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Incorporating Polymer Age and Rubber and Plastics Age.
GAINING A COMPETITIVE EDGE, SUSTAINABLY
By definition, sustainability means operating in a way that maintains or improves the needs of future generations. But for manufacturing companies, it also means reducing energy consumption whilst maintaining a balance between quality, economic viability and operational efficiency. As such, companies are putting their efforts into developing innovative solutions that offer energy efficiency and environmentally-friendly practices, while upholding their promise.
One way this can be achieved is through temperature control solutions where keeping waste to a minimum is the main goal. We’re seeing the likes of ICS Cool Energy and Wittman committing to advanced temperature control systems that minimise energy waste, prevent overheating and ensure that energy is used only where it’s needed. Couple this with automation integration and manufacturers can adjust healing and cooling processes based on real-time conditions. Not to mention predictive maintenance that can identify potential equipment failures before they occur, and thus, prevent any energy losses ahead of time and avoid production delays. Wittmann’s software, for example, tracks key figures for each production cycle which includes the associated CO2 emissions. This is calculated from the energy consumption and the amount of raw material processed.
Another area that is driving sustainable change in moulding processes is the implementation of renewable energy. LightManufacturing is just one of the companies that is shifting away from fossil fuel reliance and replacing it with solar energy. The company’s SRM innovation uses a field of suntracking mirrors that concentrate sun rays onto a rotating mould. As a result, the plastic is successfully heated and moulded without a single drop of fossil
“Aft er all, the environmental value of a product is only as good as its source.”
fuel energy. What’s more, is that these systems can use solar power even during periods of low solar irradiance or high energy demand.
Finally, with increasing pressures on the UK plastics industry, material selection is another area that’s being explored, especially on the supplier’s side of the chain. By proactively encouraging their customers to switch to alternative materials, customers won’t feel obliged to follow the ‘we’ve always used this material, so will only use this material’ tradition. In turn, suppliers can approach customers with renewable resource options that provide traceable origins and verifiable carbon footprints. After all, the environmental value of a product is only as good as its source.
The plastic manufacturing industry is at a crossroads. With sustainability no longer an option, companies seeking long-term success must demonstrate a genuine commitment to alternative practices.
EDITOR
DYNACON CUSTOM CONVEYORS
REBEKAH
JORDAN
YOU AND
“Since buying our first Yizumi D1, we have bought a further four.”
Yizumi D1 machines are playing a key role in Norham Plastics ISO 9001 accredited operations, providing the scope to produce products up to 20kg shot weight.
Operations Director Angela Clarke, said: “When we needed a machine to replace an older one, we looked around the market and Yizumi had the best combination of specification and value. Since then we have bought a further four Yizumis up to 2700 tonnes, and we are really happy with them and the service that STV provide. An unexpected bonus was the excellent energy saving of the servo hydraulics; we would definitely recommend Yizumi and STV.”
Norham Plastics puts its trust in Yizumi and STV. Will you? Give us a call today, to discuss your application or arrange a visit to our showroom and workshop.
MODEL SHOWN: YIZUMI D1 SERIES
SCOTLAND
Hardie Polymers celebrates 100 years
Founded in 1924 as J&G Hardie, Hardie Polymers, the UK-based polymer supplier, celebrates its 100th anniversary this month.
During the 1960s and 70s, Cycolac ABS was one of the earliest engineering plastics available. Hardie was closely involved with supplying the material to Hoover for the manufacture of vacuum cleaners, to NCR for cash register machines, and to the Singer sewing machine company.
By the 90s, the business had evolved to be a major distributor of injection moulding machines and substantial growth was driven by the rise of mobile phone manufacturing.
With the news of one of Motorola’s manufacturing facilities closing in early 2001, the Hardie business needed to pivot its strategy to survive. What followed was a tough period, but by focusing efforts on polymer sales, the business expanded its customer base throughout the UK and has never looked back.
“Technology will be a driving force in shaping the future of the polymer industry."
In 2021, Isy Ferguson, managing director, and Bartosz Komanski, commercial director, completed a management buyout, that was backed by the team at Nevis Capital LLP.
Isy said: “2024 is a real milestone for us. We’ve built many longstanding, collaborative, customer relationships, and we’re proud to have supported so many vital industries throughout the years, and to still be a critical part of the supply chain today.
“As customer needs evolve, so too does our product portfolio. We’re continuously exploring new materials and applications, particularly those that support sustainability and energy efficiency. Our goal is to ensure that we remain at the forefront of the industry.”
Bartosz added: “Technology will be a driving force in shaping the future of the polymer industry. From advancements in material science to chemical recycling and more efficient manufacturing processes, we see technology enhancing our ability to deliver innovative solutions. We’re already embracing digital tools and smart technologies to improve customer service, optimise supply chains, and reduce our environmental footprint.”
Isy concluded: “As we celebrate our 100th anniversary, we remain committed to innovation, integrity, and the responsible use of polymers - principles that will guide us into the next century. Whether it’s pioneering the use of new materials or expanding our product portfolio, we’ve always strived to combine technological advancement with responsible practices.”
After 100 years of trading, the Hardie business supports customers in the automotive, aerospace, electronics, defence, medical, and trade moulding industries. Its customer base spans the entire UK, and it is firmly established as an independent engineering polymer supplier.
To celebrate its anniversary, the company has unveiled a fresh new visual identity.
Getting to GRIPS with the latest in sustainability and plastics
Q. What do you think the most pressing issues are today regarding sustainability and plastic?
HJ: For many years now, plastic has been in the spotlight – understandably. But it is important that there is a focus on the sustainable use of plastic – backed by sound science. A key part of this is how it is managed at end-of-life and ensuring there is the infrastructure to enable effective recycling but also considering higher up the waste hierarchy as well. A big piece of our work at the BPF involves explaining the benefits – and necessity – of the material and the many opportunities plastic offers in terms of reaching sustainability and net zero goals, including product preservation and lightweighting - but also its key role in renewable energy.
SB: Plastic is a versatile material but it has to be used and managed correctly - it has to be dealt with appropriately when products are no longer needed. We rely upon it for medical devices, packaging, electronic technology, transport, packaging, to provide green energy – and so much more. Using plastic where it is needed while minimising the amount that ends up in landfill or as energy from waste remains the focus of many organisations
Richard Brown, Chair of Judges Design Innovation
Innovate UK Business Connect UK Circular Plastics network founder Sally Beken and British Plastics Federation sustainability manager Helen Jordan talk to BP&R about sustainability, the future of plastics and why the two organisations chose to partner on an upcoming conference.
today. It’s about getting the balance right and making changes based on data-driven evidence.
Q. Will reuse play a big role in a more sustainable future, in your opinion?
HJ: It is likely to play a bigger role than it does today, particularly with the targets in the Plastic Packaging Waste Regulations (PPWR) which, although not directly applicable to the UK, are still likely to have an impact. However, it still faces many challenges and it is hard to understand the precise form it will take. Reuse or refill
Dr Sally Beken
systems need to have a lower environmental impact than single-use options, while also being convenient and addressing hygiene and safety concerns.
SB: It is important to respect the waste hierarchy – and reuse sits above recycling. But, as mentioned already, numerous factors need to be overcome for a reuse system to be viable on a large scale. There is a lot to be done to change consumer behaviour/ acceptance of new systems and the move to reusable packaging needs to be a just transition that benefits all. Finally, reusable packaging
Robin Kent Managing Director Tangram
itself should be recyclable at the end of its life – it will not last forever.
Q. Explain the story behind GRIPS.
HJ: After various discussions, the BPF and Innovate UK decided to partner on the 2024 event, as we thought the expertise and audience of our two organisations could help the event to evolve. Sustainability is only growing in importance. To underscore the event’s place as a hub where industry and academia meet, we are holding the event at the University of Sheffield (hosted by the Grantham Centre for Sustainable Futures). There will be around 60 speakers at this one-day event, spread across three rooms.
SB: For many organisations wanting to make plastics more sustainable there is often a lack of understanding about the rest of the supply chain. It’s this broad understanding that underpins effective system change — and what
Dr Carmen
HELEN JORDAN
SALLY BEKEN
better way for us to undertake knowledge transfer than get these people in the same room discussing change?
GRIPS is an event and the acronym stands for Global Research and Innovation in Plastics Sustainability. It was first held in 2021 as a virtual exhibition. It had 186 speakers and 3,106 registered to attend from around the world. It was organised and run by Innovate UK KTN (now Innovate UK Business Connect), supported by UKRI and hosted by the UK Circular Plastics Network.
GRIPS was held again as an online event the following year and attracted 2,000 people. In 2023 it was held as an inperson conference, with three separate conference streams. Around 1,000 people attended.
Q. What’s unique about GRIPS 2024?
HJ: GRIPS really brings together a diverse range of people interested in sustainability and plastics. This year’s event is being supported by the Worshipful Company of Horners due to a generous gift from Jane Williams, in memory of her husband David Williams, a former president of the BPF and past Master of The Worshipful Company of
Dr Michael Junior Hopkins Managing Director Ross Polymer Services
Horners. The event is also being kindly sponsored by Plastics Europe. This has meant the event remains completely free to attend. There will also be a small number of exhibitors. If you are interested in supporting this event, please contact the BPF events team.
