydraulics.

“The Zeres is perfectly tailored to the European market and we can already see the positive feedback,” said Baer. “Electric designs are increasingly in demand, especially in the small and mid-range clamping forces. And with the integrated hydraulics our customers now have more options for reacting more rapidly to new demands also using existing core pull moulds, for example.”

The second exhibit at the show was a ‘new-generation’ version of the twoplaten Haitian Jupiter II Series, which the manufacturer says it has introduced as a reaction to increasing demands, especially from the automotive industry.

The space-saving two-platen machine had already been upgraded in terms of design and technology for the last K-Show and is now also available in “small” tonnages starting from 4,500 kN. Externally, it is now much more compact and requires about 30 percent less footprint.

“The feedback for the Jupiter II has been extremely positive at Fakuma. Visitors are certainly surprised at how small the machine is and they are most impressed with the positive price-performance ratio,” Baer added. “We have sold both the Zeres and the Jupiter directly off the stand and we have been very pleased with the enquiries we have had.”

KraussMaffei expands injection moulding portfolio and puts small machines to the top of the class KraussMaffei has expanded its range of injection moulding machinery with additions its says makes its portfolio “more powerful, more energy-efficient and more versatile.”

The company launched two new sizes in its all-electric AX series, with clamping forces of 4,500 and 5,500 kN. In addition, it has added three new machine models for its GX series of hydro-mechanical twin-platen injection moulding machines. Both were unveiled for the first time at Fakuma.

“Our customers are increasingly asking for high-performance, energy-efficient and simultaneously space-saving solutions,” explained Dr. Hans Ulrich Golz, President of the Injection Moulding Machinery segment of the KraussMaffei Group. “With this in mind, we are working continuously on the expansion and continued development of our broad portfolio of all-electric, hydraulic and hybrid injection molding machines.”

The two new AX series product group additions, the AX 450 and the AX 550, have been developed as a result of increased demand for all-electric injection moulding machines with large locking forces, explained Jochen Mitzler, Head of Strategic Product Management for KraussMaffei.

Within the GX series the new GXH, GXL and GXV variants are said to offer the “perfect platform” for multi-component injection moulding. The feature a new, integrated turntable and a servo-electric drive unit to ensure especially fast rotations, parallel movement and precise positioning.

In addition to the new moulding machines, Krauss has reworked its CX small machine series, in the 350 – 1600 kN clamping force range and says it has “taken advantage of every opportunity to increase efficiency.” continued on page 30

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KraussMaffei put its small, CX series in the spotlight at Fakuma

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“Big machines are still important,” Golz told trade press at Fakuma. “In the last few years we have been very present in the market for large injection moulding machines, but we have a strong portfolio in the small machinery range and wanted to demonstrate that at Fakuma.”

KraussMaffei said from hydraulics and control software to automation, almost every component in the CX machines in the small clamping force range has been subjected to testing in a bid to refine efficiency, productivity and space.

“The CX series is already a successful product line. Our goal was to align this series more consistently with customer needs,” explained Golz. “Plastics processors should have the option of producing plastic with outstanding cost efficiency and flexibility.”

Specifically, the CX small machines are said to benefit from 10 percent less energy consumption, being 15 percent faster, 30 percent quieter, oil volume reduced by 20 percent, and 25 percent greater efficiency thanks to automation and faster set-up times.

“Additional highlights specifically for small machines include the new sprue picker, the ejector coupling and the BluePower Vario Drive concept. Like all machines from KraussMaffei, the new CX is equipped with the new Adaptive Process Control system (APC), which can immediately compensate for fluctuations in the injection moulding process,” explained Golz.

In terms of performance for this year, Golz told BP&R at the show that he was “very satisfied” with the results so far, with North America performing “very strongly’ in overall sales worldwide.

As for the performance of the UK market, Golz said it had been pleasing for KraussMaffei and Netstal. “Automotives have of course been a big driver for us in the UK this year,” Golz told BP&R. “However, medical has been a particularly interesting market for us too.”

In terms of the company’s progress and expansion, Golz said that there was no immediate plans for building expansion, however, it would be “ramping up production” in its production facility in China.

Billion makes a splash with In-Mould Assembly technology Billion chose to highlight the complex process of ‘In Mould Assembly’ (IMA) at Fakuma, producing a part combining plastic and water in a single cycle.

Partnering with MIHB, the company produced a hollow part from Eastman’s transparent Tritan co-polyester which was fully sealed, encapsulating water and a floating dice inside.

“The in-mould assembly process allows finished hollow products to be moulded on conventional or twin-shot injection moulding machines, using a double turning table,” explained Billion’s Marielle Bourgeon.

“Overmoulding, clipping or riveting within the mould secures the joint between the two halves. The product can also integrate inserts, filters or other components inside the tool, all in the same The fully-sealed part produced at cycle.”

Billion says the Fakuma made a main advantages ‘splash’ amongst of the process are visitors repeatability without defect, a very good welding thanks to overmoulding providing a perfect joint seal and a high internal pressure resistance.

IMA also helps to achieve productivity gains, with shorter cycle times and no manual operation. The process also benefits from cleanness, reproducibility and reliability.

The demonstrator produced on Billion’s stand at Fakuma was made of two transparent parts, a body and a lid, injected simultaneously with the first injection unit in two different parts of the mould. During the mould opening phase, the body and the lid moulded during the previous cycle were brought together in the central position of the mould, before the dice and water were integrated into the part and combined. In the last stage of the cycle, the overmoulding took place with the second injection unit sealing both parts together, before removal by a robot.

“The outstanding innovation is the ability to encapsulate a liquid inside the injected part during the injection process,” continued Bourgeon. Applications for this technology in the market include fuel tanks or windscreen wiper components for the automotive industry, as well as numerous household products such as irons.

“Multi-material know-how is definitely what Billion has specialised in developing over the past few years,” Bourgeon told BP&R at the show. “Twin-shot moulding is something we will continue to develop alongside our customers.”

Bourgeon said that 2014 had been a “very busy” year for the company, with export markets such as Europe and Africa providing

some 60 percent of sales. The UK market, she added, has been “great” for Billion this year, with the packaging sector performing particularly strongly.

15 percent sales growth for Wittmann thanks to an “automation year” Wittmann Battenfeld said its forecast for overall sales in 2014 at some €295 million was “pleasing”, however, the company was hoping to break the €300 million barrier.

Speaking at Fakuma, Michael Wittmann said that with a 15 percent increase based on figures from September 2014 against the previous year there was “no complaints” and that predictions for 2015 sales stood at €320 million.

