British Plastics
and Rubber
bp&r SEPT 2013
Intuition meets technology The new MC6 control system Engineering Passion
Plastic Pipes and Profiles
K Show On-Site Edition
Testing and Inspection
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bp&r BRITISH PLASTICS &RUBBER www.britishplastics.co.uk EDITORIAL Editor: Leanne Taylor T: +44(0)1244 680222 E: leanne@rapidnews.com
SALES Group Advertising Manager: Lisa Montgomery T: +44(0)1244 680222 E: lisa@rapidnews.com
ART
Why consumers suffering from ‘wrap rage’ should count to ten
SAM HAMLYN T: +44(0)1244 680222 E: sam@rapidnews.com
SUBSCRIPTIONS T: +44(0)1244 680222 E: subscriptions@rapidnews.com
PUBLISHER
British Plastics & Rubber is available on free subscription to readers qualifying under the publisher’s terms of control. Those outside the criteria may subscribe at the following annual rates: UK: £80 Europe and rest of the world: £115 British Plastics & Rubber is published monthly (10 times/year) by Rapid Plastics Media Ltd, Unit 2, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44(0)1244 680222 F: +44(01244 671074 © 2013 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.
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that packaging design continues to evolve, A recent survey by Which? has reported however, to those frustrated consumers, that two-thirds of consumers are becoming increasingly frustrated by ‘wrap rage’, which next time you’re wrestling with wrapping or prodding at plastic, it might be worth is caused by the packaging on everyday counting to ten to weigh up how the products being “too hard” to open. benefits might just be worth the fight. Moulded plastic ‘clam-shell’ packaging Packaging, of course, is just one of is reportedly the main offender, followed by many plastic applications shrink wrapping and peelthat will be featured at K off coverings. According to 2013, which kicks off this the survey of more than “We’ve highlighted a month. It’s been three 2000 consumers, four in selection of news from years since Düsseldorf last ten people have even hurt themselves while trying to exhibitors from the UK welcomed the plastics and rubber industry to exhibit, open packaging over the and abroad in our K trade, network and market last two years. special feature, starting at the tri-annual event. Which in turn must on page 29.” Now, as companies the mean the designers, world over scratch heads developers and and wonder where those manufacturers that have spent hours, months, years even, perfecting three years have gone, the stage is set for over 3,000 exhibitors to promote all the designs, materials, closures, machinery very best that the industry has to offer to an and logistics for the production of expected 200,000 visitors from across the packaging that is tamper-proof, food-safe globe. We’ve highlighted a selection of and secure in transportation must be news from exhibitors from the UK and increasingly frustrated themselves. abroad in our K special feature, starting on Plastic packaging has come a long way page 29. and ranges from the basic to the downright I’ll be at the show with the rest of the ingenious. Despite the fact that some BP&R team, so if you are going to K 2013 consumers might find it a bit fiddly, as either a visitor or exhibitor, please do innovations such as the ability to increase drop by stand C03 in hall 11 and let me shelf life, protect from damage, bacteria know how the show is going for you. and breaking, are all additions that, were they not there, would leave consumers with Enjoy the issue. a lot more problems than just ‘wrap rage’. Leanne Taylor — Editor Of course, feedback is important to ensure
Mark Blezard T: +44(0)1244 680222 E: mark@rapidnews.com
Static electricity control technology for use in both industrial and cleanroom areas Call +44(0)1993 706700 or visit www.meech.com
IMM control system to be rolled out across more machine ranges at K 2013 “With the MC6 we have developed a control system which meets our customers’ needs for ‘usability’ in every respect,” said Dr. Karlheinz Since its launch in May 2012, Bourdon, Vice KraussMaffei’s MC6 control President, Technologies, in system for injection the Injection moulding machines has been Moulding in use in all models of the Machinery Segment of company’s GX series. As of K KraussMaffei. “It 2013, it will be available for can be operated all other machine series, clearly and incredibly easily including the all-electric using SplitScreen AX and EX machines as well and as the CX and MX series. ProcessDesigner.” KraussMaffei says the MC6 control system is straightforward and intuitively designed to ensure optimum efficiency, with features including split-screen functionality for displaying separate content as well as the simultaneous viewing of process parameters including actual-value cycles and the injection process. The integrated ProcessDesigner tool clearly presents all current processes in visual terms and enables the user to modify them, depending on requirements, by means of simple drag-and-drop movements or swiping movements for optimum usability. Eco button for optimum machine setting KraussMaffei says in keeping with its overall energy-efficient design, the MC6 control system has been equipped with an ‘eco button’, meaning a machine setting for optimum production efficiency can therefore be made at the push of a button. Featuring the same dual-touch function as a Smartphone The MC6 is equipped with a resistive touch screen – this means the screen is pressure sensitive and therefore can be operated even when wearing gloves. The dual-touch function allows the MC6 to be operated using two fingertips, much in the same way as a Smartphone. All the mentioned
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features are not only available on the machine display, but also on the robot handheld pendant (Fig. 2). Integrated operating concept The new operating concept for industrial robots (IR) involves the integration of KraussMaffei automation solutions in the machine control system. An additional operating area for the robot is no longer required, says the company, as the control buttons are contained within the machine control system. This is designed to make the machine operators’ work easier and reduce operating errors whilst increasing productivity. Just as the robot can be operated from the machine control system using the MC6 control system, the machine can also be controlled using the robot handheld pendant. Intuitive, simple programming KraussMaffei says the WizardX and VisuX programming and operating wizards integrated in the MC6 greatly simplify the operation of automated production cells. With the WizardX graphical programming wizard, the linear robots used in the injection moulding area can be programmed quickly and without error. The programming wizard enables error-free programme code to be generated even by operators with no knowledge of programming. KraussMaffei says in VisuX it has developed a user interface that provides the operator with all the necessary information on the industrial robot (e.g. programme selection, counter, times, current axis position). All information is grouped and clearly presented on seven pages. The operator is therefore able to diagnose the current manufacturing process at any time and make any necessary adjustments. The simplifications to the programming and operation of the robots reduce personnel training requirements, says the company, therefore programming errors are avoided, saving time and money. Visit at K2013, Hall 15, Stand B27/C24/C27/D24 further information: www.kraussmaffei.com
The MC6 control system platform for complex production cells allows two-way operation
t machine and robo ection moulding nels pa or at Figure 2: The inj er op r ssed from othe can also be acce
THE BIG STORY
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on the cover
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Intuition meets technology The new MC6 control system Engineering Passion
bp&r BRITISH PLASTICS &RUBBER
contents
SEPTEMBER 2013
on the cover IMM control system to be rolled out across more machine ranges at K 2013 Since its launch in May 2012, KraussMaffei’s MC6 control system for injection moulding machines has been in use in all models of the company’s GX series. As of K 2013, the system will be available for all other machine series.
See page 4
23-27 ]FEATURE pipe and profile Global demand for plastic pipes to rise by 8.5 percent
29-35 FEATURE
EDITOR’S LETTER Why consumers suffering from ‘wrap rage’ should count to ten
INDUSTRY NEWS
08
From the Front Line
35
injection moulding
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Engineering Materials
46
Reclamation and Recycling
48
SOFTWARE
51
BUYERS’ GUIDE
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K Show: Special Feature Let the K Show commence
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REGULARS
37-43 FEATURE Testing and Inspection
14-18 FEATURE
How to ensure effective testing for material selection
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tooling and mould making Improving mould making efficiency and productivity
20-21 FEATURE purging Effective purging for injection moulders
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Industry News
news Can you turn detective in the name of plastics? The Museum of Design in Plastics (MoDiP), based in Bournemouth, UK, has launched a research project that it hopes will unearth some previously unknown facts about the history and origin of some of the products in its collection. The museum, which is the only accredited museum in the UK with a focus on plastics, is working in partnership with the University of Brighton and Adaptive Technologies Ltd in undertaking the research, which will take the form of an online game to crowdsource discovery and verification of previously undocumented facts about some of its plastic artefacts. Inspired by the FBI’s ‘Ten Most Wanted’ website, the project will combine the web, social media and gaming to motivate the public to search for unrecorded information; enable players to work together and to reach out to other groups for assistance; and encourage them in physical enquiry as well as online research. MoDiP hopes it will help to
stimulate interest from the public as well as the plastics industry. Typical examples of the ‘wanted’ facts are the designer and precise dates of manufacture of everyday products, as well as more obscure artefacts, such as this duck-shaped clothes brush (see image). “Lettering on it tells us it [the duck clothes brush] was made in England and there is evidence of injection moulding,” commented Susan Lambert, Head of MoDiP. “Wanted information includes who designed it, who made it, when it was made and the particular plastics used in its manufacture.” The project will be going live in October. further information: www.10most.org.uk
c duck This plasti vokes o pr h brus unanswered about questions its origins
s The Bank ha years spent three e th g in w revie s of relative merit tes no nk ba ng printi er th ra on polymer t en rr cu e than th r used pe pa on tt co at present
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Public consultation marks one step closer to a purse full of polymer The reality of using polymer banknotes in the UK has moved one step closer to reality, as the Bank of England announced it is to launch a public consultation programme to decide whether or not to go ahead with printing on plastic. As part of this programme, the Bank will run a number of events across the UK as part of an awareness campaign in order to give the public an opportunity to learn more about polymer banknotes and to provide feedback, before a final decision is made and announced in December 2013. Commenting, Deputy Governor of the Bank of England, Charles Bean, said: “Polymer banknotes are cleaner, more secure and more durable than paper notes. They are also cheaper and more environmentally friendly. However, the Bank of England would print notes on polymer only if we were persuaded that the public would continue to have confidence in, and be comfortable with, our notes. The results of the consultation programme on which we are embarking will therefore form a vital part of our assessment of the merits of polymer banknotes.” For the past three years the Bank has conducted a research project looking at the materials on which banknotes are printed, in particular, reviewing the relative merits of printing banknotes on polymer rather than the current cotton paper used at present. If a decision is made to move to polymer, the Bank will also introduce smaller banknotes. Polymer banknotes are manufactured from a transparent plastic film, specially coated with an ink layer that enables it to carry the printed design features of banknotes. The material allows the inclusion of ‘windows’ or clear portions in the design, which enhance protection against counterfeits. Further information: www.bankofengland.co.uk
Industry News
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news JLR investment to benefit UK automotive supply chain An announcement by Jaguar Land Rover (JLR) to invest significantly in its manufacturing site in the West Midlands is expected to have significant positive repercussions on the UK automotive supply chain. The move will see an investment of approaching £1.5 billion and the creation of 1,700 new jobs at JLR’s Solihull plant to support the expansion of its product range. Dr. Ralf Speth, JLR Chief Executive Officer, announced the major strategy at the Frankfurt Motor Show. “Jaguar Land Rover is a business driven by design, technology and innovation and this investment and level of job creation is yet further evidence of our commitment to advancing the capability of the UK automotive sector and its supply chain,” he said. JLR says it will employ some of the latest lightweighting technologies in the production and manufacture of its new
JLR has announced an investment approaching £1.5 billion to introduce allnew technically-advanced architecture in forthcoming models. Shown here is the C-X17 concept car
models. In order to fully realise the potential of this new technology, the company says it will significantly increase its spend with the supply base. UK Business Secretary Vince Cable said: “Jaguar Land Rover has been
experiencing great success over the last couple of years but this ground-breaking project takes Jaguar onto the next level.” further information: www.jaguarlandrover.com
UK ancillary supplier secures global contract TH Plastics has completed a major contract for a global automotive solutions provider, which it says not only delivers significant operational benefits but also secures a long-term international partnership. The UK-based ancillary solutions provider, which supplies, installs and supports machinery in the plastics industry, delivered a new blending and drying solution for Reflex & Allen’s main manufacturing plant in Bodelwyddan, North Wales. The plant required a new solution to replace existing equipment and to facilitate the effective handling of increasingly sophisticated work. TH Plastics secured the contract following a month-long trial of its equipment, providing a turnkey solution including design and equipment supply, as well as testing, installation, ground work and power supply. The company supplied and installed Moretto DGM gravimetric blenders, Eureka drying systems, DVM volumetric dosers and three-phase suction units for material handling. TH Plastics’ says the solution was integrated to optimise efficiency, maximise energy savings, reduce labour costs, increase uptime and improve product quality and since its installation in May has generated considerable benefits and high quality output. Energy consumption trials are currently taking place, with early indications of a 40 percent reduction. “We have benefited from a competitively priced system with proven reliability,” said Reflex & Allen’s Engineering Manager, Chris Ackroyd. “We have been so impressed, so early on in the relationship, that we have already commissioned TH Plastics with another project and believe they are capable of being long-term global partners.” further information: www.thplastics.co.uk
cturing has UK manufa f-and-a-hal hit a two tput u o h it w , year high test at its fas increasing , July 1994 rate since a recent to g in accord report
UK manufacturing output and new orders rise at fastest rates since 1994 UK manufacturing has hit a two-and-a-half-year high, with output increasing at its fastest rate since July 1994, according to the latest data from Markit/CIPS. The seasonally adjusted Markit/CIPS Purchasing Manager’s Index (PMI) hit 57.2 in August, up from a revised reading of 54.8 in July. A reading above 50 on the index signals expansion. The data indicated that the UK manufacturing sector maintained its robust start to the third quarter of 2013. After the solid increases in output and new orders registered in July, August saw the momentum continue to build, with growth rates for both variables at their highest since 1994. However, cost inflationary pressures increased on the back of rising raw material prices. Manufacturing output increased at the fastest pace for 19 years, with marked expansions signalled across the consumer, intermediate and investment goods sectors. The performance of intermediate goods producers was the strongest, with the pace of output growth hitting a series record. New orders rose for the sixth month running and to the greatest degree since August 1994. The domestic market was the main source of new contracts, although there was also a solid increase in overseas demand. Companies linked higher order volumes to successful new product launches, promotional activity and improved client confidence. On the export side, there were reports of stronger demand from the USA, China, mainland Europe, India, Scandinavia, Brazil and Ireland. Rob Dobson, Senior Economist at survey compilers Markit, said: “The UK’s factories are booming again. Orders and output are growing at the fastest rates for almost twenty years, as rising demand from domestic customers is being accompanied by a return to growth of our largest trading partner, the Eurozone.” The main negative finding from the latest survey was a marked upsurge in cost inflationary pressures for manufacturers. Average input prices rose at the fastest rate for two years and at an above survey average pace. further information: www.markit.com
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The company says a key to its success is its research and testing laboratories, where five people are employed full-time
industry news
Compounding
a Recipe
for success
According to a recent survey from the EEF, Britain’s manufacturers are substantially increasing their innovation in new products, technology and research, as well as investing in equipment, with plans to use this to grow their presence in overseas markets. One company that has recently made significant investment at its UK site is Derbyshire-based Vinyl Compounds. Leanne Taylor visited the company to find out more about their strong export growth, recent purchases and promoting ‘brand Britain’ in the global marketplace.