SB: The breadth of GRIPS is what makes it really special. So much is covered at a single event that it is a great place to learn about the latest developments when it comes to plastic recycling, improving sustainability for plastics manufacturers or embedding sustainable thinking into companies. We also have a broad audience, including manufacturers, NGOs, students, academics and government representatives. People can register to attend online too – so it has global reach. However, we will only
Pravin S Mistry Global CEO PREA Ltd.
be livestreaming talks from the main conference hall. So, we encourage people to attend in person if they can. I find it’s a fantastic event for networking and becoming system aware!
GRIPS 2024 takes place 19 September at Sheffield University’s building The Wave. If you wish to learn more about GRIPS 2024, visit iuk.ktn-uk.org/events/grips2024
Professor Edward Kosior CEO and Founder Nextek
“It’s about getting the balance right and making changes based on data-driven evidence.”
Fellow
Dr Thomas Bennett Research
University of Manchester
TEMPERATURE CONTROL
CONTROLLING EXTREME TEMPERATURES: Freudenberg innovates temperature-resistant plastics for electric vehicles
Temperature control is critical in today’s automotive landscape, especially with the growing importance of electric vehicles. Quantix ULTRA not only meets but exceeds the stringent thermal resistance requirements demanded by modern electric drives. The material’s ability to endure high temperatures offers a substantial advantage over traditional plastics, making it an ideal choice for components exposed to potential thermal events, such as those in lithium-ion batteries.
Freudenberg’s innovative material is currently being applied as a flame protection barrier within the cooling systems of electric vehicle batteries. This marks the first series’ application of Quantix
Freudenberg Sealing Technologies is setting new benchmarks in temperature management for electric vehicles (EVs) with the introduction of its advanced material, Quantix ULTRA. Engineered to withstand extreme temperatures up to 1,200 degrees Celsius without melting, this advanced thermoplastic is playing a pivotal role in enhancing fire protection within electric vehicle systems.
ULTRA, demonstrating its reliability under real-world conditions.
Withstanding direct flame exposure for over 25 minutes
The thermal resistance of Quantix ULTRA is proven by its performance in laboratory tests, where a two-millimetrethick sample withstood direct flame exposure at 1,200 degrees Celsius for over 25 minutes without igniting or melting. This level of
performance ensures that the material maintains its protective qualities even under extreme conditions.
Furthermore, Quantix ULTRA has demonstrated resilience against high-pressure emissions of hot particles, a scenario that can occur during a sudden release of gases from battery cells. While traditional materials such as aluminium may fail within seconds, Quantix
ULTRA maintains its structural integrity, passing the stress test with flying colours.
This thermoplastic is not just limited to cooling systems. Its application potential spans across various hightemperature environments within EVs, including enclosures for power supply units, cable insulation, and battery housing covers. The material’s versatility is further highlighted by its ability to be moulded into various geometries through injection moulding, ensuring both economical production and the capability to meet complex design requirements.
Temperature control in engineering plastics
The ability of engineering plastics to retain their structural integrity under
>
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TEMPERATURE CONTROL
high temperatures is a key differentiator in material selection. Unlike conventional polymers, which lose rigidity as they approach and surpass their glass transition temperature, Quantix ULTRA maintains its form and function. With a glass transition temperature that is 53 Kelvin higher than existing materials, it provides consistent performance where others would fail.
The desired thermal properties of Quantix ULTRA are achieved through a combination of advanced material science and precise engineering. The thermoplastic base is inherently temperatureresistant, and its stability is further enhanced by the addition of specific fillers, such as glass or carbon fibres. Moreover, patented crosslinking techniques reinforce the molecular structure, ensuring that components made from Quantix ULTRA maintain their shape and function under extreme thermal stress.
The initial spark for the development of Quantix ULTRA came from a strategic decision by the Freudenberg Group. It paved the way for research into new materials that would demonstrate their
“Freudenberg Sealing Technologies ensures that processing and cross-linking are in good balance with each other.”
strengths under extreme operating conditions. An interdisciplinary team of experts from several Freudenberg Business Groups contributed their know-how to the strategic program. The team initially chose the high-performance polymer polyaryletherketone (PAEK) as the base material. They modified its properties with crosslinkers and at the same time gained valuable experience of the ideal manufacturing process. The Quantix ULTRA family of materials was born when the first patents were registered in 2018. The materials are characterised by the fact that they offer tailor-made solutions for customer
problems in a wide variety of markets. The spectrum ranges from the reduction of friction and wear in the food industry to the electrically insulating flame-retardant components for electromobility.
Compounding in the injection moulding process In order to achieve these flame-retardant properties, however, the project group had to further develop Quantix ULTRA. PAEKbased materials would have been too expensive for car manufacturers. The project group chose polyketone (PK), a less expensive technical polymer that would achieve the desired properties through cross-linking. Another requirement was freedom of design, so that the material could be easily shaped into any desired form during the manufacturing process.
To achieve this, the team refined the material they had developed in the production process. The thermoplastic base material PK is crosslinked in a single step using an injection moulding process.
Sustainable and flexible manufacturing process
The desired properties of Quantix ULTRA can be specifically influenced by adding so-called fillers and
reinforcing materials. For example, added fibres can provide additional dimensional stability and strength, whereby Freudenberg Sealing Technologies ensures that processing and cross-linking are in good balance with each other.
Customers are also interested in the sustainable effects of production. Especially as these influence the CO2 footprint of their own end products. Compared to conventional polyamide 6.6 (PA 66), the production of polyketone, a base material of Quantix ULTRA, generates much less CO2. The so-called emission factor is 61 percent lower and corresponds to a value of 2.8 kilograms of CO2 per kilogram of granulate. What’s more, while previous cross-linking processes for thermoplastics were based on gamma radiation or in solutions, Freudenberg’s process does not require any solvents at all and is both more economical and more sustainable.
Efficient large-scale production
Quantix ULTRA’s compatibility with standard injection moulding processes makes it not only a high-performance material but also an economically viable option for large-scale production. The introduction of a specialised cross-linking agent during the moulding process simplifies manufacturing, ensuring that high quantities of complex parts can be produced efficiently.
All in all, Quantix ULTRA represents a new class of plastic materials that is at the forefront of all currently known engineering plastics in terms of flame resistance. And this makes the composite a sought-after material for increasing the safety of electric car batteries and keeping the fire risk of electric cars in check in an emergency.
Get connected –with solutions from ENGEL
By using iQ clamp control, we were able to reduce the clamping forces of the machine by 33% . Dirk Krines, Manager Factory e-Chain Systems at Igus, Germany
In series production, clamping forces are often chosen based on the machine operator‘s experience with the product. However, selecting excessively high forces can damage the mould and waste energy. iQ clamp control determines the optimum clamping force fully automatically and thus ensures safety with minimum energy consumption. The result – stable and efficient series production.
Plastribution hails inaugural Festival of Polymer Innovation a success
Polymer distributor, Plastribution, recently hosted its inaugural Festival of Polymer Innovation at the Heart of England Events Centre in Warwickshire on 4th September. The event, which took place on a rare dry day, was deemed a great success by both attendees and participants, with an impressive turnout of 200 industry professionals.
The event broke away from the traditional corporate event format and introduced a fresh, dynamic, and engaging approach. Attendees enjoyed high-quality presentations, networking opportunities, exhibitions and a variety of outdoor activities that added to the vibrant atmosphere of the day.
Polypipe Building Services is saving up to £36,000 annually in electricity costs thanks to a new process water cooling system at its polymer pelletising plant in Aylesford. The system, designed and installed by Isocool, features Eurochiller’s free air coolers and adiabatic coolers, both part of the Atlas Copco Group.
Polypipe Building Services, known for its Terrain brand, required a more efficient cooling system to replace its 20-year-old chillers. The new system was designed to fit within the confined space of the plant room, which required careful planning and installation.
The ‘mainstage’ served as the focal point, where several of the industry’s top companies delivered insightful, solutions-driven presentations. Leading organisations, including ExxonMobil, Ducor Petrochemicals, TotalEnergies, Berry Global, Notpla, UBQ, Engel and Summit Systems, shared their expertise, showcasing the latest innovations and advancements in polymer technology.
Plastribution ensured plenty of time for attendees to relax, with outdoor games, live music and a traditional BBQ, which helped with professional and informal networking.
Commenting on the event, participant Patrick Ottens, commercial director at Ducor Petrochemicals, said: “Honoured to have been asked to represent Ducor Petrochemicals BV at the Festival of Polymer Innovation, which was perfectly organised and hosted by Plastribution. We presented our sustainable range of PO solutions for healthcare [#DuCare]. The atmosphere was a perfect mix of professionalism, relaxation and networking perfection. Thanks again to all at Plastribution for a fantastic
event and we are looking forward to seeing everyone and more, next year!”