“This year has most definitely been an automation year,” said Mr. Wittmann at the show. “Strong sales of our automation systems, including temperature controllers, as well as our EcoPower, MacroPower and vertical machines have been especially pleasing. In the coming year we expect that our new SmartPower and MacroPower lines will drive sales.”

Mr Wittmann said that he was “very pleased” with the sales performance in the UK market, stating that markets that had previously been fairly weak were performing “very strongly”.

The company is currently expanding its production capacity in Europe, by building a new hall for a machining centre for platens for its large machine ranges, as well as a completely new facility in Austria specifically for its materials handling equipment and robotics systems.

“We are building the new plant in Austria to enable new production capacity for our robots, as we have seen a strong demand for automation,” explained Company Director, Georg Tinschert.

During the trade fair the company launched a new machine in its ‘SmartPower’ series, on display for the first time at Fakuma.

The ‘SmartPower’ is equipped with servo hydraulics as standard and is the youngest member of the company’s PowerSeries.

“It combines the advantages of hydraulic machines with those of all-electric machines: energy efficiency, precision, userfriendliness, compact design, high speed and cleanness,” explained Mr Wittmann.

Wittmann said one of the company’s aims for 2015 was to increase its market share in Asia, where he said there was “huge potential” for the company.

Further Information: www.engelglobal.com www.arburg.com www.haitian.com www.kraussmaffeigroup.com www.billion.fr www.wittmann-group.com

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PLASTIC ELECTRONICS

NEWS

Solvay and Plastic Logic are working on low-power flexible electronics for items such as sensors, mobile displays and wearable devices (Credit: Plastic Logic)

Plastic Logic and Solvay Specialty Polymers announce partnership for low power FLexible electronics

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lastic Logic, the leader in the development and industrialisation of flexible organic electronics, and Solvay Specialty Polymers, a recognised leader in polymeric materials development for the electronics sector, have announced a partnership that they say will deliver low power flexible electronics suitable for today’s ever-changing world of ubiquitous sensors, mobile displays and wearable devices.

The companies have committed to a joint development programme that will initially demonstrate and then industrialise low power variants of such devices within two years. The technology will reportedly enable product designers to develop stylish, more ergonomically-friendly devices in several emerging industrial segments, including flexible AMOLED and other displays for mobile and ‘Wearables and the Internet of Things’ - markets which are forecast to be worth $12Bn by 2020 (IHS 2013 report) and $1.9 trillion across all sectors (Peter Middleton, Research Director, Gartner) in 2020 respectively.

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“It is gratifying to know that Solvay’s innovative polymers are contributing to the development of organic transistors and advancement of flexible display technology,” said Jens Hoeltje, Director of Strategy and Marketing from Solvay Specialty Polymers.

Plastic Logic’s revolutionary technology is based on an organic transistor that can be printed on plastic substrates using only low temperature processes (<100˚C). Since the transistor is the foundation of all electronic devices, this enables the fabrication of a wide range of applications on standard engineering plastics with exceptional manufacturing efficiency. Plastic Logic has already manufactured and delivered organic transistor arrays to drive flexible electrophoretic displays, flexible AMOLED displays, and read-out circuitry for high density image sensors.

Solvay Specialty Polymers has introduced a range of electroactive polymers, being marketed as ‘solvene EAP’, that have an intrinsically high dielectric constant, which enables high charge at low applied electric fields. Integrated with Plastic Logic’s transistor technology this creates a step change in the voltage requirements for electronics devices, says the company. The improved low power performance coupled with extreme flexibility and durability makes the combined technology ideal for wearable and ubiquitous sensor technologies.

Indro Mukerjee, CEO of Plastic Logic, welcomed the partnership, saying, “Flexible electronics is now a reality and forms an important foundation for the rapidly growing ‘Internet of Things and Wearables’ markets. Plastic Logic has been working with leading companies to enable the supply chain for these markets and we are pleased to now be able to also partner with Solvay to deliever very low power solutions.”

FURTHER INFORMATION: www.plasticlogic.com www.solvay.com

NEWS

SABIC’s LEXAN polycarbonate film

Collaboration sees “industry-FIrst” transparent conductive polycarbonate FIlm

T

he new material, designed to provide “next generation” functionality, has the potential to further enhance performance, enable new innovative applications and open doors for new With smart materials product designs, being one of the fastest Ernesto Occhiello, SABIC growing areas of Executive Vice President, Technology and materials technology, Innovation, explained.

SABIC and Cima NanoTech, This could translate a Singapore and US-based into faster response company, have announced touch screens for electronics, the joint development of consumer transparent “no-line” a plastics industry FIrst: anti-fogging capabilities a transparent conductive for automotive polycarbonate FIlm windows, better EMI that has the potential shielding effectiveness for electronics, and to revolutionise the transparent WiFi/ materials used in Bluetooth antennas consumer electronics, for mobile devices like household goods, smartphones, tablets, and all-in-one automotive, architecture laptops computers. and healthcare.

SABIC engaged in a joint collaboration with Cima NanoTech in the latter half of 2013 to develop the promising new material, which will be available for customer trials later this year.

“Transparent conductive polycarbonate is a breakthrough material that customers in consumer electronics and other important industries have been seeking,” Matt Gray, Director of Marketing, Consumer Electronics for SABIC’s Innovative Plastics business, said. “Our work with Cima NanoTech is strategically aligned with our commitment to continuous innovation in areas of importance to our customers,” Gray noted.

The collaboration, leveraging both Cima NanoTech’s proprietary ‘SANTE’ nanoparticle technology and SABIC’s ‘LEXAN’ film, a polycarbonate material, has resulted in the development of a new series of transparent conductive materials that are said to be lightweight with excellent transparency, outstanding conductivity and high flexibility.

“We are very pleased to be working with SABIC to bring the key advantages of SANTE nanoparticle technology forward into a number of diverse consumer and industrial markets,” Jon Brodd, Chief Executive Officer, Cima NanoTech, stated.

Cima NanoTech says the SANTE technology, a patented selfassembling nanoparticle technology platform, stands alone in providing high transparency with ultra-low electrical resistance, which is ten times better than the incumbent indium tin oxide (ITO).

“In addition to its ability to meet optical grade specifications for display and touch applications, SANTE nanoparticle technology is also more cost effective as coating is performed via a wet coating, roll-to-roll process versus sheet-to-sheet,” Brodd said.

Sima NanoTech’s proprietary SANTE nanoparticle conductive network as seen under a microscope

The conductive SANTE network is also mechanically robust, thus allowing it to withstand flexing, stretching, torsion and tension for flexible applications. The substrate can also be thermoformed into various curved and 3D form factors, says Cima NanoTech.