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“By failing to prepare, you are preparing to fail.” This is seemingly the motto of Vinyl Compounds, a company that has taken matters into its own hands in terms of forward planning and investment to ensure that the products it sells are of optimum quality, are delivered on time and are competitive in a global marketplace. “We have to take seriously the promise that we deliver quality products on time,” said Richard Loynes, Commercial Director at Vinyl Compounds. “To this end, we have embarked on a significant programme of investment at our UK facility, including the purchase of brand new compounding lines, the latest R&D equipment, as well as investment in our fleet and on-site resources for improved logistics and transportation.” The company, based in Chinley, Derbyshire, produces an extensive range of rigid, flexible and speciality grades of PVC and has a global customer base, having truly immersed itself in the export market. “We are supplying customers on an international basis and buying our raw materials from all over the world,” continued Loynes. As part of its half its million pound investment in the last year, the company has purchased new compounding lines to streamline its manufacturing processes,
lion s made a half a mil Vinyl Compounds ha r yea t las e th pound investment in
as well as equipment for its on-site laboratory to enable raw material testing and product development. “We are investing because it’s a really tough world at this moment in time, so we’ve got to be as state-of the-art as we can. PVC technology is constantly evolving and it’s essential we stay at the forefront of this technology,” explained Duncan Makin, Vinyl Compounds’ Chairman. The company says a key to its success is its research and testing laboratories, where five people are employed full-time. As well as a library of specific formulations it keeps on record, the changeable nature of the industry means it is constantly developing new formulations as market demand dictates the use of different products. “To have constant R&D is almost unheard of in the field of PVC because it’s so mature,” said Makin. “We have a range of biocompatible plasticisers, which we have formulated and developed here. We have our own particular recipes using sunflower oil and naturally occurring materials. That’s like a generation on from phthalate free if you will – you’ve got phthalates, phthalate-free and now bioorganics.” The company says that it is proud to promote itself as a UK manufacturer and
believes that the quality of products it produces has been a key driver for its high level of export sales. “When we package our products we stamp ‘Made in Britain’ all over them. We’re proud of our products and know the quality is there, so we want people to know that it’s come from the UK,” said Loynes. “We have recently invested £130,000 in a bagging machine, which means products are weighed and produced on time. When overseas countries see the UK can be competitive, even as a small country, they respect that,” he continued. As building work continues on the Vinyl Compounds site, the company says that it will continue to be both flexible and innovative in its approach to new ideas, processes and concepts. “In this marketplace you have to stay competitive,” said Makin. “We have come a long way and have built a dedicated customer base with some big brands on board. By investing in our facility we will continue to be able to react to market trends and demand so that we can stay competitive going forward.” further information: www.vinylcompounds.co.uk
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tooling & mould making
news High-speed milling machine ensures high accuracy for UK firm Birmingham-based precision engineering firm, GB Precision, says that hard metal machining on its high-accuracy 5-axis Roeders machine is providing an effective alternative to a combination of grinding, jig boring and EDM-work for machining complex components, such as mould tool dies. The Roeders RXP500DS high speedmilling machine was originally purchased as part of GB Precision’s automation cell, together with a System 3R robot and an AGIE Hyperspark die sink EDM machine. “We selected the Roeders for its consistent accuracy – with linear motors on all 5 axes, precise temperature control and high resolution optical encoders, it was perfect for the type of work we were looking to automate,” commented company Director, Paul Turner. GB Precision says having this level of technology available has opened up additional opportunities for the company,
Roeders technology installed at GB Precision
including the possibility of directly machining hardened heat-treated components. “By machining the components this way, not only can we eliminate several secondary operations – reducing the opportunity for human error, but we can also avoid common problems, for example with components which distort during the heat treatment process. Using hard metal cutting, we have found we can produce more accurate components for our customers, in a significantly reduced overall time,” continued Turner.
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bp&r
O-ring Counterbore for mould and tool making launched Meusburger has launched a range of O-ring counterbores that it says are especially designed for use in mould and tool making. The company says the new O-ring Counterbore WZB 32112 allows for the quick and easy insertion of O-ring grooves in the injection mould. When the sink groove is made it is made through longitudinal grooves, which ensure a tight and secure fit of the Oring. For work with a long tool with overhang in the length, a guide pin can make further extension. This ensures precise and reliable centering of the groove every time, says Meusburger.
rbore WZB 32112 The new O-ring counte
24,000 RPM High Speed Machining hining
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further information: www.gbprecision.co.uk
further information: www.meusburger.com
Deep Hole Drilling up to 1500mm
Hales Tool & Die Limited Unit 10, Heybridge House Ind. Est. The Causeway, Maldon, Essex. CM9 4XL. United Kingdom
One example of the type of work that GB Precision is undertaking is the machining of mould tool dies, which include bespoke, complex 3D curved geometries within the sides of the part. The company says that the accuracy and finish are so good using the direct milling technique that parts come off the machine already in tolerance and very close to the required 0.4ra finish, only a brief machine polish is required to ensure the parts are fully in specification.
Phone 0800 634 8800 Fax 0800 634 3800
www.halestooling.com
Swiss rotary tables give 4th /5th axis for XYZ Devon-based XYZ Machine Tools has announced that any vertical machining centre in the range it offers can now feature 4th and 5th axis machining, utilising the high precision of Lehmann rotary tables. The company says being of modular build, and therefore meeting ‘future-proof’ requirements, the unit can achieve 180 degree positioning within 0.5 seconds, reportedly half the time rating of competitor units while maintaining accuracy to 10 arc/secs. Lehmann has specialised in NC tables and positioning equipment for over 35 years during which time more than 10,000 units have been installed. The compact design of the EA 500 series of three units has the rigidity of a cast iron base with hard chrome plated gear unit housing and an anodised aluminium cover to prevent damage from the likes of swarf and coolant in the machining area. The compact dimension of each unit also means machine table area and Z-axis stroke is not compromised. XYZ says being modular and using Lehmann’s CombiFlex system of build, more than 20 different methods of component clamping can be applied as standard in conjunction with manual or power-operated devices. As a result, restrictions caused by normal faceplates, chuck jaw and clamping areas of other systems are overcome. The gear-based indexing mechanism can be fine tuned for backlash if required during service life through radial adjustment of the worm. Also, the use of quadruple precision bearings provides maximum radial support against thrust generated, particularly when drilling offcentre. Internal radial spindle clamping is on the maximum diameter with integrated
Any vertical machining centre in the XYZ range can now feature 4th and 5th axis positioning with the Lehmann rotary table
pressure intensifier and pressure sensors that create a clamping factor between 300 and 4,500 Nm, a factor 10 times that of competitive products, says XYZ. This is said to eliminate any axial displacement of the spindle and loading against the spindle bearing. Built-in intelligence displays history and speed, monitors internal pressure, temperature, moisture, shock and clamping data. The three models, EA507, EA510 and EA520, have clamping torques of 300,
800 and 2,000 Nm respectively, with an indexing accuracy of 20, 17 and 12 arc/secs. The weight of each unit is 22 kg, 35 kg and 70 kg and each respectively is able to support workloads of 240 kg, 400 kg and 800 kg. further information: www.xyzmachinetools.com
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Introducing the XYZ thoroughbreds But that’s just the start of it because when you combine great value products like these, with great support, it’s easy to see why XYZ has grown to be the largest supplier of CNC machine tools in the UK. So here it is, the finished article, the 2013 XYZ range, each one the very best in its class.
Here at XYZ we have been developing, testing and refining our range of machine tools for 29 years. Our winning principles of combining outstanding build quality with the world’s best control systems, namely ProtoTRAK® Siemens and Fanuc, has seen the XYZ product become the nations first choice for prototype and low volume production.
ER N IN W
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Bespoke is the new standard in the name of tooling efficiency Suppliers to the tooling and plastic industry, Hales Tool and Die, say that more companies are choosing to outsource the machining of mould plates, treating them as ‘bought in’ components, in order to maximise efficiency in tool shops. Hales’ UK subsidiary, based in Essex, says that by offering a service where components are machined bespoke to customers drawings and models, companies can free up CNC machines and cut down on manual handling. “Whilst standard components continue to be the best solution for new tooling regarding ease of design, cost effective manufacturing and interchangeability, it doesn’t always provide the complete package,” commented John Applebee at Hales UK. “Take a mould plate for example. What starts as a fairly cheap bought-in standard part, soon becomes a very complex component having spent many hours on the CNC machines. As well as the hourly rate that toolmakers charge (sometimes achieved and sometimes not) there are the cost of cutters and other additional costs, often overlooked. Large mould plates take a considerable amount of additional handling, great if you have all of the correct equipment but in reality shops are often stretched to just outside their comfort zone,” Applebee continued. The company says that its suppliers are able to machine a single mould plate up to six metres in length, three meters in width and 1.5 meters thick with a maximum weight of 32 tonnes. “Machining mould plates is a costly exercise, unless you are really set-up for doing this, so it is a good idea to consider the benefits of external machining services,” concluded Applebee. further information: www.halestooling.com
it is a Hales say good idea to ternal consider ex machining
CAD image of a hearing aid injection mould
Toolmaker invests in machining centre for small mould making A German toolmaker that specialises in the production of precision moulds for plastic hearing aids has invested €1.5 million in a new machining centre for small-parts injection mould making. The machining centre at Toolcraft is equipped with new Exeron HSC milling machines, Exeron EDM electric discharge machines, Zeiss Contura 3D coordinate measuring machines, Erowa robot systems and Certa automation software. The company says the investment in the new machinery and equipment ensures a high level of precision is achieved in the manufacture of challenging small parts. All assemblies, insert technologies, multi-component injection moulds and part finishes are included in its range of injection mould manufacturing. According to Klaus Dörr, Head of Mould Making and Injection Moulding at Toolcraft, the new centre enables cuttingedge automated tool making with which the flow of parts can be centrally managed. This, he says, means it can produce around the clock when needed,
CAM software helps mouldmaker to reduce lead times A manufacturer of precision injection moulds says using CAM software from UKbased Delcam has led to shorter lead times and faster delivery. Industrial Molds, which specialises in all facets of injection-mould manufacture including design, engineering, tooling and special machining services, says it considers Delcam’s PowerMILL CAM system for high-speed machining to be critical to achieving the company’s eightweek average lead times. “PowerMILL reduces our lead times in a number of ways,” explained Greg Osborn, Account Manager at Industrial Molds. “It delivers the machining accuracy we need to reduce the amount of hand finishing we do. It also has a number of features that reduce programming time, plus powerful functionality, such as arc fitting, that allows us to run our machines at top speeds, which reduces machining time.”