Another participant, Jamie Riley, divisional sustainability manager, Berry CPI (Consumer Packaging International), added: “You may be tired of hearing plaudits for the event but here’s some more […] it was definitely the most enjoyable event I’ve attended and I also acquired some valuable leads making it a win-win all round.
Thank you!”
In conclusion, Mike Boswell, Plastribution Group’s managing director, also stated: “We aimed to create something truly unique with the Festival of Polymer Innovation, combining business and pleasure in a way that enables people to connect, learn and have a good time. The positive feedback from attendees has been overwhelming, and we’re delighted with how the day turned out.”
POLYPIPE CUTS COSTS WITH NEW COOLING SYSTEM
The cooling system is critical for maintaining the quality of Polypipe’s polymer products, requiring precise temperature control during the mixing process. The new system utilises a free air cooler that switches to ambient air cooling when the temperature falls below 15°C, significantly reducing energy consumption.
In addition to the main chiller units, Isocool provided a new water storage tank and replaced recirculation
pumps and pipework. Due to space constraints, Polypipe’s MecFlow plastic piping system was used instead of traditional metal pipes.
The upgrade had to be completed within a twoweek shutdown period to avoid costly production disruptions. However, despite the challenges, Isocool successfully completed the installation within the tight deadline.
The new system has not only improved efficiency but also significantly reduced energy consumption, delivering a strong return on investment for Polypipe Building Services.
Ejectors from Meusburger
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ON THE COVER
REFURBISHMENT VS REPLACEMENT: Magog maximises value with screw and barrel solutions
In this Q&A with Magog Industries, general manager, Michael Bate (inset) discusses the importance of tailored solutions for screw and barrel components and how Magog is meeting the evolving needs of plastics processors.
Q. How have advancements in materials science impacted screw and barrel design and performance?
Polymer Technology advancements continue at an ever-increasing pace, materials being developed or modified for more challenging applications, and the requirement to make plastics more environmentally acceptable results in increasing types and grades.
As a screw and barrel manufacturer, we know that simply offering standardised components will not meet each customer’s unique processing or production requirements. This means that as a company, we must ensure all our sales and technical staff are encouraged to attend trade shows and industry innovation conferences to keep aware of developments and specifically how newer types and grades of polymers process. Thus, we can offer the right solutions for our individual customers as they continue to develop their own range of products.
Another important aspect of our development as a technology-leading supplier is establishing and building long-term relationships based on mutual trust and confidence with polymer manufacturers, material suppliers, as well as our end-user customers.
In terms of specific challenges and opportunities, we put great emphasis on researching alongside our supply chain partners. We work closely with some of the most innovative surface technology companies to find solutions that are technically appropriate for providing improved wear and corrosion resilience, increasing the service life of components as well as optimising processing.
Q. What trends are you seeing in terms of customer demands and requirements?
As I have mentioned, the use of plastics is far from reducing, however, this is bringing additional challenges. The challenges our customers face vary quite dramatically
on a case-by-case basis, however, we can summarise these in a few groups.
With the increasing use of glass filler, high use of recycled materials and newer plastics, the abrasive wear characteristics on both screws and barrels have changed, meaning that some traditional heat treatments are less effective. To counter this, we provide a range of alternative surface treatments to provide optimum protection for a given type and grade of plastic being processed.
Recent developments in polymers derived from
“ Materials and production automation are probably the two main drivers within our industry at the present time. ”
alternative biobased materials rather than fossil-based ones require a full understanding of the processing and material flow characteristics in the extrusion and plasticising units we supply. An important aspect of our customer service is having a thorough understanding of the types and range of materials they intend to run on the screws and barrels we supply and the machinery they have installed. Referring to our emphasis on knowledge and experience within our sales and technical staff, we are able to interpret our customers’ needs and provide the best solutions.
The optimum design for the individual materials and installed equipment, relevant wear and corrosion resilience, and being able to provide ongoing service support are the customer needs we aim to meet.
Q. How do your solutions differ for high-volume production vs specialised, small-batch processing?
Being an end-user supplier, we know that each of our customers has some unique requirements either with regard to their processes; materials, rates, or production; type of machinery, plant configuration.
It is vitally important that we approach each new project with the same level of interest and commitment whether that be a small manufacturing / development project or a high-volume large-scale manufacturing line.
Our internal processes are designed to give us the flexibility both in terms of how we interact with our customers and how we manufacture our products.
We use a range of machines in the manufacturing of our screws and barrels. Maintaining manufacturing efficiencies with our operations means that we can provide the competitive pricing and manufacturing lead times our customers require.
Q. How do you determine when refurbishment is more costeffective than replacement?
With modern highly efficient manufacturing technologies, the actual cost difference in manufacturing new compared with component refurbishment can be close. This is one reason why when we are evaluating the suitability of refurbishment of screws, in particular, we address all aspects when assessing worn or damaged parts.
A thorough assessment including accurately measured dimensional checks, visual identification of any localised wear and non-destructive stress checks is carried out.
Once all the inspection report is completed, we evaluate repair work and costs. In some instances, this can be further broken into full factory refurbishment where components would be returned to their original, or in some cases higher, specifications and dimensions, or to a serviceable standard which would include a reduced scope of rework. The size and complexity of the component are also a consideration when making the recommendations. Many times, localised non-standard repairs are necessary such as washout in flight or sides or damaged drive splines - these are, again, identified.
In all cases, we provide the customer with a copy of the inspection report, qualified recommendations and a breakdown of cost options including new replacement.
Q. What emerging technologies or trends do you see impacting screw and barrel design in the next few years?
Materials and production automation/efficiencies are probably the two main drivers within our industry at the present time.
We are acutely aware of the technological and environmental demands within the industry which are driving innovation in materials and higher rates of recycled polymer. Maintaining our knowledge and understanding of these trends is important to us and by working closely with both material suppliers and customers, we can solidify our position as a valued partner.
We also anticipate further development in polymer recycling technologies, larger plants, integrated processes and a wider variety of material stock types. Upscaling screws and barrels is not simply a change in dimensions. Our engineers are experienced in calibrating and extrapolating process data to help optimise process quality and continued development of our surface coating technologies which will ensure we can provide components with extended service life.
Q. How are you preparing for potential shifts in plastics processing methods?
As a company, we strive to be a customer-centric organisation. To help us achieve this and keep our focus, all our activities are based around the company’s three core competencies. Process Experience, Engineering Excellence and Manufacturing Expertise.
Process Experience is about ensuring our technical staff have an in-depth understanding of plastics processing across all sectors and remain informed and updated on developments in materials, processing and automation so that we can make informed decisions and have the confidence of our external partners. Engineering Excellence is about making sure our internal processes from customer liaison, through engineering design and quality management systems, are robust and relevant to meeting or exceeding our customers’ requirements. Manufacturing Expertise ensures that both our skills and equipment are suited to the complexity of the components we supply. This allows us to maintain high standards of quality and efficiency, delivering the right products at good value and on time.
Tinius Olsen plastics testing solutions
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Bulk handling system achieves dust reduction and accurate filling at graphite plant
The European installation of Asbury Graphite & Carbons in the Netherlands opened in 2014 to take in raw graphite from around the world, reduce it into fine particles through various milling and screening processes, and fill 1,000 kg (2,200 lb) bulk bags and smaller bags, based on customer needs.
Early problems with inaccurate fill weights of milled graphite, as well as issues with dust control, prompted the company to invest in new equipment that features dust suppression for operator safety, bag evacuation devices, as well as load cells under PLC control to ensure accurate fill weights.
The former general manager of European operations Marc Stassen said the early equipment was rudimentary and produced off-weight bags: “We would only find out when the product reached the shipping department that we filled 920 kg (2,024 lb) instead of 1,000 kg (2,200 lb), for example.”
The original bulk bag filler frames operated with a poorly designed bag spout seal that wasn’t reliable. “Very often the seal inflated incorrectly or wasn’t strong enough or exploded,” Stassen said. As a result, dust and fine particles escaped, putting the plant’s compliance with Dutch health and safety guidelines at risk. Spills were also occurring with the original bulk bag dischargers, he said. “We had to do something else.”
The company turned to Flexicon (Europe) Ltd., which specialises in bulk bag filling,
Asbury Graphite & Carbons, a global processor of graphite and other carbon materials, improved e ciency and reduced dust at its European plant by implementing bulk-handling solutions from Flexicon. The new systems have helped the company achieve accurate fill weights, cut dust emissions and streamline operations.
discharging and conveying systems. “We tried one bulk bag filling station, and that reduced our dust big time,” Stassen exclaimed. “So, we went forward with Flexicon for all 11 stations, followed over the years by nine bulk bag dischargers and numerous flexible screw conveyors. They reduced dust tremendously in the plant.”