FURTHER INFORMATION: www.sabic-ip.com www.cimananotech.com

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PLASTIC ELECTRONICS

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NEWS First graphene-based FLExible display is a “signiFIcant step forward” he Cambridge Graphene Centre and Plastic Logic have successfully demonstrated a flexible display incorporating graphene in its pixels’ electronics; the first time graphene has been used in a transistor-based flexible device.

The partnership between the two organisations combines the graphene expertise of the Cambridge Graphene Centre (CGC), with the transistor and display processing steps that Plastic Logic has already developed for flexible electronics. This prototype is a first example of how the partnership will accelerate the commercial development of graphene, and is a first step towards the wider implementation of graphene and graphene-like materials into flexible electronics.

“This is a significant “This is a step forward to signifIcant enable fully step forward wearable and flexible to enable devices. fully wearable This cements the and FLexible Cambridge graphenedevices,” technology Andrea Ferrari cluster and shows how an effective academic-industrial partnership is key to help move graphene from the lab to the factory floor,” said Professor Andrea Ferrari, Director of the Cambridge Graphene Centre.

The new prototype is an active matrix electrophoretic display, similar to the screens used in today’s e-readers, the companies say, except it is made of flexible plastic instead of glass. In contrast to conventional displays, the pixel electronics, or backplane, of this display includes a solution-processed graphene electrode, which replaces the sputtered metal electrode layer within Plastic Logic’s conventional devices, bringing product and process benefits.

This joint effort between Plastic Logic and the CGC was also recently boosted by

The flat LED lamp

T

Polycarbonate enables precise manufacturing with printed electronics A special transparent polycarbonate from Bayer MaterialScience has been used to create a flat LED lamp using printed electronics.

The ‘F | limyé Flat’ lamp, is manufactured by EDC GmbH using Bayer’s Makrolon OD2015. The special feature of the LED lamp is a flat substrate made from this high-performance plastic. At just 1.8 millimeters, it is as thin as a CD and can be round or square. During injection moulding, tiny dimples 1.4 millimeters wide and 1.2 millimeters deep are incorporated into the substrate. These

Active matrix electrophoretic display incorporating graphene .

Credit: Plastic Logic

a grant from the UK Technology Strategy Board, within the ‘realising the graphene revolution’ initiative. This will target the realisation of an advanced, full colour, OELD based display within the next 12 months.

FURTHER INFORMATION: www.plasticlogic.com www.cambridge.ac.uk

then take the numerous small LEDs. “The polycarbonate’s outstanding reproduction accuracy enables much higher precision in forming the dimples than can be achieved with other transparent plastics,” said Axel Wetzchewald from the LED program at Bayer MaterialScience.

Bayer says the material grade was specifically developed for light conductors, optical systems and lenses, and provides a very high level of light transmission even with greater coating thicknesses. It is also shatterproof and is said to boast excellent dimensional stability across a wide range of temperatures. This enables the finely structured lights to be manufactured with great precision.

ECD has opted not to use conventional circuit board technology in the construction of the LED lamp. “All of the electronic elements required to operate the tiny LEDs, such as resistors and conductor tracks, are thinly printed onto the transparent substrate,” explained Eckehard Schulz, Project Manager for New Technologies at EDC. This, says Bayer, is where the excellent print quality of Makrolon OD2015 really pays off.

The lighting disk can also be fitted with flat auxiliary lenses or integrated optical systems that focus or diffuse the LED light as required. Diffusers, lens plates or reflectors can be combined or integrated to achieve uniform illumination. This gives rise to diverse potential applications for the lamp in living areas and kitchens, designer lights and shop and office lighting. Being lightweight, Bayer says the lamp is also ideal for mobile applications including cars, motor homes and the aviation industry.

FURTHER INFORMATION: www.materialscience.bayer.com

RECLAMATION & RECYCLING

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NEWS New recycling technology for maximum efFIciency and lower operating costs VECOPLAN AG, a provider of systems for the environmental and recycling markets, has launched a new process technology that combines shredding, washing and drying of various plastic materials in a closed process that is said to offer high efficiency and reduced costs.

Together with its partner, CVP (Clean Value Plastics) VECOPLAN AG says its engineers have invested more than two years of development work in the new ‘HydroDyn’ technology, which is now ready to be brought to the market and is said to generate significant advantages, both technologic and economic, compared to conventional systems.

“With this new process technology we offer plastic processing companies the possibility to recycle heavily soiled plastics at maximum energy efficiency and virtually unrivalled operating costs,” explained Stefan Kaiser, Head of Business Unit Recycling of VECOPLAN AG. This processing technology allows purification of shredded, heavily soiled materials including film, stretch film, hard plastics, packaging and technical plastics by high friction and strong circulating water flow. As a result, the company says high purity output particles are generated, free from pulp and adhesive contaminations that can be added as regrind directly into the secondary processes such as extrusion and granulation.

“While conventional washing systems operate with traditional hot washing causing high-energy costs, the hydro dynamic purification generates energy by friction, that is directly provided to the process,” said Kaiser.

The system requires no additional power supply, but uses the energy from the process in order to achieve impressive cleaning results more efficiently.

The HydroDyn technology works without any chemistry during the washing process, says VECOPLAN, with the conventional use of sodium hydroxide to remove adhesives from wafer-thin films obsolete. Furthermore, a

VEKA Recycling has received EuCertPlast accreditation

The new technology is said to be highly energy efficient and with low operating costs

water preparation technology has been developed that is implemented into the system and synchronised into the process that significantly decreases the water consumption, reduces the wastewater volume and minimises operating costs.

Due to the modular design, preconfigured and mounted on platforms, the VECOPLAN HydroDyn system can be integrated into any plant at any time and without any complication– into plants that need extension by washing systems as well as complete new facilities with plants for plastics recycling. Additionally, the modular design allows for very short on-site installation times and complete factory approval.

FURTHER INFORMATION www.vecoplan.de

VEKA Recycling secures EuCertPlas accreditation Kent-based VEKA Recycling, a UK-based PVC recycler, has achieved EuCertPlast accreditation, the European certification scheme for post-consumer plastics recyclers. Its sister plants in France and Germany are also similarly certified.

The certification works to the European Standard EN 15343:2007 and aims to encourage environmentally-friendly recycling of plastics by standardising procedures, particularly focusing on the process for traceability and assessment of conformity and recycled content of recycled plastics.

“This is an important step for us as the scheme assesses the good practice and the output quality done by the audited recycler,” explained Simon Scholes, Business Administration Manager for VEKA Recycling, which is a Recovinylaccredited PVC recycler.