need The small parts rate cu ac y hl hig to be
tooling & mould making
news
with high throughput and fast delivery. Standards in this sector are very high, says Dörr: “The tiny components make very high demands on tool making, but also on production and assembly. The required clearances and accuracy of fit of the parts are at a level which is much easier to achieve in other industries.” Small parts for hearing aids range from a 0.01g to 5g charge weight. In order to be able to offer complete solutions as part of its precision strategy, Toolcraft has a small parts injection department with 20 injection moulding machines in addition to its mould-making department. further informatioN: www.toolcraft.de
are is helping to Powermill CAM softw dustrial Molds In at es tim reduce lead
Delcam says PowerMILL’s high-speed finishing, multi-axis machining, fast calculations and toolpath-editing functionality contributes to the faster machining of high-quality parts. The programme can also reportedly be used with a wide range of materials in order to serve customers in a variety of industries. further information: www.delcam.com
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tooling & mould making
Case study: Improving mould making efficiency and productivity A UK-based manufacturer has revealed that by investing in a new EDM machine and design software it has revolutionised manufacturing processes and significantly increased toolmaking productivity. Here, BP&R takes a closer look at the benefits the company has reported and why it considers the investment key to growth. A tooling manufacturer says the combination of purchasing a spark eroder and switching to electrode design software has “completely revolutionised” the production of its copper electrodes. Leicester-based Alliance Tooling, which makes aluminium and steel injection moulds for a number of industries, including household goods, medical and dispensing products and the automotive sector, has invested in a new Sodick EDM AG60L spark eroder as well as ‘VISI Electrode’, design software from Vero in order to improve its electrode design and manufacturing processes. The new software was recently used by Alliance during the manufacture of a mould for the trigger of a household cleaning spray. “We needed ten different electrodes for the tool, which, previously, would have taken ten hours to create,” commented Luke Parsons, Managing Director at Alliance. “Each electrode used to take an hour to model, but VISI Electrode has reduced our design time by 80 percent, with each electrode now taking less than 10 minutes to produce.” The company says it first realised it needed to improve its electrode design and manufacturing processes while building a mould for a drug-dispensing component, which required a large
ned Software from Vero has streamli es trod elec of ion uct prod the
number of electrodes, but with a short production window. “This highlighted a bottleneck with producing electrode models and sparking them,” Parsons said. Alliance purchased a Sodick AG60L six-station toolchange spark eroder, which it says overcame the sparking bottleneck. “The roughing cycle is far faster than anything we’ve seen before, and with the tool-changer we can maximise lights-out usage,” said Parsons, who says the use of VISI Electrode means Alliance has electrodes ready before it needs them. “In the past we’ve been sparking electrodes as soon as they’re available, then production stopped while we made another.” Parsons explained that although implementation of VISI Electrode meant the Sodick would be fed with electrodes for sparking, the company still had to consider toolpath production before its efficient electrode process was complete. “Until recently we only had one holder, but
Alliance says using the new EDM machine and software has considerably improved its production processes
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now we’ve created a dedicated jig comprising four new electrode chucks in specific datums on a hardened and ground steel plate. This is now a permanent fixture on our Hardinge Bridgeport and we can machine electrodes in batches of four by linking individual programs together – again fully utilising lights-out machining.” Commenting on how the data export from VISI Electrode saves Alliance even more time and material usage, Parsons said: “Previously, where we had the same feature on a tool, but in multiple positions and different orientations, we had to make different electrodes of the same feature, but at different angles. Now we can fit one electrode into all the necessary positions as VISI Electrode provides the XYZ and U position so we can use the same electrode to produce all the common features. We just physically rotate it on the machine.” As well as overcoming the design bottleneck and improving the manufacturing process, Parsons says VISI Electrode also gives them the confidence that their electrodes will be completely accurate: “We only get one chance to spark an electrode in position, so there’s no margin for error. VISI Electrode doesn’t just create the electrode, it creates a coordinate sheet, a drawing report of the electrode and workpiece, XYZ and U coordinates, and the start and finish points. It gives our Sodick operator a visual picture of what he needs to achieve. This is of paramount importance for accuracy.” He says while the combination of the spark eroder and VISI Electrode has revolutionised the way they design and manufacture electrodes, it is “absolutely key” in the company achieving its aim of doubling turnover within 12 months. www.vero-software.com www.alliancetooling.co.uk
purging
news Effective purging for injection moulders CJP Sales Ltd, distributors of Dyna-Purge in the UK and Ireland, has announced it is expanding the use of purging compounds for hot runner systems. Using Dyna-Purge F, which has a fast-action cleaning function, the company says injection moulders are able to clean the screw and barrel quickly and efficiently by removing carbon deposits and flushing out coloured material. CJP says Dyna-Purge F is effective at keeping injection moulding hot runner tools free from residue build up. “The versatility of Dyna-Purge F allows you to purge through an open tool or, as preferred by some moulders, to purge into the cavity in a continuous moulding process which allows automated systems to run without delay,” commented Richard Benyon, Managing Director at CJP. What More UK, manufacturer of plastic housewares, gardening and storage products, used seven kilograms of DynaPurge F to clean red to white polypropylene in a continuous process on a 700te moulding machine. CJP says using the compound resulted in What More making an overall site saving of 12tpm of polymer. Dyna-Purge F is said to be easy to process and easy to flush and works with all polymers in a temperature range of 160°c 302°c and will safely pass though a clearance of 0.5mm, making it suitable for most hot runner feed systems. CJP says Dyna-Purge F offers injection moulders advantages including ease of use, versatility, vastly reduced scrap and downtime and greater efficiency. CJP and Dyna-Purge will be demonstrating the effectiveness of purging compounds for plastics processors at K 2013 on stand B91-5, Hall 13. further information: www.cjpsales.co.uk Dyna-Purge is a registered trademark of Shuman Plastics, Inc.
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PPCO Red (Credit: What More UK)
Dyna-Purge F
After four shots PPCO Natural
Enhanced system said to produce better quality regrind from purgings Maguire Products says it has streamlined the operation of its system for transforming purgings into regrind, making it possible to increase throughput by 20 percent and also produce finer and more uniform granulate with less dusting. Typically, says Maguire, purgings that are produced as a result of a material or colour change are discharged onto the shop floor, where they harden before being disposed of, wasting material that could otherwise be recovered. “Our Purging Recovery System (PRS) is the only low-cost equipment designed specifically for the rugged work of sizereducing heavy masses of plastic,” said B. Patrick Smith, Vice President of Marketing and Sales. In the PRS, material undergoes two stages of size reduction: first, a rotor planer slices or planes the rock-like purging into small chips and second, a granulator reduces the chips to regrind. Maguire says as a result of improvements to the system, the knives in the rotor planer are now 40 percent smaller, while their number has increased from eight to twelve. This, says the company, means the planer produces smaller chips that are more easily and uniformly size-reduced by the second-stage granulator. The more efficient cutting is also said to yield less dust. The cutting chamber of the second-stage granulator has also been redesigned to increase the flow of air generated by a blower. The material in the granulator thus is cooled more effectively, preventing melting, and it is evacuated from the cutting chamber more rapidly, according to the company.
is RPC’s facility in Llantrisant for nd pou com ging pur the g usin cy production efficien
Case study: Purging compound said to prove effective for blow moulder Purging compound developer, Aquapurge, has been partnering the RPC Group at its Llantrisant, Wales, site in the packaging manufacturer’s ongoing improvements to operational efficiency work. Aquapurge says its new Poly Clear HMEX compound has been used during blow moulding production at RPC and says the product requires just a fraction of the time previously taken to clean out previous production runs. Aquapurge Technical Director, John Steadman, commented: “We worked on white bottle production issues on start up after the weekend. Black ‘speccing’ issues were at the time disrupting production and requiring manpower intensive inspection, sometimes for a two hour period. Our solution was to trial some 10kg of Poly Clear HMEX on a twin head machine making 2 x 380ml containers. Within 18 minutes we achieved clear production with no further need for remedial work.” RPC’s Chris Walstow led the project from the client end. “We made great strides with Aquapurge on the machine purging front,” he said. “All of this
production work contributes to our company’s Overall Equipment Effectiveness (OEE) and our plant efficiency generally. We are now confident in the performance of Poly Clear HMEX in helping us achieve some of our production goals.” Aquapurge is marketing its Poly Clear HMEX as “the most universal and most effective purging compound that the company has developed” for both continuous and accumulator blow moulding of polyolefins. Aquapurge is targeting sales in the global blow moulding sector and says UK blow moulders have been first to take advantage. The company says plastic blow-
moulded container applications, typically from 0.5l upwards, are set to see immediate benefits, especially in saving downtime, material cost and colour contamination. “The accumulator blow moulding process is sensitive to inherent hold-up points in all head designs and, over time, can contribute to black specking and loosened or degraded polymer or masterbatch. At Aquapurge we question the practice of taking a risk with all these factors – and Poly Clear HMEX is our solution,” concluded Steadman. further information: www.aquapurge.com
Purging being loaded into PRS
These enhancements make possible finer granulate, says Maguire, with minimum hole sizes in the screen of the secondstage granulator reduced from 9.52mm to 6.35mm. Maguire has received the CE certification required to make the PRS available in Europe. further information: www.maguire.com
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Plastic pipes take to the screen in ‘modern library’ of information The International Pipes Conference has released a DVD containing all its papers since its first convention in 1970 in Southampton, UK, up until the most recent event in Barcelona in 2012. Over 1000 papers are included in what it says represents a major technical and commercial source of information derived from the world of plastic pipe technology. This collection of papers is said to cover a wide range of subject matter that includes landmark reference projects, novel applications, installation methods and design, environmental issues, technical standards and testing, new systems, raw materials and additives, scientific advances, new systems and prototyping, no-dig solutions, manufacturing expertise as well as industry and trade aspects. Zoran Davidovski, current Chairman of the organisation behind the conference and exhibition, said: “We have amassed a
Brazilian pipe and fitting producer invests in a PVC pipe extrusion line A Brazilian pipe and fitings producer has invested in an extruder/pipe head combination from KraussMaffei Berstorff for the production of PVC pipes. The machine, which is equipped with two new models, the 36D KMD 108-36 E2/R twin-screw extruder and the KM-RK 23XL pipe head, will be used at Krona Tubos e Conexões S.A’s plant in Joinville to produce sewage pipes ranging from 75 x 1.8 to 250 x 7.3mm in dimension. “The Joinville production plant is regarded as one of the most modern pipe plants in South America and we are very proud that this factory will soon be operating two new models of extruder and pipe head for PVC pipe extrusion,” said
rich source of knowledge and experience by collating these documents. In looking all the way back to 1970, you see that most of the presentations have a lasting relevance for the industry. From the use of electronic microscopy for analysing the molecular performance of our pipe systems to the industrial use of plastic pipes for a sugar refinery in the Caribbean, this DVD is a modern library. It is the history of an idea that is forever evolving.” Davidovski is convinced that the DVD will appeal to a varied audience. “It will be of direct interest to all those involved in the plastic pipe industry — from raw materials through to manufacture and distribution. Technical bodies associated with the industry should also find the content very useful. Civil engineers in the
Bruno Sommer, Manager of the Extrusion Division at Krauss Maffei’s Brazil subsidiary. In combination with the pipeheads, KraussMaffei says the parallel 36D twinscrew extruders are designed for processing a wide range of PVC formulations. The HPG (high performance geometry) screw concept is said to provide high process engineering flexibility by ensuring careful and homogeneous material processing. According to KraussMaffei, the 36D’s long processing unit increases process reliability and guarantees high production security. It says all pipeheads are designed according to thermal and fluidic aspects in order to ensure excellent pipe quality. Perfect melt distribution ensures small wall thickness tolerances, thus making production economical.
building sector and in gas, water and sewer utility companies could also value the DVD subject matter. Plastic pipes provide a whole world of versatile and sustainable solutions as witnessed by the many fascinating examples provided.” Earlier this month, the International Plastic Pipes Conference hosted an event in the Chinese city of Xi’an and on 3-4 October 2013, there will be a similar affiliated conference and exhibition in Moscow. The next global Conference will take place on 22 -24 September 2014 in Chicago. The DVD, entitled ‘A World of Plastic Pipes’ is now available for €50 plus postage costs from Balassa Éva by emailing eva@congress.hu further information: www.ppxvi.org
further information: www.kraussmaffeiberstorff.com
rstorff twinKraussMaffei Be s in the 36D serie screw extruder es pip C tion of PV for the produc
pipe & profile
The DVD represents a major technical and commercial source of information derived from the world of plastic pipe technology
news
pipe & profile
news Olympic legacy lives on through plastic pipes Polypipe, the UK’s largest plastic piping systems manufacturer, recently exhibited at an exhibition designed to showcase the very best work from the companies that helped to create London 2012 stadia and infrastructure. Polypipe supplied a number of product systems for a variety of applications across the Olympic build, including six different systems for the Athletes Village alone. Polypipe’s Terrain Fuze HDPE Drainage system was used extensively on the Athletes Village, and several of its products, including its Firetrap sleeves and Rainstream pre-tank filters, were developed in order to meet the specific needs of a number of other areas across the Olympic Park. Adam Turk, Commercial Director for Polypipe Terrain, said: “As a proud UK manufacturer we were delighted to see our products selected and widely used in such a successful home Games. London
WORLDWIDE
Polypipe supplied a number of its HDPE pipe products for London 2012
2012 was not only a sporting success, but also a triumph for British manufacturing and construction and we are delighted to share the story of Polypipe’s contribution.” Polypipe’s contribution to London 2012 has previously been recognised by the ODA’s ‘Learning Legacy: Lessons Learned from the London 2012 Games Construction’ report, and as part of the ‘Plastics for Gold’ exhibition at the
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Museum of Design in Plastics (MoDiP), which formed part of the Cultural Olympiad, celebrating plastic’s contribution to the Games. further information: www.polypipe.com
Composite pipe wins innovation award Three companies have won an award for a new composite pressure pipe for the transportation of water in infrastructure applications. Composite Fluid Transfer, Ticona and Valéron Strength Films, will jointly receive the JEC Americas Innovation Award in the ‘Pipes and Water Management’ category for the new Fiberflex-11 pipe. The composite pipe incorporates Ticona’s Celstran CFR-TP continuous fiberglass reinforced HDPE thermoplastic composite tape, which is wound around a specially designed, extruded thinwall HDPE thermoplastic liner and heat consolidated by a proprietary process developed by Composite Fluid Transfer. The pipe construction adds an outside layer of HDPE film manufactured by Valéron to protect the system from both ultraviolet and abrasion damage. The Fiberflex-11 pipe is said to be lighter than comparable diameter and pressure-rated composite and plastic pipe. Two people in the field can reportedly lift and carry the pipe easily, avoiding the high cost of using large unloading equipment. The pipe can easily be altered to operate at higher pressures, in tougher environments, at higher temperatures, with larger diameters and with any type of piping system connections, according to the manufacturer. further information: www.ticona.com The Fiberflex-11 pipe
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pipe & profile
news Nothing fishy about HDPE pipe brackets HDPE pipe and injection-moulded brackets are playing a vital role in the commercial offshore farming of fish known as ‘aquafarming.’ The pipe is being used by the Norwegian Akva Group, a prominent company involved in aquafarming, which uses circular fish cages in the Norwegian Fjords ranging in diameters from 13 to 64 metres consisting of two concentric rings of HDPE pipe welded watertight and kept in position by brackets.
The core components of fish farms: two tightly welded plastic pipe rings as floats with diameters of 60 meters or more, which are held together and in position by brackets.