CLEAN FILLS AT THE TARGET WEIGHT
The bulk bag fillers are arranged in pairs beneath bins holding the finished graphite product. An operator inserts
the bag loops into the fill head’s four retractable hooks, and pulls the inlet spout of the bulk bag upward over a heavy-duty flexible collar, which inflates to create a dust-tight seal. A filtered air displacement vent at the fill head prevents the escape of dust during filling. “Nothing can escape,” Stassen observed.
The operator sets the target weight on the PLC and initiates the filling cycle. A slide gate opens above the filling chute and a rotary valve meters product from the bin above.
Load cells beneath the deck are linked to the PLC, which closes the slide gate when the bag reaches the target weight. As the bag fills, a densification/ deaeration deck vibrates to stabilise the bag for storage and shipment. The operator deflates the bag spout seal, ties off the bag, and removes it with a forklift.
Each operator runs two fillers side by side, connecting a second bag while the first one is filling. When the first bag is full, the PLC automatically signals the system to begin filling the empty bag. “The
ABOVE: A SPOUTLOCK clamp ring positioned atop a TELE-TUBE telescoping tube applies constant downward tension as the bag empties and elongates for full and dust-free evacuation. >
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operator is continuously busy hanging new bags and taking away full bags,” Stassen added.
DUST-FREE BULK BAG DISCHARGING AND CONVEYING, TOO
Asbury’s plant unloads incoming raw materials with nine BULK-OUT BFF bulk bag dischargers, designed to eliminate dust during discharging, collapse and removal of empty bulk bags, increasing plant safety.
Bulk bags of incoming material are loaded by forklift into the discharger frames. Operators create a dust-free bag/ hopper interface by connecting the bag spout to the SPOUTLOCK clamp ring which sits atop the TELE-TUBE telescoping tube. During discharge, the telescoping tube lowers the clamp ring as the bag empties, applying continual downward tension to keep the spout taut.
INSET: Asbury Graphite & Carbon’s final product. ABOVE: At the Twin-Centrepost bulk bag filler, the operator secures the bag spout to the fill head with inflatable collar to assure dust-free filling. The height-adjustable fill head accommodates various bulk bag sizes.
look empty but still had 20 or 30 kg (44 or 66 lb) inside and, when we removed the bag, the material ended up on the floor. Now, no material remains.”
materials that tend to pack, cake, smear, plug or fluidise— or break and slip in the case of graphite—without crushing or grinding material against the tube wall.
Promoting evacuation, POPTOP extension arms on the dischargers’ upper frames automatically raise the bulk bag into a steep V shape. FLOW-FLEXER bulk bag activator plates raise and lower the opposite bottom edges of the bag, directing material toward the bag outlet spout, reducing waste.
“In the past,” Stassen pointed out, “we hung the bag from a frame and let the material gravity fall. The bag would
DIFFERENT CONVEYORS MOVE DIFFERENT MATERIALS
From the 140 l (5 cu ft) floor hopper below each bulk bag discharger, a fully-enclosed flexible screw conveyor ranging in length between 8 and 16 metres (26 to 52 ft) moves the material to several silos.
The BEV-CON conveyors specified are designed to propel difficult-to-move
Feeding the finest particles to the jet mill line, a FLEXIDISC tubular cable conveyor moves graphite and coke powder from a dedicated bulk bag discharger. The fine particles exiting the bag flow into a rotary valve that meters them into the conveyor, which consists of ultra-high molecular weight polyethylene conveying discs attached to a steel cable and enclosed inside a polymer tube. The convey line is a continuous
“Each operator runs two fillers side by side, connecting a second bag while the first one is filling. When the first bag is full, the PLC automatically signals the system to begin filling the empty bag.”
circuit, kept under tension by a wheel near the inlet end and driven by another wheel at the discharge end. The material rides gently in the spaces between the discs. The convey line makes a 90° turn past the inlet and moves vertically to 9 metres in height before turning 90° again to the discharge point above the feed hopper and downspouting to the jet mill. The gentle movement reduces the risk of abrasion, and the enclosed circuit ensures dust-free operation.
After processing, another set of flexible screw conveyors, ranging from 4 to 8 metres (13 to 26 ft), transfers the materials to the bins above the bulk bag filling stations.
Since the first bulk bag fillers and dischargers arrived, Stassen has added only Flexicon systems. “We didn’t look at other equipment. We have good service […] they are quickly here to support us, we are good partners at this moment and they understand our needs and issues best.”
THE DC DIFFERENCE: WITTMANN STAYS AHEAD OF THE ENERGY CURVE
Ahead of FAKUMA 2024, Wittmann examines direct current (DC) solutions for injection moulding, o ering potential energy savings, reduced carbon emissions, and lower operating costs compared to traditional AC-powered systems.
The environment, the circular economy, can now safely be considered the most topical factor in business today. Net Zero, energy efficiency, carbon footprint, traceability and sustainability are all concepts that have taken root in today’s world.
The ISO 140001 standard is now probably the minimum requirement for any injection moulder doing business in any market, and other environmental validation systems such as EcoVadis are steadily gathering up customers.
The emerging environmental ‘food chain’ is connected like never before: everything counts – from the smallest business practices to the behaviour of billion-dollar corporations. Simply put, in this chain you pass on your environmental credentials to others; your environmental successes, failures, and resulting numbers become part of your customers’ - right up to the consumer or end-user. Every business
depends therefore on the environmental performance of the previous link in the chain (its suppliers) before attempting to add environmental value of its own.
In these circumstances, the primary factors of production cannot be altered throughout the chain and are where the most environmental gains (and losses) can be established. In this world, your factory ideally wants to take delivery of equipment, components or material already low-carbon; carbonneutral or carbonnegative. Enter equipment
supplier Wittmann: Since it acquired Battenfeld in 2008 Wittmann, has been unique in manufacturing all of the equipment required in injection moulding cells and Wittmann has also led the drive for each piece of equipment to be as transparently low-energy as possible.
take
Wittmann is very conscious that many of its plastics processing customers are on the front line when it comes to the role of environmental legislators. By 2050, for example, the EU wants to be climate-neutral. The resulting Green Deal will make it mandatory for manufacturing companies to gradually reduce their CO2 emissions.
“Until this year, the role of the temperature controller had been the missing piece in the Wittmann DC jigsaw.”
As part of the quotation process, companies will increasingly be asked to quantify the energy that will mould products, parts and components – and on a perunit basis.
The idea of product carbon footprint (PCF) is therefore coming into sharp focus as it eventually would.
The benefits of DC power Wittmann has accordingly designed new software to help - part of the company’s
The World’s Leading Injection Moulding Machine Manufacturers
Borche’s UK facility, based in the West Midlands offers a wide range of Servo Technology Machines up to 6800ton clamping force which bring substantial energy savings. We have stock machines available for immediate delivery and an experienced team of UK service engineers, with spare parts ready for prompt delivery.
Manufacturing Execution System (MES) - which will launch next month at the FAKUMA show in Southern Germany, October 15-19.
The new software will provide answers as soon as a Wittmann production cell is switched on. The processor will receive a complete overview of the production progress. Key figures will be displayed for each individual cycle and the CO2 emissions can be added in at that point – each indicated in grams per cycle.
The calculation of CO2 emissions is based on two values. One is the energy consumption of the injection moulding production cell and the other is the shot weight, i.e. the amount of raw material processed per cycle.
The role of temperature control – an integral part of the cell – will be critical in managing this task. Processes that require the management of an unvaried pattern of 220°C over lengthy production schedules are energy-intensive, by definition.
Moulders are therefore enabled to compute the PCF of each moulding - but how can this number be further reduced?
This question has spurred Wittmann to investigate all the options in the power supply itself which has yielded bicycle-powered robots to solar-powered injection moulding machines (IMMs). The key finding is that Wittmann has found that substituting direct power, or direct current (DC) to moulding cells instead of alternating current (AC) can deliver a rise in energy efficiency and profitability of up to 15%.
The creation of DC networks
TEMPERATURE CONTROL
“Wittmann found that substituting direct power to moulding cells instead of alternating current can deliver a rise in energy efficiency and profitability of up to 15%.”
parallel to the existing AC power supply offers the processing advantage of providing the generated DC power unconverted for direct use. The conversion losses incurred on the way from an in-house photovoltaic system through direct voltage converters to the processing machine are by comparison to AC absolutely minimal.
Until this year, the role of the temperature controller had been the missing piece in the Wittmann DC jigsaw.
Efficient solutions
At the K2022 exhibition, Wittmann presented for the first time a DC-powered allelectric EcoPower injection moulding machine as a conceptual study. A robot from the WX series, also directly supplied with DC current via a joint interim circuit, handled the finished moulded parts.
However, June 2024 saw Wittmann extend the range
of injection moulding components available for use in DC networks by adding temperature controllers. The new Wittmann Tempro Plus DC reaches exactly the same high-performance rates as the equivalent conventional Tempro Plus AC-powered models. The Tempro plus D90 DC presented in Vienna in June is suitable for temperatures of up to 90°C and has a heating capacity of 9 kW with 750 V DC. The cooling capacity is 40 kW for a differential temperature of 75 K.