He added: “Other benefits of the scheme include improved transparency and greater traceability of collected postconsumer waste. Given there is strong demand from the recyclates buyers for a guarantee on the product they buy, we can assure customers of our full compliance with environmental obligations and the high quality of our PVC-U pellet and pulver derived from post-industrial or postconsumer window frame material.”

FURTHER INFORMATION www.veka-recycling.com

Plastic is “ideal material” to demonstrate possible and proFItable circular economy Speaking at the RECOUP Plastics Recycling Conference and AGM recently, Dr. Helmut Maurer from the European Commission outlined its recent proposals and reFLected that more attention should be on plastic as a speciFIc waste stream.

He also questioned whether resources should really be addressed through waste policy and indicated that a rethink could be needed for the development of separate resource policies.

Maurer noted that too much plastic is sent to landfill which could be used and recycled and concluded that plastic is an ideal material to demonstrate that it is “possible and profitable” to move towards a circular economy model.

Dr. Maurer giving his keynote address

The event, held in Peterborough, also saw a video address from DEFRA Resource Minister, Dan Rogerson, confirming that he is passionate about the challenge and opportunity to deliver a step change in the recycling of plastics, as well as his support of RECOUP and the plastic supply and recycling chain in its ongoing work.

He also confirmed a Government and public body commitment to work with the plastics industry to achieve recycling targets and realise a genuinely resource efficient economy.

In a separate address, RECOUP’s Chief Executive, Stuart Foster, pointed to figures made available by the Environment Agency, suggesting that of the estimated £28 million that was received for plastics

PRNs in 2013, very little was allocated towards communications, despite initiatives such as ‘pledge4plastics’ being seen as critical to increasing household plastic recycling levels.

He identified that the RECOUP annual survey, due out soon, is likely to report household plastic packaging collection levels in the region of 475Kt for 2013, with further gains in the number of pot and tray collections and modest increases in bottle collections. It was also noted that the design for recyclability guidance would also be updated and re-issued before the end of the year.

FURTHER INFORMATION www.recoup.org

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RECLAMATION & RECYCLING

NEWS

(L-R) Mark Hunter, Nick Clegg, Roger Morton and Danny Alexander

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Deputy Prime Minister gets a rundown on recycling issues Innovation in recycling technologies and growing employment opportunities for graduates and apprentices captured the interest of the Deputy Prime Minister when he visited a Manchester-based resource recovery company during his ‘Northern Futures’ campaign in October.

Nick Clegg spent an hour at Axion Consulting’s Bramhall offices where staff, apprentices and placement students described key developments in their work, including recovering materials from fuel cells and from end-of-life vehicles.

He also met project managers running national collection schemes for recycling carpets, vinyl flooring and rigid PVC, and heard of the need for enforcement of environmental regulations to ensure a ‘level playing field’ for businesses like Axion.

He was greeted by Axion’s Commercial Operations Manager, Judith Clayman, and Axion Director, Roger Morton, who said: “Mr Clegg was clearly extremely impressed by the innovative work we’ve done in building our Trafford Park plant to recover metals and high-grade plastics from end-of-life vehicles that go back as new components into new cars like the BMW Mini.

“He recognised the value of our innovative process developments in green technologies and was also very excited by the collaborative research work that we are doing with Johnson Matthey and Technical Fibre Products on recovering materials from spent fuel cells.”

Mr Clegg was accompanied by Chief Secretary to the Treasury, Danny Alexander, Mark Hunter, MP for Cheadle & Bramhall and Liberal Democrat Chief Whip, along with Jeremy Meal, Liberal Democrat candidate for Bramhall South and Woodford.

‘Design-for-recycling’ with new industry guidelines Plastics Recyclers Europe has released a set of ‘design-for-recycling’ guidelines for PET trays.

These guidelines, one for clear thermoforms and another for coloured thermoforms, outline the basic principles for creating PET trays suitable for recycling. PRE says that its new guidelines represent the first compulsory step in this direction.

The group is also calling for dedicated sorting and the creation of a specific waste stream for PET trays. It believes that these two actions are essential to help reach upcoming EU recycling targets.

PRE said that it plans to call on the value chain (inclusive of converters, retailers, brand owners and raw material producers) to join forces and build up a ‘PET trays platform’, similar to the EPBP (European PET Bottle Platform – www. epbp.org).

FURTHER INFORMATION www.plasticsrecyclers.eu

FURTHER INFORMATION www.axionconsulting.co.uk

Plastic Recyclers Europe has releases a new set of design guidelines for PET trays

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PURGING COMPOUNDS

The new purging compound has been designed to reduce scrap rates when processing caps and closures for beverage packaging

NEWS New purging compound for clean colour and material changes in the processing of thermoplastics Chem-Trend has launched a new purging compound that it says can “significantly reduce” scrap rates from colour or material changes in the manufacture of thermoplastic caps and closures for beverage packaging.

The newly developed Lusin Clean 1060 purging compound has been specifically developed for the cleaning of screws, cylinders, nozzles and hot runner systems of injection moulding machines for parts made of polyolefin.

According to FDA regulations, all components of Lusin Clean 1060 are permitted for use in applications where a direct contact with food cannot be

excluded. The formulation of Lusin Clean 1060 is in compliance with European Plastics Regulation 10/2011.

Chem-Trend says Lusin Clean 1060 “rapidly and thoroughly” removes residue from injection moulding machines and is therefore particularly suitable for frequent colour or material changes. In addition, the new purging compound removes black spots, carbon residue and cracked

materials. The ready-to-use purging compound consists of high-grade plastics with high-efficient cleaning additives.

Lusin Clean 1060 can be used at processing temperatures up to 290°C. FURTHER INFORMATION: www.chemtrend.com

Purging with Polymer is it really saving you money?

M

any plastic processors still depend on standard polymers for purging based on the principle of a cost effective and straightforward purging solution – but is it really cost effective?

Richard Benyon, Director at There are advantages UK-based CJP Sales Limited, to using standard polymer, looks at the differences including having material on between using standard site or being able to utilise polymers and commercial regrind, however, when you compounds for the most count the cost of lost material effective purging solution. and production, a commercial purging compound comes out significantly cheaper.

The purging using the Dyna-Purge compound

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The purging using the PP

Unlike standard polymers, a product such as Dyna-Purge has wide processing parameters, with grades that range from 148°C – 287°C and 172°C– 310°C, allowing simple transitions between materials, such as purging Nylon 66 30GF at 290°C to PVC at 180°C. Standard polymers have set processing parameters and are designed to flow through your machinery as easily as possible, making for a less effective purge. These materials are also not engineered to clean carbon or lift pigment from low flow areas.