The brackets, also made from HDPE and weighing between 25 and 45kg, are injection moulded by Plasto, also based in Norway, using a large-volume, custom-built machine developed and manufactured by Wittmann Battenfeld. A critical starting parameter for Wittmann when designing the bespoke machine was an ability to handle a shot weight of 50 kg HDPE, with the potential to make even heavier components for the open sea. “Following a detailed analysis of sizes and weights in the spacer range, we knew that a 1000 tonne machine would suffice on the clamping side, but that the injection side would require a special solution,” commented Battenfeld’s project leader, Edmund Kirsch. “On the basis of these findings, we chose a MacroPower 1000/19,000 as the basic model, with its proven two-platen clamping unit, combined with the largest matching injection unit featuring a 165 mm screw. Plasto suggested that its maximum injection capacity of 14,433 cm³ should be increased to the required volume of about 85,000 cm³ by means of an additional module in the form of a piston reservoir.” Portuguese equipment manufacturer, Plasdan, also partnered the project by providing a device known as a “shot pot” unit, a 250 mm plunger injection unit with a theoretical shot volume of 66,000 cm³. This plunger unit, operating via two hydraulic cylinders, is mounted above the machine’s plasticising unit on fixed mechanical anchorage points and connected with the melt stream coming from the machine’s injection unit via a manifold valve. The machine has now started production of the brackets at the Plasto facility in central Norway.
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further information: www.wittmann-group.com
Solvay celebrates 15 years of high-performance PVDF for pipes Solvay Specialty Polymers is celebrating its 15th anniversary as the global supplier of Solef 60512 polyvinylidene fluoride (PVDF) resin for the oil and gas industry, used in demanding applications such as pipe liners and high-performance pipes and tubing since its commercial development in 1998. A supplier of highly engineered flexible pipe systems for offshore applications, NOV Flexibles in Denmark, also marks 15 years of producing pipe made of Solef 60512 PVDF. Solef PVDF is a key component of the company’s deep-water riser concepts, withstanding high pressure and high temperatures. NOV Flexibles uses Solef 60512 in single-layer extrusion over the metallic carcass, a unique safety benefit in risers to prevent gas accumulation between polymeric layers. “Solef has an outstanding track record in terms of safety, long-term performance, and reliability in the oil and gas industry and has become the industry standard for harsh field conditions,” said Marie Schmidt, Oil and Gas Global Market Manager for Solvay Specialty Polymers. “Over 700 km of pipe made of Solef 60512 has already been produced and installed globally.” Solef 60512 was developed in the early 1990s specifically for offshore applications. Solvay says it offers a unique combination of mechanical and thermal properties, very low permeation to fluids and gases, as well as excellent chemical resistance. The company also points out that it contains no plasticiser, thus ensuring safe, long-term performance with no migration or loss of additives over time. further information: www.solvay.com
Solvay Specialty Polymers is celebrating its 15th anniversary as the global supplier of Solef 60512 polyvinylidene fluoride (PVDF) resin. Credit: Solvay
will lated applications Construction re h in wt gro impetus for provide the most ns, gio re l ba glo nd in all plastic pipe dema says Freedonia
The global demand for plastic pipes to rise by 8.5 percent through to 2017, says the Freedonia Group
Global demand for plastic pipes to rise by 8.5 percent According to the latest report by market research group, Freedonia, the global demand for plastic pipes is to increase 8.5 percent annually through to 2017, with advances coming mainly from increased construction spending worldwide, as well as from the ongoing trend of plastic pipe replacing other materials, such as copper, concrete and steel. Here, BP&R takes a closer look at the report’s findings. The report suggests global demand for plastic pipe is projected to rise 8.5 percent annually through to 2017, to 11.2 billion metres, improving significantly from growth posted between 2007 and 2012. Advances will come in large part from increased construction spending in all global regions, given that plastic pipe is most heavily utilised in construction applications. In addition, a rebound in the key US market will spur growth. Plastic pipe will also gain market share as it continues to replace other materials, such as copper, concrete and steel, due to its low cost, installation ease and performance advantages. Construction to be fastest growing market Construction-related applications will provide the most impetus for growth in plastic pipe demand in all global regions, suggests Freedonia. For example, recovery in the US construction industry will result in double-digit gains in pipe demand. The US is home to the world’s second largest construction market and recovery from its recent housing crisis will provide strong opportunities for plastic pipe. China, which maintains the world’s largest construction
market, will also contribute greatly to growth. As China’s population continues to urbanise, the need for plastic pipe utilised in residential, non-residential and nonbuilding construction will increase. While plastic pipe use is not as widespread in the oil and gas and process manufacturing markets, improvements in resin formulations have enabled plastic to increase its market share in recent years. For instance, HDPE and fiberglass are being more widely used in the oil and gas industry. In process manufacturing applications, HDPE’s greater flexibility has resulted in its increased use. In addition, fibreglass finds use in process manufacturing applications when particularly hazardous materials are present. Going forward, demand for HDPE and fiberglass is expected to benefit from gains in manufacturing output and growth in crude oil and natural gas production and consumption – including increases in exploratory drilling, well drilling and pipeline construction activity. HDPE pipe to take market share from dominant PVC PVC is by far the most widely used pipe resin, accounting for over 55 percent of global plastic pipe demand in 2012, according to Freedonia. Going forward, however, HDPE is expected to take market share from PVC in a variety of construction applications. For instance, as PEX becomes more common in many regional markets, the material will supplant PVC portable water distribution pipe. Additionally, fibreglass is beginning to be utilised in a wider array of water and wastewater settings because of its performance advantages. further information: www.freedoniagroup.com
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THE NO. 1 FOR WORLD PREMIERES: K 2013 Get ready for your most important global business and contact platform. On a net exhibition space of more than 168,000 sqm, some 3,000 exhibitors from over 50 countries will be presenting innovative solutions and visionary concepts in the areas of machinery and equipment, raw materials and auxiliaries, semi-ďŹ nished products, technical parts and reinforced plastics. Plan your visit now. Welcome to your K 2013.
International Trade Fair No. 1 for Plastics and Rubber Worldwide
k-online.de
For further information contact: International Trade Shows Link Ltd. Ramsay House, Marchmont Farm _ Link Road Hemel Hempstead _ Hertfordshire HP2 6JH Tel. +44 (0)1442 23 00 33 _ Fax +44 (0)1442 21 98 98 info@itsluk.com
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www.quick-mould-change.com
Let the K Show commence After months of anticipation and build up, the plastics industry will journey to Düsseldorf this month as the K Show opens its doors. With over 3,000 exhibitors, on over 168,000 sq. metres of exhibition space across 19 halls, K 2013 is set to offer a broad range of exhibits, new technology and innovation from across several sectors of industry. Over the following pages we highlight some of the most interesting news and previews from a selection of exhibitors at the show. BP&R will be at the show, on stand C03 in Hall 11, so make sure you come along and see us. If you’re not there, then you can still catch up with all the latest daily news from the show via our website www.britishplastics.co.uk and via our twitterfeed: @BritishPlastics
Injection Moulding Arburg to present new IMM and lightweighting technology Arburg will display more than ten exhibits on its stand at K this year. The electric Allrounder 820 A, which completes the high-end electric Alldrive series will make its world premiere in Düsseldorf. Both a 4,000 kN toggle-type clamping unit and the size 2100 electric injection unit have been developed for this machine. Arburg says that with these developments, the gap between 3,200 and 5,000 kN in the electric clamping unit range has been closed. The same applies to the hybrid Hidrive range, for which this new toggle size will also be available in future. With the new clamping force and injection unit sizes for electric machines, Arburg says there is now greater modularity in the range. Arburg’s automation display will be in operation on a two-component Allrounder 470 S, which will be demonstrating particle-foam composite injection moulding (PCIM). A plastic wheel rim will be injected onto a particle-foam tyre. Transfer of the pre-moulded part to the mould will be followed by overmoulding of the tyre with TPE. The six-axes robotic system will be used for all handling tasks, from insertion of the foamed tyre through to transfer of the finished parts to the packaging system, which includes printing of the bags during the process. Also on display will be a fully-electric cube-mould application for the production of juice container closures, which will be presented with Foboha. On the electric two-component Allrounder 720 A with a
Show Map Messe Dusseldorf K
k show
16-23 October 2013 Düsseldorf - Germany Visit us hall 11 booth H11
Map Key Red – Feature area – ‘Plastics Move the World’ Dark Blue – Science Campus Light Blue – Machinery and Equipment Green – Raw Materials, Auxillaries Yellow – Semi-Finished Products, Technical Parts and Reinforced Plastics
clamping force of 3,200 kN, the large size 800 injection unit will be arranged horizontally. The small size 400 injection unit is arranged horizontally and on the moving mounting platen of the machine. In this application, fully electric means that both rotation of the cube and the linear sliding motion of the 12+12-cavity mould are driven electrically. Visit - Hall 13, Stand A13-1/2 www.arburg.com
Temperature Control New heating and cooling unit takes to the halls Frigosystem, suppliers of temperature control equipment, have developed a new heating and cooling unit that will be presented at K 2013. These units combine both heating and cooling in a compact single unit and allow precise temperature control in the range -10°C to + 90°C and guarantee the end user constant fluid pressure.
The cooling unit uses biogas and long lasting sealed compressors, with condensation said to be efficient over a wide range of operating conditions. Energy savings are maximised by the free cooling function, allowing operation without compressors when ambient conditions allow. Frigosystem equipment is available in the UK through Intelicare. Visit - Hall 10, Stand A74-3 www.inteliCare.co.uk
Slitter Rewinders Atlas to present ‘next generation’ technology at K 2013 Atlas Converting Equipment Ltd. will present its ‘next generation’ Atlas CW Series and Titan SR9 Series slitter rewinder technology for film and flexible materials at K 2013. The Bedford, UK-based company launched its new Atlas CW3600 and CW1040 Series slitting and rewinding technology platform during 2012 and has also recently introduced the CW5000 Series available in widths from 3,600 to 5,400mm. The complete CW Series of more compact film slitting solutions now covers machine widths from 2,500mm to 10,400mm at speeds of up to 1,500m/min. Major benefits of the new technology are said to include higher efficiency,
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k show
16-23 October 2013 Düsseldorf - Germany Visit us hall 11 booth H11
www.quick-mould-change.com
provide unsurpassed levels of slitting productivity, design modularity and rewind reel quality. New features include reduced power consumption, faster set-up time and improved sustainability.
precision measuring system for determining specimen thickness. Visit - Hall 10, Stand J18 www.instron.com
Visit - Hall 3, Stand B91 www.atlasconverting.com increased productivity and reliability, higher quality rewind reels, reduced noise levels and more effective, operator-friendly control systems. The new Atlas CW1040 Series has been designed to cope with the increasing speed of film production lines and along with a sustainable, increased running speed the CW Series also reportedly has faster acceleration and deceleration cycles. Compared to a conventional primary film slitter running at 1,500m/min. producing rewind lengths of 8,000m, Atlas says the CW Series will have a faster rewind cycle, but at only 1,200m/min. Atlas says it has now sold over 40 of the new CW Series slitter rewinders in widths from 2,500mm to 10,400mm for BOPP, BOPET and CPP films. The new generation Titan SR9 Series secondary slitter rewinders will also be presented at K 2013 and Atlas says they
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Testing Equipment Instron to display new impact test and melt flow equipment At K 2013, Instron will be showcasing measuring and testing systems for determination of the rheological properties of plastics and evaluation of the behaviour of materials and components under static and dynamic loads. Amongst the exhibits will be the CEAST MF50 melt flow tester, and the new CEAST MF30 with manual mass selector, a CEAST 9050 pendulum impact tester, and a CEAST 9350 drop weight tester. The group will also be presenting automated testing systems, accessories and software for the laboratory and the shop floor. This includes the new AutoX750 Automatic Contacting Extensometer, the TrendTracker software package, and an automated carousel system for tensile testing that features a
QMC and Robotics Stäubli to demonstrate quick mould change and new robot At this year’s K Show, Stäubli’s Connectors and Robotics Divisions will jointly present a range of products specifically designed for the plastics industry to improve productivity and production flexibility. Stäubli Connectors has devised a quick mould change (QMC) demo application to be shown at K, which it says illustrates how easily, quickly and reliably
even the heaviest tools can be changed on a modern injection moulding machine. Also on display will be the division’s complete range, presented interactively, including a new multi-coupling plate (MCI209) that provides centralised nonspill connections for all mould temperature control circuits; preventing pollution and reducing the consumption of heat transfer fluid. Jointly exhibiting is Stäubli’s Robotics division, which has a range of four- and six-axis robots specifically designed for automation applications in the plastics market. These, it says, combine high precision and ultra-short cycle times with straightforward programming and easy communication with the IMM. Being unveiled at the show is Stäubli’s new TX340 SH 6-axis shelf robot designed in response to customer demand for a robot that can be mounted on top of the IMM, giving exceptional reach to both sides of the machine with excellent payload capability; increasing production flexibility within a smaller footprint than conventional gantry robots. Visit - Hall 11, Stand 11 www.staubli.com/en
Email: connectors.uk@staubli.com
The company says its three divisions, namely construction, infrastructure and packaging, will present extrusion solutions that operate energy-efficiently and save material whilst maintaining high standards of quality. In response to the trend towards increasing use of recycled materials in profiles, the construction division of the group will showcase a newly designed extruder combination - the conEX 63 P conical extruder mounted in a ‘piggyback’ configuration on a twinEX 78-34P. The two counter-rotating twin-screw extruders combined are said to achieve an output of about 500 kg/h. The infrastructure division is rolling out a new, gearless single-screw extruder series for K 2013. The solEX GL series includes four models with screw diameters of 45, 60, 75 and 90 mm and battenfeldcincinnati says the new machines achieve high standards of quality achieved with low melt temperatures, low energy input and an optimal capital/output ratio. The packaging division is also focusing on efficiency. New initiatives on display will include the ‘Multi-Touch roll stack’, which is said to produce stress-free film at high line speeds with an accuracy of one percent, as well as a new anti-wear concept for planetary roller extruders, which are being used for applications such as calender feeding and pelletising. For the PET industry, battenfeldcincinnati says it will showcase its specialised single-screw extruder with an integrated compounding section for outputs between 500 and 1,000 kg/h. Visit - Hall 16, Stand B19 www.battenfeld-cincinnati.com
Extrusion battenfeld-cincinnati to focus on energy and cost reductions battenfeld-cincinnati is planning its appearance at K 2013 around the theme of high performance and energy efficiency in extrusion technology.