This DC Temperature Controller version already comes with a 1.1 kW synchronous motor and an inverter as part of the standard equipment package. The motor drives a seal-less submersible pump with a maximum working pressure of 7.5 bar and a maximum flow quantity of 60 l/min. The inverter enables direct connection to the machine’s interim circuit as well as
speed control in line with the desired process parameters. In this way, power conversion loss is prevented and the pump speed is adapted to the requirements of the process. The net result is a hefty two-fold increase in energy efficiency.
Now that the concept has been tried and tested, Wittmann is ready to roll out the solutions to the marketplace: The FAKUMA 2024 exhibition will be the platform for Wittmann to demonstrate DC energy as a power source for injection moulding systems.
On an EcoPower B8X 180/750 DC Insider cell with an integrated WX142 robot in DC version from WITTMANN and also a DC-compatible Tempro plus D temperature controller, the housing of a plug-in connector for DC technology will be manufactured using a 2-cavity mould supplied by Harting, Germany. A Harting Han Lock & Light connector will securely connect the temperature controller, with a safety feature that prevents disconnection until the machine’s power supply is turned off. An additional lighting element on its base serves as a visual status indicator.
The system will be powered by an ultra-modern sodium-nickel battery from Innovenergy. The battery has a total capacity of over 45 kWh which can provide uninterrupted power for the machine throughout an eighthour workday.
Future solutions always present initial hurdles and doubts for early adopters. However, these carbonsaving numbers at source will present impeccable credentials to OEMs looking to source the lowest possible PCF numbers for their products and components.
The HASCO ejector delay unit Z 1725 /. . . offers simple solutions for the demoulding and the separation of sprues. It enables two-stage ejector demoulding.
▪ Increased process reliability
▪ Clean separation of the sprue
▪ No production downtimes
▪ Cost saving through simple demoulding solutions
@POLYMERMAN ON PRICES
WherenextforUKpolymerpricing?
Improvements in exchange rates, falling shipping, feedstock and energy costs look set to mitigate polymer price increases.
In the previous @polymerman article, the following factors were considered in the context of PE and PP prices, with the expectation that price increases would be applied towards the end of the summer. Where the supply-demand balance was in favour of the sellers, then prices did move upward, and this was particularly evident for LDPE where supply was really quite limited. Furthermore, the lower end of the price range across both LLDPE and some HDPE grades was hiked, although attempts to move the premium grades often proved a little more challenging as buyers did their best to resist. The PP market remained well supplied and sellers did well to recover the increase in feedstock costs, again greater success was achieved where supply was snug, and this was most apparent for PPCP grades.
1. Logistics costs
2. High liquid feedstock costs
3. Increasing gas prices
4. Underlying demand
Of the factors outlined above, it appears that logistics costs have fallen back slightly, and Brent Crude Oil prices, which in turn influence liquid feedstock costs, have now fallen below the levels present at the start of the year. An unexpected factor that is helping to mitigate cost pressures is the increased strength of the GBP against the USD with gains of almost 5% through August, with consequences for shipping and crude oil costs which are typically priced in USD.
With the fall in liquid feedstock costs has come a reduction for September in C2 (Ethylene), C3 (Propylene) and to a lesser extent SM (Styrene Monomer) pricing, with soft demand also adding to this downward pressure.
As the calendar year-end approaches, we look set for some challenging negotiations between plastic converters and polymer producers, with each seeking to achieve the best profitability either through sales price or input expense. As always, market fundamentals will determine the true market action and here the supply-demand balance will be key. And with no signs of demand improvement from China, most materials will continue to trend towards surplus which will result in strong competition for available volumes.
Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution.co.uk | www.pieweb.com
Brent Crude £ per tonne
TEMPERATURE CONTROL
SAVE ENERGY, IMPROVE QUALITY The advantage of temperature control solutions
Q: How do speed control pumps improve temperature control precision and energy e ciency?
Speed control pumps are a breakthrough for industries like plastic moulding, where temperature control needs to be precise and adaptable. Traditionally, achieving the right temperature was a manual process that involved setting ranges for temperature and flow rate, and then adjusting them until the desired quality was reached. This method was both time-consuming and energy-inefficient. However, with speed-controlled pumps, the process has become significantly more precise and automated.
Editor Rebekah Jordan spoke to Dave Palmer, general manager of ICS Cool Energy, who discussed how ICS’ advanced temperature control systems can improve efficiency, reduce energy consumption and enhance product quality in plastic moulding.
enabled by industry-standard protocols such as OPC UA, Profibus, and Profinet.
By integrating with IoT devices and cloud-based systems, manufacturers can monitor key performance indicators such as temperature fluctuations, energy usage, and system efficiency in real time. This data-driven approach enables predictive maintenance— where potential equipment failures can be detected before they cause downtime— and process optimisation, where adjustments can be made on the fly to improve efficiency.
The speed control technology allows pumps to adjust dynamically, responding to the specific cooling or heating needs of the process in realtime. This capability means the temperature differential (ΔT) between the supply and return flows can be finely managed to ensure stable temperatures. By adjusting the pump speed to suit the exact demand at any given moment, energy consumption is kept to a minimum.
For instance, our eco.line systems have demonstrated power savings of up to 92% compared to traditional systems using uncontrolled peripheral pumps. In a typical three-shift operation, in a typical three-shift operation, under production conditions with the flow rate at 85l/ min and heating capacity at 27 kW, energy consumption can be reduced from
approximately 14,495 kWh annually to just 1,160 kWh. This not only helps manufacturers save on energy costs but also contributes to reducing their carbon footprint.
Q: Can you elaborate on the concept of ΔT control and its benefits in optimising temperature gradients?
ΔT control refers to the regulation of the temperature difference between the inflow (supply) and outflow (return) of the temperature control system. This controlled differential allows for a more stable and uniform temperature across the entire mould, which is critical in ensuring the quality and consistency of the final product.
ΔT control leads to better product quality by ensuring that the mould cools evenly, which helps to prevent issues like warping,
uneven solidification, or surface defects. The dynamic adjustment of the pump speed to maintain the desired ΔT also helps to optimise energy use, reducing unnecessary power consumption. This, in turn, decreases operating costs and lowers the environmental impact of the production process.
Q: How can advanced temperature control systems be integrated with other Industry 4.0 technologies for enhanced process optimisation?
Industry 4.0 is all about connectivity and data-driven optimisation. Our temperature control i-Temp units, such as the eco.line range, are equipped with digital interfaces that allow them to communicate with other machinery on the production floor. This connectivity is
Q: How do variations in composite materials and product geometries a ect the required temperature levels? Different materials require specific temperature settings depending on their thermal properties. For instance, high-performance plastics used in the automotive or medical sectors need precise temperature control to ensure that moulding processes are consistent and defect-free. Each material reacts differently to heat, meaning that achieving the right temperature is crucial for avoiding issues such as warping or improper solidification.
Product geometry also plays a role. Complex shapes, especially those with varying thicknesses require maintaining proper mould temperature to achieve consistent quality. This is why control and dynamic temperature adjustment capabilities over cooling and heating processes are important to ensure uniform temperature distribution across the mould.
Tool-Temp ensures that your processing facilities are kept at the ideal temperature – o ering over 60 standard models and enough individual solutions to satisfy any special requirements you may have.
Main features of our new MATIC temperature control units
Simple operation
Modular Control that is easily expandable
Preset actions and easily configurable recipes
Anticipatory behavior & predictive maintenance
Connectivity
Energy e icient control
Please contact us on 01933-442633 or info@tool-temp.net to speak with a member of the Team.
HONOURING LOCAL HEROES:
Labour MP recognises Clearfield’s contribution to the circular economy
Andrew Cooper has been the MP for Mid Cheshire since the 2024 United Kingdom general election and previously served as a councillor for Northwich Town Council and Cheshire West and Chester Council.
Staff at the Winsford site appreciated MP Cooper’s visit and were able to share their experiences of working in the facility, where they spoke to him about all things plastic, and demonstrated why Clearfield Envirotech is quickly becoming an integral part of the local community in Winsford.
During his visit, MP Cooper, toured the advanced recycling facility, familiarising himself with the processes involved when recycling plastic items into newly finished products as part of the circular economy; highlighting the importance of sustainable recycling, not just locally, but also with the spotlight on plastic pollution worldwide.
While visiting, MP Cooper asked insightful questions about the technical aspects that Clearfield Envirotech’s customers expect from their products. He remarked: “It was a pleasure to visit Clearfield Envirotech. It was clear when meeting staff, the importance of each individual’s role within the company.”
John Ellis, business development manager, expressed: “I enjoy working at Clearfield Envirotech, it was wonderful to have Andrew Cooper here and see how much he cares about our quality of service and product. It’s clear that he values the hard work we put into making Clearfield Envirotech remain the pinnacle of Recycled plastic recycling and supply.”