Dyna-purge, for example, is a mechanical, non-abrasive and non-chemical purging compound that gently scrubs the screw, barrel and hot runners. There is no need to change barrel heat settings, just fill the screw and let the compound lift contamination and colour.

A recent study carried out by CJP compared polypropylene (PP) to Dyna-Purge for a dark blue colour change, using a standard 120-second purge cycle on a 22 te BOY injection moulding machine. The Dyna-Purge produced two scrap mouldings, whereas the PP produced 120 scrap mouldings and 45 minutes wasted processing. The PP did not clean the machine effectively, unlike the Dyna-Purge.

Clearly, polymer is cheaper to purchase, but when one considers the lost production time, wasted polymer, cost to landfill, scrap or regrind to black, makes specialist purging compounds an overall more cost-effective solution.

FURTHER INFORMATION: www.cjpsales.co.uk

John Steadman (right) Aquapurge technical director, Richard Brayne

Aquapurge celebrates Interplas 2014 with European success Leading purging compound developer, Aquapurge, used Interplas 2014 to introduce its new French, Spanish and Italian subsidiaries to the UK market and with almost 200 contacts made, says it was “over the moon” with the show.

“Trade has been very brisk for the company up to and including the three days here at Interplas 2014,” said John Steadman, Aquapurge’s Technical Director.

“I am delighted that Aquapurge’s three new European subsidiaries are paying their way after just a few short months of trading and are enjoying the show so much. Our push into Continental markets will continue for the foreseeable future.

In addition to France, Italy and Spain we have excellent distribution via Berlin into Germany and are developing a number of other subsidiaries that are set to trade in 2015.”

On the technical side, Aquapurge used the pre-Interplas period to market a series of machine purging videos across a number of fronts. The company worked with other suppliers to the industry, such as G&A Moulding and Engel, in order in order to push home the purging message.

“Our video pages are a mixture of information and training, which was partly the reason for getting involved with G&A Moulding,” explained Steadman.

“Although machine purging is becoming more commonplace in the industry, we still have a lot more educating to do and Aquapurge is determined to play its part.”

The Aquapurge purging videos show a number of general technical points and also highlight ways to deal with traditionally difficult material changeovers; from PVC to Acetal, for example, or from Polyethylene to Polycarbonate or from Nylon 66 to EVA. Information is also given on product updates and developments, including a new and improved version of the Barrel Blitz Universal (BBU) compound designed for colour changes, material changes and carbon removal.

polymer in order to completely clear the production line and change from one colour change to another. That’s a lot of cost and time saved,” Steadman added.

Plastic blow-moulded container applications, typically from 0.5l upwards are set to see immediate benefits from Aquapurge Poly Clear HMEX especially in saving downtime; material up-cost (changing virgin into regrind) and colour contamination.

“Interplas 2014 gave us a great opportunity to once again preach the value of purging to our audience,” continued Steadman. “It’s becoming clear to all that a processor that can quickly purge its machines can avoid losing business by having to make new customers wait in line. A practice of machine purging thus gives suppliers an opportunity to flex with market demand and grow the business.”

“We now supply BBU in a powder formulation that completely clears out the screw and barrel of the machine – no need for temperature considerations; special operating programmes or cleandowns; just in and out in the quickest and easiest fashion, restoring the machine to brand new,” continued Steadman.

At Interplas, customers of Aquapurge involved in blow moulding were also testifying that regular purging means regular machine up time. “Just ten kilos of Poly Clear HMEX can save the blow moulder running almost 100 kilos of

FURTHER INFORMATION: www.aquapurge.com

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41 bp&r

PROCESS CONTROL AND MONITORING

42 bp&r

CASE STUDY:

A precise looK inside the cavity for zero rejects

I

n 1994, the German Soehner Group established Waldon Limited to provide local production of precision moulded components for a major customer, a global leader in alternator and starter motor systems.

The Kistler MultiFlow To meet the need technology In the following case for more production study, BP&R looks at how capacity, Waldon a process optimisation moved to its current site in Tonyrefail, and control system for South Wales, in 1997 production monitoring and for 12 years from Kistler Instruments achieved continuous has resulted in zero growth until 2009 when the recession reject parts for a UK began to bite, making precision moulder. a reassessment of its production A precision part processes essential to reduce internal rejects and manufactured by costs. At the time, the internal reject rate was Waldon in the region of five percent, which increased both production costs and the risk of rejects reaching the end customer.

“There is no future in seaside buckets manufacturer, and spades,” said Richard Kempa, Waldon’s however, was later Project Manager, when talking about the replaced replaced by a need to concentrate on precision injection Kistler Como Injection moulding, rather than trying to compete on system and sensors. price with countries having much lower labour “The Kistler Como costs. “To succeed,” he continued, “injection Injection system moulders in the UK and Europe must use the very provides us with best technology available, not only to produce often a window into the complex products with high precision but also to minimise or cavity,” said Kempa. “As even eliminate rejects.” It was this approach that he says led a result, within 12 months Waldon to install Kistler Instruments’ CoMo Injection cavity Waldon had become best in group pressure monitoring system in 2009. for product quality and, for the past three “Injection moulders Installed on an Arburg machine years, has consistently achieved virtually with a four-cavity mould equipped with in the UK and Europe zero reject production.” integrated cavity pressure monitoring Waldon now has three moulding machines equipped must use the very equipment, Kempa says the Como with Como Injection, including two with MultiFlow hot best technology Injection system “quickly proved its runner balancing. Adding hot runner balancing required available, not only to value” by simplifying machine setup produce often complex the Como system to and “virtually eliminating” rejects. be interfaced with products with high After the initial installation proved so the EFI Systems hot precision but also effective, Waldon decided to install an runner control system to minimise or even additional system to reduce internal already installed, which eliminate rejects,” reject rates of other production was made possible Kempa systems. In 2010, Kistler pressure

by EFI programming sensors and Como Injection were their controller to installed in its eight cavity mould used to produce automotive communicate directly with electric motor wire guide rings and quickly reduced the internal CoMo Injection. reject rate to less than one in a million.

Waldon is now expanding Despite this increase in productivity, a significant portion of into markets outside of An open mould on Waldon’s Arb urg Waldon’s production was relocated, as a result of a customer, the automotive industry, injection moulding machine accounting for some 40 percent of the company’s business, including medical, where moving its own production out of South Wales. a new contract for the Now with overcapacity, Waldon used its reputation for high production of 30 million precision moulded components for a quality, precision mouldings to rebuild the business and further product used in the healthcare sector is being negotiated. expand a developing relationship with an existing customer, a global leader in tyre pressure sensing. At the recommendation FURTHER INFORMATION: of its parent company, Waldon built new tooling, which was www.kistler.com fitted with a cavity pressure monitoring system from another

NEWS Dynisco extends machinery directive compliance to 4-20mA Pressure Sensors Dynisco has launched its range of 4-20 milliamp (mA) pressure sensors with the Guardian safety relay switch, so they meet the Performance Level ‘c’ (PL ‘c’) standard of the European Machinery Directive (EN ISO 13849-1).