Injection Moulding BOY prepares for K 2013 at full speed At K 2013, injection moulding machine manufacturer, BOY, says energy efficiency
will be a key theme of the products it will exhibit. The company, which specialises in manufacturing IMMs with clamping forces below 1000 kN, says it will showcase how machines with smaller screw diameters can achieve low energy consumption. BOY will launch its latest IMM at the show, the BOY 25 E. The machine, which is the successor model to the BOY 22 E, will be manufacturing dishes on the company’s stand. BOY says the new 25 E is a completely new development, based on proven machine components from the previous models. Also new at K 2013 will be the BOY 25 E VH. This insert-moulding machine will be equipped with a horizontal injection unit and enables parting line injection. During K 2013, the machine will demonstrate the insert moulding of hexagonal pencils with a T-handle in a two-cavity mould. Visit - Hall 13, Stand A43 www.dr-boy.de
Masterbatch New formulations demonstrate technical innovation Colloids will display products that it says demonstrate technical innovations in masterbatch and additives at K 2013. The first of the company’s recent additions is the ‘Pace’ series, which includes masterbatches based on solvent black (nigrosine) and/or carbon black as well as formulations offering improvements in frictional properties or heat stabilisation. Secondly, the all-new ‘Sustain’ line of bio-based masterbatches for environmental sustainability will be introduced to visitors at the show. Typically made from corn starch or cane sugar and available in either universal or polymerspecific (polyamide, polyethylene and polyesters including PLA) masterbatches, Colloids says the Sustain range is fully recyclable and will not impact on the
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We W e put ut care into chemicals We know We w that that everything e we do and how h we do it has a dir direct ect impact on our planet. In honoring commitment creativity our commitmen mitmen nt to sustainability, sustainabilityy, Perstorp Perst combines the power and cr eativity of science to deliver environmental cutting-edge ge solutions so olutions l that satisfy customer cust needs, answer to society´s envir onmental demands offer care and of fer continuous economic success. We We like to think of it as putting car e into chemicals. presenting At K Fair 2013, Perstorp will be pr esenting exciting new thermoplastics, plasticizers and additives for the plastic materials market. Visit us at K Fair 2013 at stand B15 in hall 07.2 at Dßsseldorf Fairgrounds
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quality if mixed with fossil-derived polymers of the same type, unlike biodegradable polymers. Additionally, Colloids will shows its ‘etec’ range of antistatic, dissipative and conductive compounds. These are designed for applications where varying degrees of permanent electrical conductivity are required. Visit - Hall 8A, Stand D01 www.colloids.co.uk
Injection Moulding Two new injection moulding machines to be premiered Engel will have a total of 25 exhibits at K 2013, 12 of which will be presented on its stand, including two new injection moulding machines. The new machines on display will be the e-speed, which Engel says will manufacture the first composite brake pedal produced in a one-shot process and the e-motion 30 TL, the biggest vertical machine ever presented by Engel at a trade fair. The company says the manufacturing cells on display will combine high levels of process integration and automation, strong performance, sustainability and process reliability. The exhibits will cover the medical sector, with the premiere of tri-component injection moulding of drip chambers for blood transfusions, the e-speed range for fast-cycling packaging applications and a tie-bar-less, all-electric machine for the production of components for the teletronics industry. In addition at K 2013, Engel will devote a special exhibition area to automation, which will include the trade fair debut of the company’s largest robot, the Viper 120. Visit - Hall 15, Stands B42 and C58 www.engelglobal.com
Injection Moulding Manufacturer will showcase 8 integrated production centres Negri Bossi says it will exhibit its latest innovations on an 800m2 stand entirely dedicated to injection moulding at K. The company will be showcasing eight integrated production centres featuring machines with both two-platen and toggleclamp injection technology, equipped with Smart Energy devices to minimise power consumption. First of all there is the new Bi-Power VH 1000, the smallest of the two-platen hybrid range of large machines. There will also be a 650 tonne version of the
evergreen Vector series with integrated robot, set up with a mould making polycarbonate headlight reflector dishes. Another first at the show will be the latest version of the Canbio series – a Canbio 210 equipped with a mould for automotive heat shield caps in PA66 +25 percent GF. This unit — like the previous one — will also feature an integrated Sytrama robot. Negri says all the machines in the 160-500 tonne range will be equipped with the new Smart Flex clamping units with optimised structural rigidity and V-rails to guide the mobile platen, thus creating an oil-free moulding zone. In addition, the full electric version of the Vesta 300 will also be on show. As well as the Smart Flex clamping unit, Negri says the machine also features a new actuator with ultra-rapid ball bearing screw to meet the specific needs of the packaging and medical industries requiring short cycle times. The company says another solution designed for the medical sector, the electric version of the Eleos 65, an extremely compact twoplaten machine, will mould a polypropylene syringe component at the event. There will also be an EOS 120 hydraulic version with inverter on the variable-capacity pump exhibited from Negri’s LSR family. Visit - Hall 15, Stand B22 www.negribossi.co.uk
Recycling Machinery Erema to launch new generation recycling technology at K 2013 Erema, a specialist in plastic recycling systems celebrating its 30th anniversary as a business this year, has announced that it will be launching a new core technology at K 2013. Erema is describing its development as a “new dimension” in plastic recycling system engineering. Erema’s systems are based around a large patented cutter/compactor and extruder combination which can be used for a wide variety of recycling jobs according to the configuration in both inhouse production waste recycling and severely contaminated post-consumer waste applications. The company launched its first
generation of machines in its founding year, 1983. The technology combined a cutter/compactor with a – back then, still radial – extruder, which made it possible to cut, compact and extrude waste plastic in a single, continuous process. In its second-generation machines (from 1993) the extruder was located tangentially to the cutter/compactor. This, Erema claims, enhanced the quality of the end products while increasing output and performance. Additionally, a newly defined scaling of the cutter/compactor in relation to the screw diameter of the extruder connected (patented) made feeding even easier with very large individual portions. Project-oriented modifications to the cutting tools in the cutter/compactor also helped to optimise this process. The longer dwell times in the big cutter/compactor made it possible to direct the material to the extruder with much more homogeneous temperature distribution. The company will present the new generation of its recycling machinery at a special presentation on its stand.
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16-23 October 2013 Düsseldorf - Germany Visit us hall 11 booth H11
Visit - Hall 9, Stand C05 www.erema.at
Injection Moulding Ferromatik Milacron to present four core IMM systems Ferromatik Milacron will present four system designs across its own stand and partner stands, featuring injection moulding machines in the modular FSeries along with two all-electric machines from the Elektron series. Machines from Ferromatik Milacron will display at the Mold-Masters and DME stand, both of which are now part of the Milacron group. The modular F-Series, ranging in size from 500 to 6,500 kN, can be configured as an all-electric, hydraulic, or hybrid machine, depending on the user’s manufacturing requirements. At K 2013 visitors will see an all-electric F 200 with a clamping force of 2,000 kN equipped with a size 50 Advanced Performance (APe) electric injection unit. Using a four-cavity mould and an IML system by H. Müller from Switzerland, this machine will
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k show
16-23 October 2013 Düsseldorf - Germany Visit us hall 11 booth H11
demonstrate production of thin-walled rectangular lids with labelling. An F 350 hybrid with a clamping force of 3,500 kN will be on display, as well as an all-electric 2,700 kN cube moulding machine, the F 270 CUBE. In addition, Milacron says K 2013 will see the introduction of a new small machine in the Elektron series with a clamping force of 300 kN, bringing the total number of machines in this series to eleven. Visit - Hall 15, Stand C06 www.ferromatik.com
www.quick-mould-change.com
feedstocks - yet it still delivers the quality and durability expected for car interior trims. Luxus says the major benefits of Hycolene are both the weight saving it offers, typically a 10-12 percent weight reduction for each component and improved scratch resistance over current talc-filled PP alternatives. Hycolene is currently being tested by Renault Nissan at its UK-based European Technical Centre, using interior trim mouldings from the Nissan Qashqai. Current activity with auto manufacturers indicates that Hycolene will be used in volume production vehicles by 2015. Visit - Hall 5, Stand A45 www.luxus.co.uk
Infrared emitters and systems products for heating and welding to be dislayed Heraeus Noblelight will be showing application-optimised infrared emitters and systems at K 2013 for use during the assembly of plastic products from individual components after injection moulding. Infrared heating helps to weld plastic components together without the need for adhesives or other fastening devices. Many of these production steps are significantly facilitated and speeded up by using infrared emitters. Heraeus Noblelight says both time and energy are saved when quartz glass emitters are matched exactly to the product and process and will demonstrate this at the show. Visit - Hall 10, Stand G59 www.heraeus-noblelight.com
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Recycled Materials sustainable polymers at exhibit at K 2013 UK-based plastics solutions provider, Luxus, will be showing its latest evolution in high performance recycled content polymers at K 2013. The company has recently developed a lightweight PP for ‘A’ surface interior applications, known as Hycolene, based on both prime and recycled materials. The recycled grade is said to offer automotive manufacturers a material with up to 60 percent recycled content gained from post-industrial and post-consumer
Static Control Equipment control and cleaning ranges on display at K Meech International, a specialist developer and manufacturer of electrostatic controls and related solutions, will exhibit at K 2013 with its range of Hyperion static control equipment and series of its web-cleaners designed for the plastics industry. The company says it has successfully developed a new line of anti-static products suitable for the plastics industry, as businesses become increasingly aware of the impact static can have on in-house activities. The company will exhibit its web cleaning equipment with the message it could help minimise wastage and achieve higher levels of productivity within the plastics industry. Meech’s non-contact web cleaner, the Cyclean, will be displayed, which the company says is capable of removing contamination to below one micron.
results have shown that on average the WDS 80 model with a 75 litre hopper has an energy consumption at 2.2 kW/hr, less than half that of the conventional drier – this further reduces to 0.9 kw/h when the RCE function (anti stress function) is activated. Tests have also reportedly shown that an impact modified PA66 from the bag with a moisture content of 0.5 percent is dried to a level of 0.14 percent in just 2.7 hours. New Omap dryers are available in the UK through Intelicare. Visit - Hall 09, Stand B74 www.inteliCare.co.uk Testing Equipment New Melt flow indexer at K 2013 UK-based Ray-Ran Test Equipment will present a new microprocessor controlled melt flow indexer machine, the 6MPCA, which includes a host of new features, such as highly accurate microprocessor temperature control. It will also display the auto density measurement system, a new piece of equipment based around the three-column system that is normally supplied. It is able to determine the height of the samples and floats by means of an encoder. Ray-Ran will also present its bulk density apparatus at K 2013, which can be used to test the apparent density of material, which is the weight per unit volume of material, including voids, inherent in the material as tested. Visit - Hall 11, Stand B30 www.ray-ran.com
Visit - Hall 11, Stand B60 www.meech.com Materials Handling Developments in dryers to be discussed at show New Omap will be discussing the development of equipment to both save energy and improve functionality at K. The company is in the process of increasing the insulation on all its drying hoppers up to 50mm and is also developing a new control system for dryers, which incorporates touch screen functionality and will be configurable to the specific material being dried. Tests are currently being undertaken by a customer using the company’s existing WDS ‘honeycomb rotating drum’ dehumidifier dryer, against a conventional twin tower dehumidifier dryer. To date,
Masterbatch UK manufacturer to announce global expansion UK manufacturers of white, black, colour and additive masterbatches, Silvergate Plastics, will unveil plans for major global expansion at K 2013. The company says it is further investing in its manufacturing capability in North Wales to accommodate a significant increase in capacity, product range and geographical reach and official details will be revealed at the show. Visit - Hall 05, Stand B40 www.silvergate.co.uk
Email: connectors.uk@staubli.com
NEWS from the front line - k show special
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UK companies will exhibit at a ‘UK Village’ at K 2013
I can’t think of the K Show in DĂźsseldorf without the 10 CC track, ‘One night in Paris’, springing to mind. Certainly, one night in DĂźsseldorf is ‘like a year in any other place’ and veterans of the K Show have surely This month, Philip Law, Public and shaved six months Industrial Affairs Director at the off their life with British Plastics Federation talks their assiduous ‘Alt Beer’, nocturnal networking attendance and and political endorsements as he nocturnal writes for BP&R in a special edition networking over the of his regular column, which looks ‘Alt Beer’. It’s still at the UK plastic industry’s the largest platform involvement in ‘K 2013’. globally for our industry and I’m pleased to say there will be almost 100 companies from the UK plastics industry exhibiting there. The BPF’s UK Group at K 2013 will be 30 companies strong and will be located in both Halls 5 and 12, ready to seize the scientific and technological developments on show in DĂźsseldorf cannot opportunities stemming from the expected 200,000 visitors to be exploited to the full without the skill and imagination of product the show. The companies in Hall 5 will be materials based and designers and we hope to develop more traction in this those in Hall 12, machinery area in the future. and equipment orientated. p dro as a back Also in Hall 12 will be a UK DĂźsseldorf acts Visit - The ‘UK group’ will be located in tworking with ne l na ur village designed to provide a ct “no r fo Hall 12, Stand D35 platform for small companies Alt beerâ€? www.bpf.co.uk and service providers. The BPF has put together a website to promote the UK Group and we are producing ‘A guide to the best of British at K 2013’ which includes the contact details of over 600 companies and is supported by UKT&I and the K 2013 is Knowledge Transfer Network. expected to draw Essentially, it provides a rationale for buying plastics-related a crowd of over materials, products and equipment from UK sources and it will be 200,000 visitors widely and freely available at the show. The UK industry’s presence in DĂźsseldorf was given a recent boost by Prime Minister David Cameron’s recent letter of ‘congratulations’ to the BPF on its 80th Anniversary. I know there will be those who will say that the Government should be doing a lot more to support manufacturing, but actually the letter was a ringing endorsement of plastics manufacturing activity in the UK and an endorsement of the contribution of plastics products to a sustainable economy. We have sent copies to member firms and we do hope that they will show it to their employees and also send it to their customers. It was a letter not to the BPF staff but to the entire BPF membership. The BPF’s profile with UK Government is now at a very high s 4URNKEY 2$& RECYCLING level. We were invited to mount an exhibition about the industry systems in the foyer of the Department for Business Innovation and Skills in July, which was on display to hundreds, if not thousands, of s 3TANDALONE SHREDDERS civil servants and the general public passing by. As a side benefit, AND BRIQUETTERS it helped the BPF forge a relationship with the Museum of s %STABLISHED FOR Plastics in Design (MoDiP) based in Bournemouth, which has now YEARS led to MoDiP staging a permanent exhibition of the history of bp&r design in plastics in the BPF’s London headquarters. The INFO WEIMAUK COM WWW WEIMAUK COM
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testing & inspection
news Materials testing laboratory latest to offer R&D assistance Shropshire-based materials testing laboratory, Gammadot Rheology, has announced it has agreed to work with notfor-profit research organisation, RAPRA Limited, as a ‘preferred service provider’. RAPRA offers impartial and independent support to members and non-members involved in all kinds of polymer-related R&D from a range of service providers it recommends on a project-by-project basis. Steve Shaw, RAPRA Executive Director, commented: “We are extremely pleased to be working with Gammadot Rheology, experts in this area where scientific testing and measurement of ‘real’ materials are merged with highly specialised software modelling tools.” He added: “These both enable the designer to reliably predict the behaviour of a material during processing to
range of testing Gammadot Rheology offers a logy and materials rheo iding prov on d base services characterisation
maximise quality and performance of a product as a result of optimal manufacturing.” Gammadot Rheology offers a range of testing services based on over two decades of providing rheology and materials characterisation support to the plastics and rubber industries. Mark Edwards, Gammadot’s Principal,
said of the agreement: “Gammadot is looking forward to working alongside RAPRA and providing the membership and other clients with fast, accurate solutions to all their rheology and material characterisation needs.” further information: www.gammadot.com
The 3-in-1 box
Sample preparation is simplified with new design A new packaging concept for pans is serving to simplify the preparation and archiving of test samples in differential calorimetry, according to the Netzsch Group. The company says that until now the preparation of sample pans for thermal analysis measurements was complicated by factors such as static build up in the plastic packaging, which could potentially contaminate the sample pan. Additionally, if the packaging lid was closed incorrectly, the crucibles and lids might become deformed and therefore rendered useless. Netzsch says its new approach to the packaging of sample pans now allows for a more efficient process during sample preparation. The new 3-in-1 box contains 96 crucibles or lids, sorted in an anti-static plastic box. The company says the presorted arrangement and the anti-static material allows for individual pans and lids to be easily withdrawn from the box. This also helps to prevent the danger of contamination or deformation. The new box also contains a Sample Identification Card, which allows for the documentation of samples and measurement results. Netzsch says the box is an easy-to-handle storage unit for pans and lids with benefits in both transport and archiving. further information: www.netzsch.com
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testing & inspection
news Spectrometer added to polymer characterisation portfolio Kidderminster-based FlemingPTC has announced the acquisition of a new Spectrum Two Fourier transform infrared spectrometer (FTIR) to complement its portfolio of polymer characterisation techniques.