Q. What does the local MP visit by Andrew Cooper mean for Clearfield as a whole?
The visit by Andrew Cooper, the newly elected Labour MP for Mid Cheshire, is a significant endorsement for Clearfield Envirotech. It underscores the importance of the company’s role in the local economy and highlights its contributions to sustainability through innovative recycling practices. MP Cooper’s visit not only raises the profile of Clearfield Envirotech within the community but also demonstrates the government’s
Editor Rebekah Jordan caught up with Clearfield Envirotech’s business development manager, John Ellis, after the company welcomed Andrew Cooper, the newly elected Labour MP for Mid Cheshire, to its plastic recycling facility last month.
interest in supporting businesses that prioritise environmental sustainability. This recognition could lead to increased opportunities for collaboration with local and national government bodies, potentially opening doors for grants, partnerships, and further investments in the company’s growth and development.
Q. How has Clearfield become an integral part of the Winsford community? Do you plan to strengthen it going forward?
Clearfield Envirotech has become an integral part of the Winsford community by actively engaging with local residents and providing employment opportunities in the area. The company’s commitment to sustainability and its role in the circular economy resonate with the community’s values, making Clearfield not just a business, but a community partner. By involving local workers in meaningful roles and promoting environmental responsibility, Clearfield has embedded itself in the fabric of Winsford.
Q. How do you collaborate with other local businesses or organisations to enhance your recycling efforts?
Clearfield Envirotech collaborates with local businesses and organisations through a network of partnerships aimed at enhancing recycling efforts and promoting sustainability. These collaborations involve working closely with local councils, businesses, and community groups to raise awareness about recycling and encourage responsible waste management practices. Clearfield also partners with other local manufacturers and businesses to ensure that recycled materials are efficiently used within the community, reducing waste and promoting the circular economy.
Furthermore, Clearfield is an active participant in local environmental initiatives and regularly collaborates with local environmental groups to support community clean-up efforts and recycling drives. These collaborations not only enhance Clearfield’s recycling capabilities but also foster a sense of shared responsibility for the environment within the Winsford community.
PACKAGING
“Clearfield has become an integral part of the Winsford community."
Q. How has Clearfield Enviroteach's membership in the BPF helped build its reputation in the plastic recycling industry?
Membership in the British Plastics Federation (BPF) has been instrumental in enhancing Clearfield Envirotech’s reputation within the plastic recycling industry. The BPF provides a platform for Clearfield to stay informed about the latest industry trends, technological advancements, and best practices in plastic recycling. This membership has enabled Clearfield to benchmark its operations against industry standards, ensuring that the company remains at the forefront of innovation and sustainability.
Moreover, being part of the BPF has allowed Clearfield to participate in industry-wide discussions and initiatives, helping to shape policies and practices that benefit the entire sector. This involvement has not only boosted Clearfield’s credibility but has
also positioned the company as a thought leader in sustainable recycling, further enhancing its reputation both within the industry and among its customers.
Q. What specific plans do you have for growth in the next few years, and how do you envision expanding your operations?
Clearfield Envirotech has ambitious plans for growth over the next few years, focusing on expanding its operational capacity and broadening its reach within the plastic recycling industry. The company aims to invest in new technology to increase the efficiency and scalability of its recycling processes, enabling it to handle larger volumes of plastic waste and produce higher-quality recycled products.
Additionally, Clearfield plans to diversify its product offerings by developing new recycled plastic products that meet the evolving needs of its customers. This could include entering new markets or collaborating with other industries to create innovative solutions that further promote the circular economy.
Overall, Clearfield Envirotech envisions a future where it not only grows in size and capacity but also continues to lead the way in sustainable recycling practices, making a positive impact on both the environment and the communities it serves.
ELASTOMERS AND RUBBER
FOSSIL-FREE FUTURE:
UPM DRIVES SUSTAINABILITY TRANSFORMATION OF THE RUBBER INDUSTRY
UPM is committed to creating a sustainable future by transforming wood-based materials into biochemicals. Its new German biorefinery will produce renewable alternatives to fossil-based chemicals which can be used across diverse industries.
UPM, whose history goes back 150 years to the origins of the Finnish forest industry with pulp and paper production, is using its vast experience in forestry and forest products to transform materials for a fossil-free future. The company is starting up its wood-based biorefinery later in 2024 that will produce biochemicals made from responsibly sourced European hardwood.
UPM is focused on scaling biorefineries, producing a variety of renewable fuels and chemicals made from sustainable biomass. At its biorefineries, the company is creating ingredients that will provide a significantly improved carbon footprint compared to fossil-based alternatives and provide better choices to consumers.
ELASTOMERS AND
RUBBER
UPM’s Leuna biorefinery: turning wood into biochemicals
Woody biomass from sustainable forest management practices and side streams and sourced from certified, regional beechwood forests will be processed at the €1,180 million biorefinery in Leuna, Germany. The biorefinery aims to produce 220,000 tonnes annually.
The wood is harvested and recovered by UPM’s network of foresters and forest owners and supplied to the Leuna biorefinery for conversion into biochemicals. From the wood, cellulose is used to produce bio-glycols, lignin for renewable functional fillers and hemicellulose for industrial sugars.
The journey of UPM Biochemicals’ bio-based ingredients can be fully traced from forest to biorefinery. Thus, the end consumer can connect their product back to the carbon value of the Central European forests.
All the wood comes exclusively from sustainably managed forests and is 100% either FSC or PEFC-certified and covered by a third-party verified chain of custody. The certification confirms that the forest is being managed in a way that preserves biological diversity and benefits the lives of local people and workers while ensuring it sustains economic viability.
Wood is selectively harvested forest, not from clearcuts, and a substantial part of the forest is always retained in harvesting. Using only individual trees means that the remaining trees accelerate their growth – increasing their value as a carbon sink – and new trees grow from the undergrowth and emerge through natural regeneration.
UPM’s commitment to delivering renewable circularity
The biochemicals can replace their fossil-based counterparts across apparel, textiles, automotive, packaging and more. The renewable biomonoethylene glycol (BioMEG) is a drop-in solution and can therefore be fully integrated into existing production and recycling processes, enabling
the transformation of the entire chemicals value chain towards renewable circularity.
UPM’s BioPura BioMEG will serve as a base material for various industrial products and consumer goods, such as PET bottles, packaging materials, polyester textiles and engine and battery coolants. Renewable BioMPG can be converted into cleaning agents, deicing fluids, fragrances and cosmetics.
UPM’s BioMotion, ligninbased Renewable Functional Fillers (RFF) are a completely new, sustainable alternative to replace carbon black and precipitated silica in various rubber end uses such as tyres, hoses, rubber floorings and scores of other rubber applications. Thanks to a
“All the wood comes exclusively from sustainably managed forests and is 100% either FSC or PEFC-certified.”
commercial agreement with BioMotion RFF with Artigo Flooring, a comprehensive distribution network is ready to develop the local markets and ensure that customers can use RFF in rubber and plastics applications from the moment the Leuna biorefinery is operational.
UPM BioMotion RFF is also being used in an upcoming concept tyre, as a result of a collaboration with Nokian Tyres. By integrating a sustainable alternative to fossil carbon black, carbon emissions in tyre production are significantly lowered when the lighter weight, 100% renewable alternative to traditional CO₂-intensive fillers is used in the tyre’s side walls.
Functional fillers represent approximately 30% of a tyre, primarily carbon black and precipitated silica. According to an initial test series by Nokian Tyres, replacing functional fillers with UPM BioMotion RFF will act as a highly relevant component on the path towards sustainable mobility.
Q. Who are you and what do you do?
I’m Carlos Saboga from Marinha Grande, Portugal and I’m the European technical sales manager for Progressive Components. Currently, my main role with Progressive in the EU is the development of the Tool and Asset Management/Monitoring business in the EMEA region.
Q. What materials and products does ProComps specialise in?
Progressive Components offers advanced solutions for unmatched tooling performance, with product lines consisting of standard and proprietary mould components, mould monitoring devices and software, and innovations for improving mould maintenance.
Meet the experts: CARLOS SABOGA, Progressive Components
OEMs, with availability and comprehensive support through direct distribution and authorised dealers around the world.
Q. What monitoring systems or software does ProComps use to track production processes and equipment performance?
now connects with all of Progressive’s monitoring devices, Asset Tags, and Asset Plates.
With ProFile, customers will not be searching anymore for; information about where their assets are, how their assets are being maintained, or their assets’ level of productivity.
ProFile provides customers with:
• Remote data access: Access global asset data available 24/7 to help make informed decisions.
Q. What key benefits can customers expect when they partner with your company?
Altogether, the above collection of advantages delivers convenience for the mould builder and unmatched tooling performance for moulders and
Our ProFile v4 is a cloud-based tracking system designed for injection moulders, mould builders, stampers, and OEM supply chain management. ProFile solutions can be utilised simply as an asset management system to organise and track global tools and equipment, or it can be fully harnessed for complete real-time monitoring and production improvement capabilities. ProFile
• Centralised data: Safe, easy to find/ update, centralised storage of asset data.
• Data exchange: API-powered data exchange with customers’ existing ERP, MES or Business Intelligence systems.