The certified safety relay also complies with U.S. standard NFPA 79 clauses A.9.2, A.9.4.1, and A.9.4.3.2.

Pressure sensors with mA output are often preferred because, among other reasons, they allow for longer wire runs without process-control signal loss. However, until now, mA sensors have not been available in a Guardian configuration.

“A pressure sensor, used in a safety function on an extruder, is one of the machine components that must comply with the latest European safety directive that became effective in 2012,” explained Mike Davis, Dynisco Director of Product Management. “Compliance is required for new extruders put into service in the European Community and existing equipment being retrofitted by

The new, hardened pressure sensors

the manufacturer. In addition, extruder users who have a global presence and a desire to set uniform safety standards worldwide, or any company with a strong culture of safety, will want to protect their equipment and personnel by using Guardian sensors.”

Dynisco says the new sensors are the ideal choice for manufacturers and users of plastics extruders that need to comply with the European standard, or who simply want a higher level of safety in their equipment. The key Guardian component, says the company, is an internal relay safety switch. It responds to input from the pressure sensor bridge, detecting an open bridge, a loss of power to the pressure sensor or a user-selected pressure level.

Upon detecting one of these faults, the relay contacts open, sending a signal to

New sensors are hard on the outside but sensitive at heart Switzerland-based producer of process monitoring and control systems, Priamus, has developed a new procedure to manufacture cavity pressure and temperature sensors for use in injection moulds from a material resistant to abrasion.

The patented material is said to be extremely hard and chemically resistant, enabling it to withstand the abrasive, highly filled and chemically corrosive plastic melts that can gradually damage the front of the sensors.

“Alternative methods, such as thin layers of Titanium Nitride or chromed surfaces, have not proved themselves in

The Dynisco range of 4-20 mA pressure sensors

return the extruder to a safe condition.

The guardian-equipped sensors serve as a safety backup, bringing the extruder into compliance without the expense and complication of redundant sensors and external relay modules.

“When we first developed this relay mechanism, we applied it immediately to our millivolt (mV) and mA-HART sensors and it’s worked very well,” explained Bill Desrosiers, Dynisco Vice President of New Business Development. “By extending the Guardian safety function to the 4-20mA product line, we can offer PL’c’ compliance across the entire portfolio.”

FURTHER INFORMATION: www.dynisco.com

the past,” said Priamus. “This was because they did not withstand the wear, the surfaces were washed away, or because the outline of the sensor front could not exactly be mapped. The consequence was a visible mark on the moulded part.”

Cavity temperature sensors with the new, hardened sensor front are successfully being used in highly abrasive conditions, according to the company.

These applications have proved that even under such extreme conditions a significantly longer lifetime can be achieved.

FURTHER INFORMATION: www.priamus.com

43 bp&r

WE ARE YOUR GLOBAL PARTNERS

www. toolingportugal.c om

PORTUGUESE ENGINEERING & TOOLING MEMBERS 3DTECH, Lda.

INTERMOLDE, Lda.

MOLDOESTE II, Lda.

SIMOLDES AÇOS, S.A.

ANÍBAL H. ABRANTES, S.A.

JDD, Lda.

MOLDOPLÁSTICO, S.A.

TECNIMOPLÁS, Lda.

DISTRIM2, Lda.

LN MOLDES, Lda.

MPTOOL, Lda.

TECNISATA, S.A.

DT2 NEW CONCEPT, Lda.

MICROPLÁSTICOS, S.A.

PLANIMOLDE, S.A.

TJ AÇOS, Lda.

FAMOLDE, S.A.

MOLDEGAMA, S.A.

PMM, Lda.

TJ MOLDES, S.A.

GECO, Lda.

MOLDES RP, Lda.

PORTUTECMO, Lda.

UEPRO, Lda.

IBER-OLEFF, S.A.

MOLDIT, S.A.

RIBERMOLD, Lda.

VIDRIMOLDE, Lda.

IBEROMOLDES, S.A.

MOLDOESTE, S.A.

SET, S.A.

www.3dtech.pt www.aha.pt

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www.famolde.com www.geco-moldes.pt www.iber-oleff.pt

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www.microplasticos.pt www.moldegama.com www.moldesrp.pt www.moldit.pt

www.grupomoldoeste.com

www.grupomoldoeste.com www.moldoplastico.pt www.vangest.com www.planimolde.pt

www.pmm-moldes.com www.portutecmo.pt www.ribermold.pt www.set.pt

www.simoldes.com

www.tecnimoplas.pt www.tecnisata.com www.tj-moldes.pt www.tj-moldes.pt www.uepro.com www.vidrimolde.pt

NEWS Thermoplastics ‘bowl over’ the world of cricket A. Schulman, an international supplier of high-performance plastic compounds, powders and resins, has developed a PC/ ABS compound to replace fibreglass in professional cricket helmets.

A. Schulman’s Perrite division’s Ronfalin C PC/ABS is the first thermoplastic material to replace fibreglass for use in sports goods.

Perrite’s Ronfalin C is used instead of glass fibre in the shell of the professional Masuri cricket helmets.

“Masuri, the creator of the most widely used professional cricket helmets, approached us with the challenge of developing a ‘next generation’ helmet,” explained Tim Combes, General Manager of Hampshire-based B M Injection, a technical moulder and tool maker.

“Masuri wanted the new helmet to use the principals of their proven double skin, fibre glass and polyurethane foam sandwich construction. We contacted Perrite, our long-term supplier of engineered materials, knowing that their technical teams could propose the right material to meet these challenging requirements.”

The England team helmet

TPU panels make vehicle scratches less of a prickly topic Innovative technologies from PolyOne Corporation have enabled Citroën to launch groundbreaking exterior protective panels on the new C4 Cactus passenger car.

Working closely with the Citroën design team, PolyOne developed a specialty OnColor Smartbatch colour and additive system that allows the distinctive ‘Airbump’ panels to meet stringent UV stability, appearance and durability requirements.

Heinrich Lingnau, Vice President and General Manager, EMEA, for A.Schulman, said: “One of Masuri’s wishes was to design a helmet which would exploit the impact and shock absorbing properties of our C PC/ABS material to produce a light weight, protective helmet.

In fact, each component of the helmet was carefully designed using a material which could guarantee the maximum protection of the players.”