The system, from Perkin Elmer, is equipped with an ATR accessory, which allows polymer samples of all forms to be easily tested. FlemingPTC says FTIR is an obvious technique to add to the facility, which already boasts DSC, TGA, capillary rheometry and MFR/MVR testing. The instrument is said to be able to rapidly produce spectra from either polymer pellets or products for the
Clean. Safe. Practical.
purposes of identification, which in turn can be used to confirm generic type and/or contamination. FlemingPTC says the latest generation software enables spectra to be readily compared to comprehensive material databases such that the tested polymer, often with its grade and manufacturer, can be identified within minutes. The ATR system allows penetration of several microns into the surface of a sample, thus lending itself to the analysis of small samples sizes, which can be essential if sample size is limited or the area of concern is small. further information: www.flemingptc.co.uk
96 DSC pans* – intelligently pack packed ed The 3in1 Bo Boxx off offers: ers: Comprehensive protection Easy withdrawal
ee ur fr st yo ple at e u q Re am n13891 uct s / prod sch.com z t e n . www
Visit us at the K 2013: Boo oth E42, Hall 10
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Unit 6 Element Court, Featherstone Wolverhampton, WV10 7FE Tel: +44 (0)1902 306645 uk.thermal@netzsch.com
* suitable for current-model heat flow
Unique archiving s stem
lled a Regain has insta testing ct pa im pendulum oratory lab D R& its at system
The new FTIR
Testing system helps plastics recycling company improve product quality Regain Polymers has recently installed a pendulum impact testing system at its R&D laboratory, where it is being used to investigate new additive technologies and blending methods to produce specific compounds. The West Yorkshire-based recycling company invested in the Zwick model HIT 5.5 Joule capacity system to replace a dated impact test machine and says it is now able to produce highly reliable test results which is assisting in improving the quality of the products it supplies. Regain, which recycles a wide range of rigid plastics, produces compounded HDPE, LDPE, PP and also talc-filled HDPE and PP from recovered polymer regrind feedstocks. Laboratory testing at the company includes using DSC to calculate PE:PP ratio in mixed polyolefin blends and mechanical testing for determination of tensile and flexure characteristics. Dr. Clint Bainbridge, from Regain’s R&D Laboratory, said: “We had the need to carry out both Charpy and Izod impact tests and it was imperative that the selected system offered a method of efficiently and quickly changing the test specimen tooling and pendulums.” further information: www.zwick.co.uk
Choosing the right polymer material for a product goes above and beyond the technical data sheet, says Michael Lock, Principal Consultant at Smithers Rapra, who writes for BP&R on what designers and engineers should consider and understand regarding a material’s suitability for an application.
T
he technical data sheet for a plastic material offers a snapshot of selected information and can offer a useful means of comparing some test data, or be useful in testing for quality, however, there are other considerations of which a material specifier should be aware. Firstly, thermoplastic materials are viscoelastic in nature, their properties are highly time, temperature and stress dependent; factors which effect long term durability performance. The significance of this is often overlooked at the design stage. The stress–strain characteristics can be summarised as: the stress–strain relationship is not linear; dependent upon strain rate; dependent upon temperature; characteristics can be changed significantly by the incorporation of fillers. A material technical data sheet provides typically physical, mechanical, electrical and thermal test data and possibly some fire, environmental, chemical or regulatory compliance information but tends not to consider the long term performance characteristics of the plastic and complex loading modes. Permanent loading (creep) and cyclic loading (dynamic fatigue) have greater potential to cause failure than a single loading event. Such long term properties ultimately influence product design and the performance of the final product in use. This is particularly relevant to companies investing in R&D and considering material selection for new products. Incorrect material selection can prove very costly. Engineers and designers have become increasingly aware of the importance plastics play across a wide band of engineering applications. Advances in electronic and automotive engineering depend heavily on plastics and the aerospace industry on advanced plastics composites where the long term performance becomes more critical. Secondly, care must be taken in direct comparison of data as different producers in different territorial regions may publish data which notionally appears the same but was created using subtly different test methods (e.g. ISO, BS, ASTM, UL etc.), or using different conditions of test (e.g. load and test temperature in the Melt Flow Rate test, or the flexural stress in the Heat Deflection Temperature test).
Plastics are often produced as a family of grades originating from a basic material, which can be “engineered” by the use of suitable additives and/or specialised structural chemistry. For example, in certain fire hazard applications a specified fire performance can be required. A range of flame retardant additives are available but in higher performance applications, especially for zero halogen solutions, the additive loading can be enough to dramatically affect mechanical performance, then a property balance must be found. It should also be realised that even simply adding a colourant to some plastics can have considerable affect, subject to the pigment used. This can result in changes to the crystallisation rate when processing which may affect dimensions due to shrinkage, increase any tendency to warpage, reduce impact performance or even affect cycle times. Any fire rating (e.g. UL 94 yellow card) or expensive regulatory approval achieved by the base plastic may not carry the approval once modified. Hence beyond the basic test data there are factors which can influence not only the final performance of a product manufactured from the modified plastic, but also its processibility and approval status. Another consideration when reading material technical data sheets is that some hygroscopic plastics, such as polyamides, exhibit different performance to some tests dependent on the degree of water content. In these cases the technical data sheet often carries two columns of data, one showing dry as moulded (DAM) data and the other after moisture conditioning. It is thus important to understand the likely environment in which the polyamide product will be required to operate. Furthermore, in some instances it may be important to characterise the melt rheology of a plastic material at the product design stage, especially in terms of anticipating any processing issues. Melt rheology can also be used for measurement of product consistency and potential batch-to-batch variance. Most material technical data sheets refer to Melt Flow Rate (MFR), also known as Melt Flow Index (MFI), however, this has limited value as it represents only one point on a melt rheology curve. When additional rheology information is required the technique of Rotational Rheometry can create useful data providing viscosity data over a range of conditions. Either the temperature can be varied at a constant strain rate or the temperature can be held constant over a range of strain rates (oscillation frequencies). It is possible that the material supplier has such rheological information available on request. Consequently, when reviewing material technical data sheet information it is vital to understand the context of the published data in terms of the specific material and intended application. further information: www.rapra.net
testing & inspection
How to ensure effective testing for material selection
news Static light scattering explained in new white paper Malvern Instruments has published ‘Static Light Scattering Technologies For GPC/SEC Explained’, a guide for those assessing the value of a light scattering detector for gel permeation/size exclusion chromatography (GPC/SEC). Covering the theory and practice of molecular weight measurements using static light scattering, Malvern says the basic guide serves as both an introduction for those with no prior knowledge of the technique and a reference document for anyone looking to enhance their understanding. Light scattering detectors are used extensively within GPC/SEC detection systems to determine exact molecular mass, particularly in the development of polymer, protein and macromolecular
species. The new white paper explains the differences between all the light scattering techniques used in GPC/SEC detection including: Multiple Angle Light Scattering (MALS), Right Angle Light Scattering (RALS) and Low Angle Light Scattering (LALS). A key focus, says Malvern, is the practical uses of these different technologies and their respective advantages and disadvantages for different applications. Static Light Scattering (SLS) is widely used to determine the exact physical size or molecular weight of a molecule without the need for external calibration. Malvern
testing & inspection
Static light scattering delivers absolute molecular weight measurement within a GPC/SEC analysis
says it offers a range of light scattering detectors, which are individually compatible with any GPC/SEC system, or can be combined with refractive index, viscometry and UV detectors in an integrated triple or tetra detection Viscotek system for comprehensive polymer, protein and macromolecule characterisation. The white paper is available as a free download from the Malvern Instruments website. further information: www.malvern.com
Humidity Controller Lacerta Technology’s
Improvements mean savings for humidity tester Lacerta Technology, manufacturers of instrumentation for the characterisation and analysis of plastics, says that thanks to improvements in manufacturing and supplier agreements it has been able to reduce the price of one of its popular humidity testing instruments by 25 percent. The ‘Humidity Controller’ system works by pumping a gas (normally air) through a desiccant into the instrument. A valve, controlled by a humidity sensor (placed in the experimental sample chamber) is used to divert some of the gas flow through a water reservoir and then back into sample. Using this feedback function ensures good control of the humidity within the sample environment and Lacerta says humidity ranges of 10 to 85 percent can typically being achieved. Humidity as an experimental variable in thermal, microscopy and rheological experiments is well known and an important parameter to control or measure. Lacerta Managing Director, Dr John Duncan, commented: “I am delighted that we can pass on the savings we are making in the factory directly to the scientist in the laboratory.” further information: www.lacerta-technology.com
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InstronÂŽ offers high-performance testing systems to determine the flow properties of thermoplastics and the mechanical properties of plastics. Our testing systems, accessories, and software are paramount for improving the efficiency, repeatability, and accuracy of measurements both in the laboratory and on the shop floor.
When Material Performance is Critical... TRUST Instron See these products demonstrated live at the K Show, Hall 10 at Booth J18
news Weather-Ometer used to measure impact of surface temperature on plastics German-based SKZ, one of Europe’s leading accredited and certified quality assurance institutes, has launched a research project to better predict the impact of surface temperature on the weathering behaviour of plastics. A critical factor in the project is the surface temperature of the plastic specimens, which may differ in natural weathering when compared with accelerated laboratory weathering. In order to undertake its research, SKZ is using weathering technology and services from Atlas Material Testing Technology. Surface temperature has a significant impact on the aging behaviour of plastics as they weather. To improve the comparison of laboratory and outdoor exposures, SKZ says specimen surface temperatures need to be measured and taken into account during laboratory weathering. To accomplish this, SKZ is using a Ci4000 Weather-Ometer with Specific Specimen Surface Temperature System (S3T) from Atlas. The Ci4000 Weather-Ometer is said to continuously read specimen surface temperatures with a pyrometer and assigns a measurement to the respective specimen via an RFID tag. Each specimen’s weathering behaviour is characterised by colour and physical properties. By including surface temperature measurement into the predictive model, artificial laboratory weathering is better correlated with natural, outside weathering. The weathering sequences are then analysed and described with a modified Arrhenius model. further information: www.atlas-mts.com
eter
er-Om
The
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Coronation Road, High Wycombe, Bucks HP12 3SY, UK Tel: +44 1494 464646 | go.instron.com/Trust
Weath Ci4000
by Dr. Sarah Elliott from Bruker UK
trometer Figure 3: Bruker Alpha FT-IR spec
Measurement approach Nowadays, quality control and routine analysis performed by IR spectroscopy usually uses the ATR (Attenuated Total Reflection) technique. Virtually no sample preparation is required so ATR is much easier than the conventional transmission mode. The sample is pressed on the ATR-crystal, which is the measurement interface. From the ATRcrystal, the IR radiation penetrates a few microns into the sample surface. The spectrometer’s detector measures the absorbance resulting from the sample. Most types of sample are suitable for ATR measurement (e.g. solids, liquids, powders, pastes, pellets, slurries, fibres etc.). The analysis takes less than a minute, including sampling, measurement and data evaluation. It is even possible to differentiate between the top layers of a polymer laminate, which cannot be achieved in transmission mode.