• Increase productivity: Increase uptime, quality, and throughput while reducing costs.
• Financial gains: Experience 5- and 6-figure gains. Typical payback within 3 to 12 months.
NEXT LEVEL MOULD MONITORING!
WIRELESS ACCESS TO TOOLING INFO
Progressive leads the industry with mould monitoring technology and has further advanced its product line with the addition of ProFile® v4 and the Bluetooth® enabled CVe Monitor® RT:
• Real-time visibility to mould performance and KPIs.
• Comprehensive PM and Work Order management.
• Secure, role-based access and reporting.
Contact us at the QR code below for a demo and proposal that meets your timeline, budget, and goals.
ELASTOMERS AND RUBBER
Manufacturing expanded SPONGE RUBBER EXTRUSIONS
Expanded sponge rubber extrusions are used across a diverse range of industries due to their unique properties and versatility. Sponge rubber, or expanded rubber, refers to rubber that has been manufactured into a foam-like material by adding blowing agents that cause the rubber to expand during the extrusion process. This results in a product with the elasticity of rubber and the cushioning properties of foam. As sponge rubber can effectively seal against environmental factors, it is ideal for applications that require tight seals and vibration damping from automotive door and window seals to gaskets for electronic devices.
Manufacturing process
The process to manufacture an expanded sponge rubber seal begins by selecting the base material. With the widespread availability of a variety of rubber compounds, such as EPDM, neoprene and silicone, it is possible to choose a compound that can meet the specific requirements of the application. This selection is foundational, as it dictates the subsequent
Seals Direct, examines how sponge rubber extrusions are manufactured and discusses common applications that use this type of product.
qualities and applicability of the final extrusion.
This stage is important to prepare the sponge rubber extrusions for direct application in various products and ensure it meets all necessary specifications and quality standards.
Applications of sponge rubber extrusions
Once an appropriate rubber compound has been chosen, the compounding phase begins. This involves mixing the base rubber with various chemicals and fillers, including curing agents, accelerators and blowing agents. These additives ultimately define the rubber’s density, elasticity and other mechanical properties. The compounding must be precise to ensure consistent quality and performance of the sponge rubber.
and forced through a die that is shaped according to the profile of the desired extrusion. When activated by heat, the blowing agents release gases that cause the rubber compound to expand and form a cellular sponge-like structure. This expansion is controlled to meet specific dimensions and shapes required for various applications.
The rubber mixture is then fed into an extruder which is where the mixture is heated
Sponge rubber extrusions are used extensively across a broad spectrum of applications due to their exceptional sealing and insulating properties. One of the most common uses is in the automotive industry where they serve as essential components for door and window seals, boot seals and various other sealing applications. The flexibility and durability of sponge rubber make it ideal for withstanding the vibrations and temperature variations typical in automotive settings.
After extrusion, the expanded rubber section needs to be cured to set the shape and properties. Curing involves a continuous vulcanisation process often using salt baths or hot air tunnels. This step cross-links the rubber molecules by solidifying the extrusion’s structure and imbuing it with strength, elasticity and dimensional stability.
In the building and construction sector, sponge rubber extrusions are vital for ensuring energy efficiency and structural integrity and so, are often used for their insulation properties. They are used as weather stripping for windows and doors, keeping out moisture, wind and environmental debris.
Finally, the extrusions are cooled, cut to specific lengths or coiled and may undergo additional finishing touches such as flocking or adhesive backing.
Within the electronics industry, sponge rubber extrusions are used to create seals and gaskets for enclosures. These applications often require specific rubber compounds with waterproof and dustproof properties to safeguard sensitive electronic components. This wide array of applications underscores the adaptability and effectiveness of sponge rubber extrusions in meeting diverse industrial requirements.
ROTATIONAL MOULDING
SOLAR ROTATIONAL MOULDING: A ZERO-EMISSION SOLUTION FOR PLASTIC MOULDING
LightManufacturing founder, Karl von Kries, explains the development of Solar Rotational Moulding (SRM), a sustainable alternative to traditional plastic production that replaces fossil fuels with solar energy.
When the idea to reduce rotational moulding emissions to zero came to Karl von Kries, he expected it to fail. He thought, “After all, if it could be done, wouldn’t someone have done it already?” Yet as he saw the high cost of energy in the rotomoulding factory where he worked, he decided he had to try something new.
Von Kries engineered a field of sun-tracking mirrors, called heliostats, to reflect sun rays onto a rotating mould. This concentrated solar energy heated the plastic and successfully produced products without a single drop of fossil fuel energy. “Not only did the idea fail to fail, it succeeded beyond my expectations,” said von Kries.
With this new SRM system, von Kries founded LightManufacturing. The company and its technology
not only enhance sustainability in the plastic production space, but also help customers significantly reduce product costs by eliminating the cost of fossil fuels.
SRM versus traditional rotational moulding
Traditional rotational moulding uses a lot of fossil fuel energy. Some estimates show that for every kilogramme of plastic moulded into a product about a kilogramme of carbon is released. “Solar rotational moulding is an alternative that not only eliminates emissions but also dramatically reduces production costs. Without the need for fossil fuel inputs, manufacturers can save up to 30% on production,” noted von Kries.
SRM captures and concentrates the sun’s thermal energy directly. An array of heliostats track the sun’s position and reflect its rays onto a rotating mould. The system integrates
“People are often surprised when I tell them that SRM can be even faster than traditional rotomoulding. It seems counterintuitive but when you look deeper at the thermodynamics, it makes sense.”
photovoltaic panels to provide power for mould rotation. von Kries said: “Think of it like using a magnifying glass to focus sunlight, but on a much larger scale.”
In contrast to traditional methods, where burning fuel heats the air in an oven to convectively heat a mould, SRM’s radiative systems heat the mould directly “like a space heater” von Kries explains. “People are often surprised when I tell them
ROTATIONAL MOULDING
that SRM can be even faster than traditional rotomoulding. It seems counterintuitive but when you look deeper at the thermodynamics, it makes sense.”
Solar rotational moulding creates more efficient automation
Radiative heating also allows the mould to reach the optimal temperature while surface and air temperatures remain stable. “Because we’re radiatively heating the mould, we can build a lot of advanced technology right into the chamber,” von Kries explained. “This means our systems can be highly automated, using sensors to monitor the process and adapt to changing solar conditions, which isn’t possible with traditional rotational moulding. This streamlines operations and boosts efficiency.”
Sensors inside the moulding chamber continuously monitor internal and external temperatures and feed data to a central control system. The system automatically adjusts the heating cycle based on real-time conditions. For example, if cloud cover temporarily reduces the amount of solar energy, the system extends the heating cycle until the mould reaches the desired temperature. Once that temperature is achieved, the system reroutes the heliostats to the next mould to ensure continuous production.
Cooling is equally automated. As the heliostats move to heat a second mould, fans automatically kick in to cool the first mould. Once the entire cycle is complete, an alert notifies the operator to remove the finished products from the moulds. Automation not only frees up operators during long rotational moulding cycles (which can take 30 minutes or more for products like water tanks) but also improves the consistency and quality of the final products.
Market applications and opportunities for LightManufacturing systems
A SRM system is shipped as a “factory in a box” that costs much less than standing up a traditional rotomoulding facility. The deployable factory doesn’t require a building, concrete pad or electrical/ water/gas hookups. This means manufacturers can set up their plastic production centres close to home and eliminate not only production fuel costs but also the fuel and costs involved in longdistance transportation. “This adds another important layer of sustainability,” highlighted von Kries.
SRM’s versatility benefits a variety of markets, from commodity part moulding to green consumer products and even LEED-certified building components. For commodity moulders, companies that produce high-volume, standardised products such as water tanks, fuel tanks, and outdoor furniture, SRM presents a competitive edge. In traditional manufacturing, energy inputs account for
around 10-30% of a finished part’s cost. Therefore, SRM systems offer impressive returns on investment.
SRM also offers a way for manufacturers to cater to the growing demand for eco-friendly products in both consumer and commercial markets. Whether it’s kayaks, garden products, decorative architectural features, or an outdoor speaker system for a cruise ship, SRM enables companies to market their products as both competitively priced and sustainably produced.
SRM is also well-suited for markets with carbon pricing
“SRM is an alternative that not only eliminates emissions but also dramatically reduces production costs. Without the need for fossil fuel inputs, manufacturers can save up to 30% on production.”
incentives, sustainable content legislation, or other green initiatives. As governments and organisations worldwide continue to adopt policies that favour low-carbon manufacturing, SRM’s zeroemissions profile becomes a substantial advantage. Manufacturers may be able to generate carbon credits or avoid carbon import taxes by switching to SRM.
Global implications of SRM SRM has far-reaching global implications. For developed countries, SRM offers a way to reduce plastic production’s environmental impact and cost. In developing nations, SRM enables manufacturing of water and septic tanks in areas without industrial infrastructure - increasing access to water and septic tanks and other critical products. “I’m very excited to see this technology used to reduce water scarcity and improve sanitation around the world,” concluded von Kries. “I’m glad the LightManufacturing team built a long-shot idea into a new kind of manufacturing.”