In addition to the material used for the helmet’s shell, A. Schulman provided BM Injection with the glass filled polyamide for the rim. “This is colour matched to the four colours of the helmet’s cloth layer in navy blue, maroon, dark green and black. Originally, we purchased the nylon in natural and tried to masterbatch ourselves. However, being glass filled nylon, we really struggled to achieve a good consistent colour match of the rim to the cloth,” explained Combes. “We asked Perrite to help us and they now offer a colour compounded glass filled nylon grade which has significantly reduced our waste.”

The result of the teamwork between the raw material producer, B M Injection and Masuri was a product, which according to the users, looks and feels even better than the original helmet.

FURTHER INFORMATION: www.aschulman.com

“We are thrilled at the opportunity to be part of this effort by bringing enabling technologies to the Citroën team as they pioneer new directions in automotive design,” said Christoph Palm, General Manager, Colour and Additives for PolyOne. The air-filled Airbump panels, manufactured from thermoplastic polyurethane (TPU), can compress up to 20mm, and bounce back to shape in an instant.

Citroën says that this will reduce the cost of vehicle ownership by reducing damage due to everyday bumps and scratches, such as those from shopping trollies or the doors of other vehicles.

“By working with Citroën and its Tier One suppliers, we were able to develop an advanced solution that provides the panels with uniform, attractive, and durable colour despite exposure to sunlight, heat, and detergents,” Palm continued.

“TPU materials are rarely selected for a vehicle’s exterior, but by working together, we were able to overcome several material-related challenges.”

FURTHER INFORMATION: www.polyone.com

PolyOne technology is used in the protective side panels of the new Citroën Cactus

45 bp&r

EINGINEERING MATERIALS

46 bp&r

NEWS New materials solutions for automotive lightweighting and surface aesthetics Borealis and Borouge have introduced several new and upgraded material solutions that they say have been engineered to enable the automotive industry to achieve greater cost efficiency, higher performance and improved sustainability in vehicle components.

The companies say the new lightweight grades, ‘Fibremod WE380HP’ and ‘Daplen EE058AI’, are representative of their commitment to offering new and multi-faceted solutions to automotive OEMS around the globe.

“Borealis and Borouge are attuned to the needs and demands of the automotive industry,” said Harald Hammer, Borealis Vice President of Engineering Applications. “We will continue to develop lightweight PP solutions for automotive compounds that not only help our customers and partners achieve broader, long-term sustainability objectives, but also enhance automotive surface aesthetics.”

In so-called hybrid grades, reinforcing polypropylene (PP) with a combination of glass fibre and mineral filler yields a special performance grade. As one such grade, Fibremod WE380HP is a new hybrid PP compound comprised of 20 percent glass fibre reinforcement and 10 percent mineral filler. It is intended for use in both structural and visible automotive parts, such as underthe-bonnet (engine covers, gear housings) and high-end interior applications (window frames, arm rests). As a replacement for other materials, Fibremod WE380HP is a lightweight solution that contributes to lower fuel consumption and reduced CO2 emissions without compromising on visual aesthetics or performance. The grade can bear a high mechanical load, offers excellent processability, outstanding dimensional stability, low warpage, good heat resistance and allows for self-colouring, according to Borealis and Borouge.

The recently-launched thermoplastic olefin (TPO) compound, Daplen EE058AI, is not only lightweight, but also offers tiger stripe-free technology, as does the upgraded Daplen EE189HP. The phenomenon of tiger stripes – the visually recognisable periodic change of surface gloss – is caused by converting processes and is a general problem of all thermoplastic

Fibremod WE380HP is a new hybrid PP compound intended for use in both structural and visible automotive parts as well as highend interior applications.

Photo: © Borealis

materials, including polyolefins. The newly-developed, tiger stripefree TPO compound Daplen EE058AI is said to boast an excellent property profile and is designed to be a fitting replacement for conventional T15 and T20 interior materials.

FURTHER INFORMATION: www.borealisgroup.com www.borouge.com

Things heat up for DSM with launch of ‘next DSM launches generation’ highnext generation of temperature Diablo high temperature polyamides resistant polyamides at Royal DSM, the global Fakuma 2014.

Life Sciences and Materials Sciences company, launched its next generation of Diablo high temperature resistant polyamides at Fakuma 2014.

The new grades are part of both DSM’s Stanyl polyamide 46 and Akulon 6/66 portfolios and are aimed at applications in automotive engine compartments where temperatures can reach as high as 260°C. The company said the technology provides a “significant improvement” in long-term temperature resistance components, such as air intake manifolds with integrated intercoolers, ducts, charge air cooler end caps, mixing tubes and resonators used in the latest car engines.

The latest version of Stanyl Diablo polyamide 46 is able to withstand a continuous use temperature of 230°C, while the new Akulon Diablo withstands a 220°C continuous-use temperature.

DSM says both new grades have improved resistance to short-term high temperature peaks as measured by deflection temperature under load (HDT).

New Stanyl Diablo has an improved HDT of 267°C, while the new Akulon Diablo has an HDT of 245°C. The long-term heat ageing and the HDT of the new materials are proof of their superior characteristics compared to competing materials currently on the market, the company told press at Fakuma.

The new grades also have improved resistance to chemicals and gases in EGR (exhaust gas recirculation) systems. They have very good processing properties and create finished parts with high burst pressure weld-line strength as well as excellent surface finish.

FURTHER INFORMATION: www.dsm.com

In association with Hardie Polymers – www.hardiepolymers.com

// Materials Technical//

Blog

This month, polymer expert and technical blog author, Dr Charlie Geddes, looks at how to avoid getting caught out by creep.

Creepy things can happen with long term loading of thermoplastics

Designers and users new to thermoplastics often get caught out by ‘creep’, the quaintly named but descriptive term for long term deformation. When a load is applied to a thermoplastic there is an immediate deformation due to stretching of polymer chains, which is largely reversible, but some are unaware that, over a long period of time under load, there is a slower increase in deformation due to unentanglement and slippage of polymer chains, most of which is reversible. The irreversible part is the viscous component of viscoelastic materials.

Creep deformation (creep strain), as well as increasing with time and with increasing load, is also sensitive to temperature, particularly above the glass transition point. After one year at room temperature under a modest load of five MPa, polypropylene exhibits creep deformation of 1.5 percent. Under the same conditions polycarbonate would deform by only 0.2 percent. At a service temperature of 60ºC, polypropylene creep deformation increases to 2.5 percent for the same loading.

Deformation under creep conditions, as well as increasing with time, load (stress) and temperature, is reduced by increasing the level of crystallinity, by the addition of fillers and by introducing crosslinking. Because of its higher crystallinity, polyacetal (POM) is five times more resistant to creep than polypropylene.