Figure 1: Spectra of polypropylene with varying talc content. 0% (a), 10% (b), 20% (c) and 40% (d).
Many of today’s plastics are multi-component systems with multiple constituents like different polymers, fillers, plasticisers and compatibilisers. By systematic selection and blending of these constituents in appropriate mixture ratios, tailor made substances with optimised material properties can be made. Identification and quantification of individual components is important for quality control and analytical purposes. Fourier transform infrared (FT-IR) spectroscopy is one of the fastest and most accurate methods for analysis of polymers. High quality IR spectra can be recorded in a few seconds; usually there is no need for sample preparation or consumable costs. FT-IR spectroscopy allows quick verification that a given product is within specification or to quantify one or more of its constituents. It provides information about the identity of incoming raw materials, possible contaminants, the quality of the products and can even identify unknown polymeric samples.
testing & inspection
Analysis of fillers in polymer products
ID of talc filler in a polymer Our first example deals with the identification of talcum powder that is used as a filler in polymers. It is the powdered form of the silicate mineral talc, Mg3Si4O10(OH)2. It is mixed with polymers in order to optimise their properties such as elasticity, impact resistance or colour fastness. Talc can be easily identified by using FT-IR spectroscopy. Figure 1 shows the measurement of four different polypropylene (PP) samples with different talc contents. The upper spectrum is pure PP; the spectra below have increasing talcum content up to 40 percent. The most prominent features are broad bands around 1000cm-1, 670cm-1 and a broad band around 400 cm-1. Quantitative analysis can be performed because the amount of talc directly relates to the intensity of the named bands.
polyethylene/polypropylene copolymer ‘Tafmer’ which contains no styrene. With these spectra, calibration method is set up. A band correlating with styrene content and that is unobstructed by matrix effects is identified. The fingerprint region of the reference spectra (figure 2) reveals two areas where integration can be performed: 1492cm-1 and the more pronounced band at 699cm-1. There is a direct correlation between the height/area of the peak at 699cm-1 and styrene content: The SEBS spectrum with 14.5 percent displays the highest peak whereas the peak is almost absent in the Tafmer spectrum. A calibration based on the intensity of the styrene Quantification of styrene content band at 699cm-1 is set-up. Reference spectra t en nt Our second example shows the of styrene co are added to the method with respective on ti ca fi ti an Figure 2: Qu quantification of styrene in a reference values of styrene content. Then the thermoplastic elastomer sample. The spectral range and method (height/area) are triblock copolymer ‘styrene-ethylenedefined. The calibration formula is calculated. butylene-styrene’ (SEBS) with known Using the calibration model, styrene styrene content is used as a reference concentration of the unknown sample is sample. SEBS is a very versatile determined to be 3.6 ± 0.1 percent. compatibiliser that stabilises polymer Bruker’s compact Alpha FT-IR blends and is also used as a stand-alone spectrometer, Alpha, with diamond ATR and polymer. The contents of the individual high-pressure clamp is an ideal tool to monomeric units are variable so there are analyse polymers, fillers and polymer many possible repeating units with additives. It is easy to use, cost effective and different styrene contents. Our reference requires minimal maintenance. sample has 14.5 percent styrene. Additionally we use a similar polymer with further information: bp&r 4.9 percent and the www.bruker.com/uk
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injection moulding
Engineering Passion
news
The tool mover
Tool-mover puts moulds in safe hands UK manufacturer, RUD Chains, has launched a manipulation device for the safe turning and tilting of heavy and awkward plant items such as plastic injection moulding tools. The ‘Tool-Mover’ is said to offer safety features including turning the load at the centre of gravity to ensure a secure movement, as well as a frequency controlled drive, to ensure the risk of damage to both tool and operator is limited. RUD says the Tool-Mover is easy to use and position, as it does not need to be bolted to the floor and can be moved to locations in a facility by a crane or fork lift/pallet truck. It is able to turn injection moulding tools with a weight from 6.3 to 32 tonnes. Tools can easily be cleaned on the table due to its low platform height and
the device itself is covered with polyurethane plates in order to help preserve the tools. further information: www.rud.co.uk
QUALITY USED MACHINERY
140mm Berstorff ZE130A 40D corotating twin screw compounding line,300rpm screws,500Kw motor W&P UG200 face cutter,centrifugal dryer & pumps.
THERMOFORMERS
1040mm wide Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.
1900mm Egan/Omam Sheet line 1700mm Line for ABS and PMMA 1500mm Bandera 3 roll stack 1350mm Welex/union sheet line. 1300mm Battenfeld sheet line 1040mm Welex Coex sheet line. 1040mm Welex 3 roll stack 890mm Welex PET Shet line 1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line
DIES
Structural changes see machining moved from Netstal to KraussMaffei As part of a structural realignment, KraussMaffei will take over machining operations from Netstal’s site in Näfels, Switzerland, with the latter focusing on finishing and assembly. The move will reportedly see the Näfels site beome a “centre of excellence” for injection moulding, focusing on developing fast-cycling premium products with short cycle times and high levels of precision for the beverage and packaging industries, medical engineering and highprecision parts sectors. The Group says the KraussMaffei PETForm product portfolio will be moved from Munich to Näfels so that all PETrelated technology areas will be concentrated in Näfels in future. “Our goal is to strengthen the position of Netstal as a premium brand and to develop the Näfels site in an evercompetitive market environment with intense cost pressure,” said Dr. Hans Ulrich Golz, CEO of Netstal. further information: www.kraussmaffeigroup.com
Tel: +44 (0) 1793 827666 Email: sales@transxl.co.uk Website: www.transxl.co.uk
SHEET EQUIPMENT
1300mm wide Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders. 1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.
www.kraussmaffei.com
100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent. 110kw dc motor and drive. Temperature panel 1987.
250ltr Motan Luxor 80 Dryer With Twin Desiccant Beds Which Provide Consistently Low Dewpoint Air To Process, While Reducing Energy Consumption.
EXTRUDERS 50mm Welex single screw coextruder 60mm Betol BC60. 25:1 l/d 80mm Cincinnati twin screw extruder. 90mm Egan extruder 30Dv, 150hp 90mm Kaufmann STMP single screw extruder 90mm Welex single screw extruder 4.5” (115) Welex single screw extruder 140mm Berstorff Twin screw extruder 150mm Egan extruder.
PROFILE LINES
60mm Cincinnati Alpha60 extruder with inverter drive powering a 37 kW motor , electrically heated barrel with fan cooling. 2003.
MIXERS
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TRANSXL INTERNATIONAL THORNHILL SOUTH MARSTON SWINDON WILTSHIRE SN3 4TA ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk
Case study: Sure route to success for Plastek In 2010, Unilever initiated a project to incorporate a radical new design of actuator on its range of Sure aerosol deodorants. Aiming to develop a solution that was both functional as well as appealing to a masculine aesthetic, Unilever chose Plastek UK has announced to work with the UK-based Plastek the successful Group to manufacture and culmination of a three- assemble a complex, fiveyear project with client, component design. Unilever, to create a Plastek UK was involved in the radically different new development and redesign of both actuator for its Sure the product and the tool, but says it brand of men’s played its key role in implementing deodorants. Here, BP&R the means by which the five takes a further look at individual components could be the design and technology manufactured and assembled to employed at the the high quality requirements and Nottinghamshire-based exacting timescale of the total company. project. This, it says, meant a significant investment by the company in new injection moulding machines from Ferromatik, including one with a turntable for cube technology to handle the advanced, high-cavitation moulds, as well as advanced CMM measuring machinery and high speed automated assembly equipment incorporating automatic camera-controlled quality inspection. “This type of project is hugely demanding in terms of expertise, experience and scrupulous planning,” said Plastek UK’s General Manager, Mick Shaw. “Yes, there has been a great investment in new equipment, but that would be worth nothing without the development of the measurement and standardisation protocols which allow our teams to produce these complex components to the required levels of accuracy in a completely consistent manner. That’s where the project succeeds or fails. “The two high speed assembly units will be producing multiple millions of actuators every month and the importance of this project to Unilever is mirrored by the enormous effort that has been made within Plastek UK to ensure a trouble-free implementation. Accordingly, we have been able to relocate existing machinery and deploy the new facilities without any interruption of supplies to other clients and the new manufacturing cell employs sophisticated new material feeding systems from Colortronic and Motan, the latest twoshot cube moulding technology and conveyor feeding of moulded parts to assembly to minimise labour and provide assured quality control.” The new actuators are now in full production and, besides the valuable on-shelf presence, feature a soft-touch, anti-slip button and a unique locking mechanism. further information: www.plastekuk.com
tuator The new ac product on the Sure
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engineering materials
// Materials Technical //
Blog
In association with Hardie Polymers – www.hardiepolymers.com
This month, polymer expert and technical blog author, Dr Charlie Geddes, discusses engineering polymers for longlasting colour when exposed to the elements Looking for colour stability in plastics for outdoor exposure? When it comes to outdoor exposure, ABS (acrylonitrile-butadiene-styrene) struggles a bit because the butadiene in the rubbery phase is prone to oxidation and yellowing on exposure to UV light, particularly after heat ageing. This makes it difficult to maintain brilliant whites and bright colours with ABS. By blending an acrylate rubber with the styrene-acrylonitrile rigid phase, to give acrylic-styrene-acrylonitrile (ASA), the weathering resistance is greatly improved, while retaining the other attractive properties of ABS – toughness, high gloss finish, friendly processing and low mould shrinkage.
In the same way that blending ABS with Polycarbonate (PC) increases the high temperature working limits by up to 20 degrees celsius and improves fire performance ratings, PC-ASA blends not only improve heat resistance and fire performance, compared to ASA itself, but has the added benefit of good weathering resistance and full colour choice, compared to PC-ABS. Automotive manufacturers have spotted that PC-ASA blends for grilles and internal components in cars and trucks do not require the additional cost of painting. Healthcare, consumer electronics, electrical equipment and street furniture are other markets that have seen the benefits of PC-ASA. 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.
turers have Automotive manufac blends for SA -A spotted that PC components in cars grilles and internal require the t and trucks do no nting pai of st co additional
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news
The global market for engineering plastics is expected to increase to approx. US$ 90 billion in 2020
Global market for engineering plastics to reach US$90 billion by 2020 The global market for engineering plastics is expected to increase to approx. US$ 90 billion in 2020, according to the latest study by research group, Ceresana. Ceresana says that given their physical and chemical properties, many industrial, electrical, and electronic parts as well as everyday products are made from engineering plastics. Faced with an increasing demand for ever more efficient and lighter materials, this trend will continue to gather momentum. “On a global level, electrical and electronic applications as well as consumer goods are among the most important sales market for many engineering plastics. Almost 25 percent of global demand originates in each of these two sectors,� explained Oliver Kutsch, CEO of Ceresana. The study suggests the third largest market is the transportation sector, followed by construction. On a regional level, however, notable differences become apparent. In Western Europe, for example, transportation is the largest sales market. Asia-Pacific, on the other hand, mainly utilises engineering plastics in the production of consumer goods, processing almost 30 percent of regional demand in this sector. Ceresana says individual products show distinct differences in regard to application areas. While Transportation accounts for 35 percent of polyamide (PA) consumption, household and consumer goods are the major application area for acrylonitrile butadiene styrene (ABS). The full study is available from Ceresana’s website. further information: www.ceresana.com/en
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reclamation & recycling
news Designers urged to ‘challenge the norms’ in drive to increase recycled polymer use Product designers should ‘challenge the norms’ with clients and think along more ‘circular’ lines to encourage greater uptake of recycled polymers in new goods, urges a UK-based plastics reprocessor. Recognising strong market drivers, such as resource scarcity, oil price volatility and growing consumer demand for sustainable products, while working within the pre-set design constraints presented by recycled polymers, are further important factors, according to Keith Freegard, Director of Axion Polymers. “Engaging with product specifiers and designers to make them recognise the clear environmental, economic and sustainable benefits of using recycled plastics is essential if we are to increase the uptake of recycled content in new items,” he commented. “This is vital if we are to realise the wider aims of sustainable manufacturing and the circular economy,” said Freegard, who will be speaking on ‘Increasing use of recycled plastics in products’ at REPLAST 2013, the British Plastics Federation’s (BPF) sixth annual plastics recycling
use of recycled polymers rs should encourage the Keith Freegard says designe
conference on November 6. The theme of this year’s event, at the Institute of Materials, Minerals and Mining in London, is ‘Driving Manufacturing Using Recycled Plastics’ and the conference will examine how to increase the size of the UK plastics recycling industry and its market. Key speakers from industry will outline how positive drivers to encourage more reuse could include reducing producer responsibility obligations under the PRN system by introducing an ‘offset’ allowance for the proportion of PCR recyclates used in new products.