UBQ: A sustainable additive in polyolefin formulations
Q. How does UBQ compare to traditional polyolefins in terms of mechanical properties like tensile strength and resistance?
UBQ is a bio-based, thermoplastic composite material made from mixed, municipal household waste. The highly sustainable products are created by applying a unique and patented low-energy process suitable, at its production facility in the Netherlands with a capacity of 80.000t/a, for a partial replacement of polymers. Polyolefins, like polypropylene and polyethylene, are typically formulated by blending with additives, fillers, and impact modifiers to achieve the desired mechanical properties. UBQ serves as an additional sustainability additive, used primarily for its positive carbon footprint impact, within this formulation. As part of the matrix, UBQ affects the mechanical properties by increasing flexural strength while decreasing tensile strength and impact properties. However, these performance changes can be compensated for by adjusting the formulation using conventional or recycled products. Hence, UBQ offers a novel additive for formulators who are looking for sustainable solutions.
Q. What are the thermal properties of UBQ?
As a composite material with thermoplastic behaviour, UBQ itself has no specific melting point. The thermal stability of the finished product is achieved through the antioxidant, and UBQ has little to no effect on this aspect. In a formulation, UBQ has very little effect on the overall thermal properties and heat distortion temperature.
Editor Rebekah Jordan caught up with Kurt Kronawittleithner, global director of applications, UBQ Materials, to discuss how using UBQ as an additive in polyolefins can offer comparable mechanical properties and promote a circular economy.
Q: How does UBQ perform in regards to chemical resistance, UV stability, and weathering?
When it comes to UV stability and weathering, the addition of UBQ, as an additive in polyolefins, has improved the carbon footprint while fulfilling all performance requirements. Stringent requirements of various demanding applications, including outdoor furniture and automotive components have been proven. These applications are known for their rigorous requirements regarding UV resistance and durability against environmental factors. While it is essential to acknowledge that every additive impacts the material properties to some extent, UBQ has undergone extensive trials and tests that show formulated solutions meet defined performance requirements including UV stability and weathering.
Q. How does blending UBQ’s material with other materials affect its sustainability and environmental benefits?
When using UBQ as a sustainable additive, companies are improving their carbon footprint significantly,
taking waste away from landfills and incineration, and, importantly, contributing towards a circular economy. By using household waste destined for landfills or incineration as a feedstock material, UBQ possesses several advantages, avoiding methane emissions, groundwater leachates, and environmental and health hazards associated with these linear waste disposal methods. As an end-of-the-life solution for residual waste, UBQ supplements existing recycling efforts by maximising resource recovery and creating a valuable material resource that can be repeatedly utilised by the existing industry among various sectors.
UBQ replaces oil-based plastics and other finite resources with a carbon footprint up to 15-20 times lower than alternative resins and up to four times lower than recycled plastics, conserving resources, and promoting a circular economy. UBQ’s novel material allows brands and manufacturers to fulfil the growing demand for renewable resources, and helps companies achieve their sustainability goals including recycled content requirements and circularity.
UBQ in pure form cannot be compared vs. polyolefins; rather it’s used as a partial replacement. UBQ is used as a material replacement or additive to conventional plastics in durable and semi-durable applications.
Q. What are the key drivers and trends shaping the demand for UBQ in end-use industries?
Circular approaches are increasingly gaining traction across industries, and UBQ plays a vital role in this trend.
The endless availability of UBQ, derived from household waste, provides a sustainable option for formulators looking to meet their performance requirements while achieving sustainability targets. As industries continue to prioritise sustainability, we will see increased demand in key markets such as building and construction, consumer durables, automotive, and logistics and supply chain applications. I am convinced that every industry will have sustainable targets in the future, and UBQ is an excellent tool to help achieve those goals.
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Dave Raine
Rethinking plastics from a supplier’s perspective
Dave Raine discusses the opportunities for sustainable innovation in light of the UK plastics industry’s current pressures, focusing on the role of suppliers to drive change through alternative thinking and material substitution.
As we head into the final quarter of 2024, the plastics industry in the UK is facing a variety of pressures, reflecting both global trends and specific regional challenges. Environmental regulations and policies continue to place pressure on us as an industry, as increasing scrutiny on the environmental impact of plastics becomes more visible. The UK government has implemented several policies aimed at reducing plastic waste. But this, in my opinion, is merely aimed at pacifying public awareness of plastic pollution, and whilst companies in the plastics industry are under pressure to develop and adopt more environmentally friendly materials and practices to meet these evolving consumer preferences, the fact remains that in most cases, plastics are the right material for the job. So, what to do?
The UK faces issues with plastic waste not being effectively recycled, partly due to limitations in recycling infrastructure and technology, but speaking to several companies within the PMMDA who are involved in material handling, there is clearly an increasing focus on managing plastic and converting plastic waste - and improving recycling rates remains the goal. However, there are other avenues to pursue, some of which require
investment, but some which just require alternative thinking.
At a recent seminar, an interesting topic evolved, and having worked in the raw materials supply sector in the late nineties and early 2000s, the conversation resonated. As products evolve or are replaced by new designs (automotive face-lift programs, for example), a request to a material supplier may be: “Can you supply ABC grade of material please – we need X tonnes per year” – when questioned why that particular grade, a normal response would be: “That’s what it says on the drawing.” Suppliers of material have, in most cases, a wealth of experience, and when faced with the economic pressures we are currently seeing, customers may be more willing to look at an alternative if suggested, but maybe don’t have the experience or knowledge to ask – if it’s always been made from GF Nylon, but there are no
mechanical or thermal issues with changing, could we consider GFPP instead – does this offer a cost benefit to the customer, and without prompting, would they have even considered it?
This article is both brief, and also uses a broad-brush approach to what’s clearly a complex and involved process, but it’s also, hopefully, a catalyst. In the current climate, as suppliers, we have a duty of care to all customers, as without them, we have no market. As such, we will need to adopt new approaches to customer requests – even if we have no direct links to polymer sales, advising or helping customers to remain competitive globally has to be our long-term goal, and automation, material supply, and machine technology aimed at allowing more PCR usage are just some to the things we can use to help facilitate this.
Dave Raine Chairman, PMMDA
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Philip Law
BPF’s Philip Law on the federation’s new initiative to boost productivity and sustainability in the UK plastics industry by launching practical guides and a talent development program.
BPF invests in the future
The summer seems already well behind us as we launch into Quarter 4 in top gear. Productivity is to the fore with the BPF’s initiative, ‘Productivity Redefined’, publicly launched at Plastribution’s recent Innovation Festival. This initiative is the product of considerable strategic thinking and a significant reorientation of BPF’s activities in the aftermath of Brexit and the growth of aggressive nationalism in certain regions of the world. The conclusion was that the world’s trading environment could become more hostile and competition to win new business around the globe.
Out of the need to help the UK industry sharpen its competitive edge, BPF established a Central Expert Committee on Productivity. Fittingly chaired by BPF president Nigel Flowers, inspired by industry experts Ian Ray and Andy Jewell and skilfully supported by BPF’s Graeme Craig, the Committee embarked on a wholesale review of the factors which influence productivity and began drafting new guides for the industry. Two years of collaborative work carried out by key stakeholders in the industry then ensued. The guides aim to help improve efficiency through the deployment of best-practice methodology in the technologydriven factories of the future.
‘Productivity Redefined’ is available in free downloads to members. The first three focus on
Energy Management, Equipment Effectiveness (part I: Injection Moulding) and Product Design. Three more guides are expected by the end of the year: Automation, Digitalisation (Part I: Real Time MES, Part II: ERP/MRP) and Waste Minimisation. The guides will be revised annually to ensure they keep pace with industry standards and innovation. Phase II is already underway with more documents in the pipeline for 2025.
We tend to look at subjects in boxes and we shouldn’t forget that productivity is a key aspect of sustainability as it is all about a more efficient use of resourceshuman, physical or in the form of energy - a point I will be making at the forthcoming GRIPS event.
The search for new talent is a constant struggle and BPF is persisting in its efforts to interest the younger generation in a career in plastics. Our Career Ambassadors Campaign helps to equip people in the industry with the tools required to go into schools and address children
about the career opportunities available in plastics. The BPF’s next Career Ambassador training will take place online on Wednesday 23rd October. It will be led by Rachel Brickell from Cogent Skills SIP Ambassador Programme. Attendees are taught how to use the SIP ‘Futures in Science’ handbook to create lesson plans aimed at secondary school children in years 9 to 12. Ambassadors are taught how to build relationships with teachers, career advisors and parents, in addition to how to deliver an inspiring presentation about their career.
The BPF has also partnered with STEM Learning UK to provide Career Ambassadors with access to the STEM network forum and resources, so you can have access to a whole range of resources to deliver the best career outreach activities to the next generation! Those who train to become a Career Ambassador also become a Cogent SIP Ambassador and STEM Ambassador, joining a network of like-minded professionals.
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