In designing components that will be subjected to long-term loading, designers should use creep modulus values instead of the normal short-term modulus in mechanical design equations and finite element analysis. Because comprehensive creep data is expensive to generate, the data will not be readily available for all grades and designers may have to use data for similar grades. Components should be designed to avoid long-term loading as much as possible, for example in snap-fit assembly.

Extrapolating creep data to longer times can be risky, with the possibility of material failure (creep rupture) lurking just around the corner.

Got a view on the above?

Blog posts will also be published on the BP&R website at www.britishplastics.co.uk - feel free to leave your comments.

SOFTWARE DIRECTORY manufacturing management directory enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com Epicor’s ERP (on-site, hosted & SAAS) manufacturing software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution.

It seamlessly integrates with Epicor Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.

real time production monitoring, scheduling and process monitoring Epicor Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: ukmarketing@epicor.com Modules: Production Monitoring, Process Monitoring, “Drag and Drop” Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts’ Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/ Public Address System Alerts, Stand-alone “Drag and Drop” Scheduler, Stand-alone SPC “Machine Analyzer”, Machine Energy Monitoring, KPI Dashboards, Visual Manufacturing (Large LED Displays), Automatic Data Import/Export Functions (For Integration with Epicor ERP & Other Manufacturing Systems/Software Packages).

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, Stand-alone 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 realtime 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.

47

A listing in the Software Directory costs £140 per bp&r programme per year. Call Lisa on 01244 680222 for details.

BUYER’S GUIDE

Eclipse Buyers Guide_Layout 1 07

MATERIALS

EQUIPMENT

MOULD RELEASE 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.

ultrasonic welding 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

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.

MATERIAL HANDLING InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk

DOSING EQUIPMENT Telsonic UK Ltd

12a - 15 Birch Copse, Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: info@uk.telsonic.com W: www.telsonic.co.uk Blog:www.telsonicuk.wordpress.com

POLYMER DISTRIBUTORS ANCILLARY

vibration welding Branson Ultrasonics

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

MASTERBATCH

CHILLERS/TEMPERATURE CONTROLLERS Motan Colortronic Ltd

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

MATERIALS MOULD RELEASE

FOR SALE Reheat Stretch Blow Moulding Machine (PET)

EXTRUSION SYSTEMS extruders and downstream equipment Cooper Plastics Machinery

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

New and used. Repairs, servicing or rebuilds.

UK agent for Lyons Electronics.

DRYERS

Make: Sidel, France Type: SBO 24/24 Year: 1994 - Preform Tipper, Hopper / Elevator, Infeed Rail - Oven & Heating Wheel - Electrical Cabinet (Siemens S5) - Operating manuals

colour masterbatch

For further details: 01925 596170 – 07838138342 Email: douglastrading@gmail.com

ASSEMBLY hot plate welding

thermocouples

Branson Ultrasonics

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

pulse staking H.T.E Engineering Ltd

48 bp&r

Unit 9, St Ives Enterprise Centre, St Ives, Huntingdon Cambridgeshire, UK, PE27 3NP T: +44 (0) 1480 467321 M: +44 (0) 7435 967632 E: john@hte.ie W: www.pulsestaker.com

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

ANCILLARIES

DRYERS/DEHUMIDIFIERS 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

INJECTION MOULDING

mixing, feeding, drying

SCREEN CHANGERS

Motan Colortronic Ltd

Industrial Plastics 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

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

3D PRINTING

3D Printing

Motan Colortronic Ltd

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

HEATING EQUIPMENT

in Plastic & Rubber

NOZZLES & NOZZLE TIPS

Tel: 01420 88645

www.projet3d.co.uk

MATERIALS HANDLING AND STORAGE

STATIC CONTROL

gravimetric/volumetric blending

Arrowquint Ltd

SECONDHAND AND RECONDITIONED

Motan Colortronic Ltd

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

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

ANGLO PLASTICS LTD

TO ADVERTISE IN THis SPACE

hopper dryers

CONTACT LISA MONTGOMERY 01244 680222

LABORATORY MACHINES

PRINTING MACHINES pad

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

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.

TESTING EQUIPMENT

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

DTL Machinery UK

We Buy / Sell all Makes, Age and Sizes of Injection Moulding Machines & Ancillaries Tool room machines and also complete factories / plants Factory Clearance Services Dismantling / Removal of obsolete plant and machinery T: 01925 596170 M: 07838138342 E: douglastrading@gmail.com

hopper loaders

Ray Ran Test Equipment Ltd

HOT RUNNER SYSTEMS

SCREWS & BARRELS

hot runner controllers

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

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

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

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

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

T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

49 bp&r

BUYER’S GUIDE

EQUIPMENT TESTING EQUIPMENT

World leader in Materials Testing Instrumentation Tensile|Fatigue| Impact Compression|Melt Flow Coronation Road, High Wycombe, Bucks HP12 3SY, UK Tel: +44 1494 464646

www.instron.com

inspection & measurement

TAMPO.SCREEN.FOIL

Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com

For DOSS visual solution of Italy – Inspection & sorting machines for O’rings, Seals, Gaskets.

T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

SERVICES

Clayton Thermal_Layout 1 19/04/2

CONTRACT CLEANING Injection Moulding Extrusion • • • • • •

RECYCLING SYSTEMS

MOULDFLOW ANALYSIS

MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER

CONTACT LISA MONTGOMERY 01244 680222

50 bp&r

Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at

PARTS & SERVICE CHOOSE THE NUMBER ONE.

TESTINg/CONSULTANCY

Hot Runners Nozzles Moulds Dies Filters Screws

FLEMING

Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in: Capillary rheometry FTIR DSC/TGA MFR/MVR Extrusion Pilot-scale blown film Line Instrumented impact Flow simulation Tel: +44 (0)1299 253300 www.flemingptc.co.uk

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

TO ADVERTISE IN THis SPACE

EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.

INJECTION MOULDING EXTRUSION FLOW ANALYSIS PRINTERS printers of plastic mouldings Total Print Ltd

Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry

FLEMING

Polymer Testing and Consultancy An independent ISO9001 accredited laboratory specialising in the flow simulation of: Extruder screws & spiral mandrel,flat spiral,profile, coathanger & coex dies Compuplast distributor Stop guessing start simulating Tel: +44 (0)1299 253300 www.flemingptc.co.uk

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

cx.kraussmaffei.com

We have made our smallest one top of the class.

The new CX.

Engineering Passion

plastribution.co.uk/whos-who

Experts in engagement

0845 34 54 560