According to Freegard, designers have an important role to play in making their clients aware of the potential benefits and savings that could result from specifying and inclusion of closed-loop recyclates at an early stage in the product development process. “Essentially, designers must challenge the client brief and think about circular materials flow using proven recycled polymers that can deliver multiple benefits,” he said. “There’s enough good quality recycled material out there now for organisations to demonstrate their commitment to sustainability.” further information: www.axionpolymers.com
The wedding dress made from recycled plastic cups
And the bride wore... plastic RPC Tedeco-Gizeh Kenfig, based in West Glamorgan, has demonstrated an innovative way of recycling plastic cups – by turning them into a wedding dress. The dress has been created for Tracey Leahy, Managing Director of Mannvend, a vending machine supplier based on the Isle of Man, which has a five-year contract with Kenfig to supply plastic cups. David Lowe, General Manager at Kenfig, said: “Tracey mentioned that she was getting married and threw me a challenge of making her a wedding dress
from plastic cups. “We agreed that if the dress could be produced then Tracey would wear it for part of her wedding day, in August. We are absolutely delighted with the result,” he continued. “I’m thrilled that RPC Tedeco-Gizeh rose to the challenge and have produced such a stylish dress. It just shows how versatile plastic cups can be,” Leahy commented. further information: www.rpc-group.com
Company has new recycled product range ‘in the bag’ CeDo, a manufacturer of second-life disposable products, has launched a black bin liner that it says is now partmanufactured from the previously unrecyclable part of the British household waste stream. CeDo says its new product is a ‘Made in Britain’ success story and also a first for the plastics film recycling and waste management industries. The new bin liner is currently 30 percent composed of UK plastics film domestic recyclate, with CeDo
saying it aims to build that percentage share to 90 percent within two years. CeDo claims to be the first company to use mixed plastics film waste from UK domestic households – previously regarded as unrecyclable and landfilled – as the feedstock for its new product. The company regards this breakthrough as creating a true UK closed-loop solution. As part of its manufacturing of the new ‘Household Waste - Saved from Landfill’ range, CeDo says it has invested in proprietary ‘dry cycling’ technology in order to separate and recycle this fraction of the household waste stream. This means that no water at all is used in the process – which the company says is
A selection of the CeDo products
contributing greatly to the large reduction in the carbon footprint for the bag. CeDo’s bag is designed, sourced and manufactured in the UK. This, it says, brings considerable benefits to customers and to the supply chain. further information: www.cedo.com
Europe’s recycled plastics could reach 62 percent by 2020 Europe could reach a plastics recycling level of 62 perecent by 2020, that’s according to a recent study by Plastics Recyclers Europe (PRE). The study suggests that plastics can potentially reach a much higher recycling rate, resulting in benefits for the European Union environment, economy and resource efficiency. “This study, commissioned to Bio Intelligence Service, aims to put forward the most suitable scenario in order to further improve the sustainability of plastics via recycling in Europe in the period to 2020. Enhancing plastics recycling will save scarce resources, create jobs and reduce environmental impacts,” said Ton Emans, PRE President. Emans said that the current plastics recycling situation is “no longer acceptable”, adding that long-term economic growth, demographic changes and growing scarcity of raw materials would not allow Europe the “luxury of wasting 76 percent of all plastic materials used.” Emans said the study proposes “crucial measures” that should be taken in order to increase recycling rates for plastics. PRE says that by implementing this resource efficiency vision for plastics, 24 million tonnes of plastic could be potentially diverted from landfill, 360,000 ‘green’ jobs could be created, as well as recovering energy from waste, saving money and avoiding emissions. further information: www.plasticsrecyclers.eu
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software directory manufacturing management directory
Virtual Design and Development... are there limits? It is expected that up to £7 Million of funding from the TSB and the EPSRC will be provided to fund projects developing and using simulation and modelling tools to reduce the need for physical prototypes in the design and This month’s update testing of new products. This workshop aimed to identify from RAPRA looks at ways of doing this, in this case the question behind specifically in relation to polymers and plastic products. the Technology These projects are intended Strategy Board (TSB) to give the UK Polymer Industry a commercial edge in workshop “Towards the global market by Zero Prototypes developing and deploying the latest emerging and new using Simulation and technologies in order to make Modelling” that was as efficient as possible the process of design and held at Durham development of novel University earlier polymers and polymer-based products, maintain or increase this year. the quality and reliability of polymer end products and facilitate greater use of recycled polymers, with a high degree of confidence in the performance of end products. So, getting back to the original question posed in the title, it was generally accepted at the workshop, that in theory, there are no limits to how far virtual design methods can be employed. However, we are still many years and a very long way from accepting that ‘real’ physical prototypes are completely unnecessary. Using development opportunities presented by the companies Akzonobel and Victrex as examples, the potential of modelling tools such as REPTATE and BoB to improve the efficiency of design solution processes was demonstrated. There are clearly many more technological hurdles (amongst others) to overcome, so the workshop attempted to identify suitable projects that would help the UK Polymer Industry move to the next stage and realise more of the benefits and advantages offered by using simulation and modelling. The output of this and other workshops will form the basis of a funding call ‘Towards Zero Prototypes’ due to be launched on 21st October this year. On behalf of all our members we will continue to be engaged closely with the TSB and potential consortium partners. further information: www.rapralimited.org available for the Funding is being made ls n tio and modelling too development of simula s ype tot for physical pro to reduce the need
ENTERPRISE RESOURCE PLANNING Solarsoft Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Solarsoft Business Systems MEI Division (Europe) T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Modules: Production Monitoring, “Drag and Drop”, Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts, Trace-ability, Operator Visual Aids, Process Parameter Profiling, Email/Tannoy Alerts, Stand-alone, “Drag and Drop” Scheduler, Standalone, SPC “Machine Analyzer”, Machine Energy, Monitoring, KPI Dash-boards, Visual Manufacturing (Large LED/LCD Displays), Automatic Data Import/Export Functions (for Integration to Manufacturing Systems &Other Software Packages). Solarsoft iVP ERP SAAS Manufacturing Software (for Plastics’ Processors) Solarsoft Business Systems T: +44 (0)1909 479 886 E: andy.jewell@solarsoft.com Solarsoft’s iVP ERP (SAAS) software for the plastics’ converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, ware-housing and distribution. It seamlessly integrates with Solarsoft-Mattec’s Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’ industry.
REAL TIME PRODUCTION MONITORING, SCHEDULING AND PROCESS MONITORING intouch T: 01604 646144 F: 05601 506253 E: enquiries@ intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.
ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Standalone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages). PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Real-time production monitoring features wireless data units and OPC Ethernet machine connections. “Drag & drop” job scheduling supports frame/insert level family tooling plus KAN BAN. ERP system integration, SPC/SQC, Touch Screen Data Units, Machine Maintenance, Operator Tracking, Traceability, DNC, Energy Monitoring, Bar Coding, Pager Alerts. Easy to use systems from a €600m company with over 30 years experience. SYSCON-PlantStar MTec Services Ltd T: 0114 2476267 F: 0114 2476267 E: mt@mtec-services.co.uk W: www.mtec-services.co.uk W: www.syscon-intl.com PlantStar systems provide customised, scalable applications that deliver real-time plant floor data from any machine, shift, and plant anywhere in your business. Affordable systems available for all size of processor. Browser-based software and hardware, and wireless ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include real-time alarms, downtime & reject analysis, capacity scheduling, ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Material traceability, bar-coding.
A listing in the Software Directory costs £140 per programme per year. Call Lisa on 01244 680222 for details.
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buyers’ guide
materials
colour masterbatch
conductive plastics and coatings
InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)
The Swan Centre, 8A Swan Street, Sileby, Leicestershire LE12 7NW T: 01509 816507 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk
TBA Electro Conductive Products Ltd Unit 3 Transpennine Trading Estate Gorrells Way, Rochdale, OL11 2PX T: 01706 647718 F: 01706 646170 E: info@tbaecp.co.uk W: www.tbaecp.co.uk
mould release
FOR SALE
Telsonic UK Ltd
12a - 15 Birch Copse, Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: sales@uk.telsonic.com W: www.telsonic.co.uk Blog:wwwtelsonicuk.wordpress.com
vibration welding Branson Ultrasonics
CNC ASSEMBLY MACHINES
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.
Reheat Stretch Blow Moulding Machine (PET) Make: Sidel, France Type: SBO 24/24 Year: 1994 - Preform Tipper, Hopper / Elevator, Infeed Rail - Oven & Heating Wheel - Electrical Cabinet (Siemens S5) - Operating manuals
For further details: 01925 596170 – 07838138342 Email: douglastrading@gmail.com
masterbatch
equipment AEROSOLS
Cannon Shelley UK agents for Belotti 5 axis CNC machines T: 01480 453651 F: 01480 52113 E: sales@cannon-shelley.co.uk W: www.cannonforma.com W: www.belotti.com W: www.shelley.biz
assembly hot plate welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com Machine Techniques Ltd Units 3-5, Sutton Court, Bath Street, Market Harborough, Leicestershire LE16 9EW T: 01858 434059 F: 01858 433638 E: davidchatterton@ymail.com W: www.mactec.co.uk
158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com
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
thermocouples 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
spin welding Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com
pulse staking H.T.E Engineering Services Ltd 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
control systems and equipment
ultrasonic plastics assembly systems
quality monitoring control Kistler Instruments Ltd
polymer distributors
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.
ancillary
FLEXIBLE POLYMERS RIGID POLYMERS ADDITIVES PURGING SOLUTIONS
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C.J.P. Sales Ltd, 8 Heol West Plas, Litchard, Bridgend CF31 1PA
Tel: 01656 644907 Fax: 01656 662 397 Email: sales@cjpsales.co.uk Web: www.cjpsales.co.uk
Branson Ultrasonics 158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.branson-plasticsjoin.com
ultrasonic welding
For Temperature Control Rental turn to the experts • FLUID CHILLERS • BOILERS • AIR CONDITIONING • HEATING • DRY COOLERS/ FREE COOLING
0800 026 4717 Rental Systems
Dosing equipment
Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
LABORATORY machines
PLASTICOLOR B A Thorne (Machinery) Ltd 19A Imex Business Centre, Oxleasow Road, East Moons Moat, Redditch, Worcestershire B98 0RE T: 01527 584714 F: 01527 584784 E: bat@bathorne.co.uk W: www.bathorne .co.uk
hopper dryers
printing machines
dryers/dehumidifiers
pad
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
GATE CUTTERS
hot runner systems hot runner controllers
hopper loaders 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
extrusion systems
screws and barrels
heating equipment infra red systems
mixing, feeding, drying Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
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, extrusion tooling, 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.
Injection Moulding
metal detection & separation equipment Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
nozzles & nozzle tips
granulators
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
materials handling and storage gravimetric/volumetric blending Motan Colortronic Ltd Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan colortronic.co.uk W: www.motan-colortronic.co.uk
53 bp&r
buyers’ guide static control
parts & services
Arrowquint 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
RIDAT COMPANY
SUPERIOR PERFORMANCE. COMPETITIVE PRICE.
injection moulding
printers of plastic mouldings 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
UK manufacturer of Thermoforming & Pressure Forming Equipment, including Blister & Skin Packaging machines
Ray Ran Test Equipment Ltd
screen changers Industrial Plastics Ltd Unit 13 Canterbury Industrial Park, 297 Ilderton Road, London, SE15 1NP T: 020 7252 9600 F: 020 7252 9601 E: sales@ipl-london.co.uk W: www.ipl-london.co.uk
secondhand and reconditioned ANGLO PLASTICS LTD Buy/Sell Used Plastics Machinery Rutland Road, Scunthorpe, DN16 1HX T: +44 (0) 1276 470910 T: +44 (0) 7740 632907 E: information@ angloplastics.com W: www.angloplastics.com DM Machinery Ltd Used Injection Moulding Machine Stockists 40 Thorne Lane, Wakefield West Yorkshire, WF1 5RR T: 01924 290206 E: sales@dmmachinery.co.uk W: www.dmmachinery.co.uk
DTL Machines 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 Plasplant Ltd Unit 4, Oakhanger Farm, Oakhanger, Bordon, Hants GU35 9JA T: 01420 473013 F: 01420 475152 E: plasplant@aol.com W: www.plasplant.com Rawmec (EEC) Ltd Rawmec Industrial Park, Plumpton Road, Hoddesdon, Herts EN11 0EE T: 01992 471796 F: 01992 471797 E: rawmec@btconnect.com W: www.rawmec.com
54 bp&r
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
For more information or to order our sales brochure please contact us:
T: 0845 050 6525 or E: info@ridat.com www.ridat.com
WATER FITTINGS
EXTRUSION
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
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 MAPRA Technik Co – DOSS – MARCEL AUBERT – KAFER 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
WANTED
services ACQUISITION
Injection Moulding Business Wanted T/O between £100,000 and £1.5million. Contact in the strictest confidence, Joe Reeve, Data Plastics Ltd Email joe.reeve@dataplastics.co.uk Phone 01993 700777
mouldflow analysis
Extrusion and Plastics Services Extrusion, Compounding, Wash Plant Installation, Maintenance, Removal New Factory Setups / Single Machine CAD work / Tooling Mods / Trials Product Development / Line Trials Downstream Equipment Repairs Chillers, Pumps, Pipework, Air etc Punching / Drilling / Foiling / Wrap Filtration / Settlement Systems Process Improvement / Training 07930 150120 extrusionandplastics@hotmail.co.uk
EXTRUSION FLOW ANAYLYSIS
Payment terms: COD T: 0121 328 5222 F: 0121 328 3555 E: sales@bsplastics.co.uk
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 printers pad to the plastics industry
testing/consultancy 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
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
Contract cleaning Injection Moulding Extrusion
WANTED PLASTIC SCRAP We are looking to purchase LDPE post production scrap. Can take over 100 Tonne a week.
printers
• • • • • •
Hot Runners Nozzles Moulds Dies Filters Screws Cleaning service for processors Remove all polymers Tel:- +44 121 511 1203 Fax:- +44 121 511 1192 Email:- LesH@claytonholdings.com Web:- www.claytonholdings.com
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