British Plastics
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bp&r SEPT 2016
Polymer production - shifting sands in buyer behaviour? HOW INJECTION MOULDERS CAN SAVE ENERGY
K 2016 - A LOOK AHEAD TO THE HIGHLIGHTS
TIME TO TAKE PLASTICS RECYCLING TO GREATER HEIGHTS?
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www.britishplastics.co.uk EDITORIAL
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once more to düsseldorf...
L
ately, I often find myself lamenting how quickly the present [insert Even in an as appropriate: industry week/month/year] is passing. More that moves so than ever when as fast as putting this issue plastics, together, however, when it hit home the biggest that next month event in the marks three years since the last edition industry’s of the K Show took calendar place in October 2013. Even in an seems to industry that moves have come as fast as plastics, around at a the biggest event in the industry’s frightening calendar seems to speed. have come around at a frightening speed. That said, the 3,100 exhibiting companies have, in the interim three years, developed, progressed and enhanced machinery, materials and technologies so that once again the show presents a platform of true innovation, forward-thinking applications and products that are set to shape the world as we know it. From faster cycling, more efficient and more intuitive and intelligent machines to lighter, smarter and more easy-toprocess materials, the small selection of highlights in our K Preview feature starting on page 42 has certainly whet my appetite for what’s to be seen at the show. Oddly, knowing that many companies often keep an ace up their sleeve to
unveil something extra special during the event (read: Freeformer in 2013), the thought of what could be waiting on the show floor next month has almost got me willing it to come around faster. Almost. Enjoy the issue. Leanne Taylor, Group Editor
bp&r
THE BIG STORY Polymer production -
shifting sands in buyer behaviour? FOLLOWING THE RECENT NEWS THAT THEY HAVE SECURED AN EXCLUSIVE DISTRIBUTION AGREEMENT WITH THE EGYPTIAN ETHYLENE AND DERIVATIVES COMPANY (ETHYDCO) TO SUPPLY ITS NEW RANGE OF HDPE, MDPE AND LLDPE TO THE UK AND IRISH POLYMER MARKETS, TECHNICAL EXPERTS AT PLASTRIBUTION ASK WHETHER, AS POLYMER PRODUCTION INCREASINGLY MOVES AWAY FROM WESTERN EUROPE, IF BUYER BEHAVIOUR NEEDS TO CHANGE.
T
he history of polymer production in Europe is rich, with many of the key developments including the discovery of LDPE and development of materials technology for the production of materials such as PP and HDPE/ LLDPE taking place within the region. However, over the last two decades the production of these materials has increasingly moved away from Europe towards the Middle East
and Asia, where the economics of production are significantly lower. In particular, the attraction of converting gas to polymer and by so doing, both adding value and converting a volatile material into a relatively inert solid, is almost irresistible. Despite the challenges of supply chains and the foreign currencies so far, European polymer converters have largely been insulated from the consequences of exchange rate volatilities and commercial price risk resulting from longer leadtimes and have typically continued to enjoy product priced in the month of delivery on short notice. So far, this has left the suppliers of material from outside Europe with the challenge of managing the supply chain and managing the risk in what can be a volatile market. There is strong evidence that placing the commercial risk on the importer tends to increase volatility, as attempts are
made both to speculate on the market and also reduce risk by trying to anticipate market trends and react to them. Typically, this tends to tighten supply in a market with an upward price trend and increase supply when there is a downward price trend, as importers attempt either enhance profits, or secure purchase contracts against inbound cargoes and unsold inventories. These very behaviours and the increasing proportion of imports are likely to be a significant cause of the increased market volatility that was seen in 2015.
The turning tide
As the tide continues to turn, has the time come for polymer converters to consider moving away from the traditional approach of pricing in the month of delivery and to start making forward commitments in terms of their purchases? We believe that such an approach would 1) increase security of supply 2) reduce volatility, since the speculative behaviour of the sellers would be diminished 3) reduce the sellers need to charge a risk premium 4) put European converters on a similar platform to those in other parts of the world where forward buying is often the norm and 5) move the point of risk closer to the point of consumption where prices are more typically fixed. “Despite the combination of logic and market forces, it is suspected that old habits
tend to die-hard,” said Plastribution’s Managing Director, Mike Boswell. “Needless to say, we are eager to form effective partnerships with customers to ensure reliability of supply.” Plastribution is currently holding stocks of a range of Ethydco materials, covering all the major production methods, including conventional HDPE, MDPE, and LLDPE film grades, plus Bi-modal and narrow molecular weight grades. Also, a range of injection, roto and blow moulding grades will also be available with plans in place for PE80 and PE100 grades for the pipe market. WWW.PLASTRIBUTION.CO.UK
Polyolefins Basket
Min
Max
Average
Range
Volatility
2011
£1,083.86
£1,254.28
£1,254.28
£170.42
14%
2012
£996.99
£1,296.36
£1,190.35
£299.38
24%
2013
£1,178.07
£1,312.98
£1,252.85
£134.91
11%
2014
£1,075.70
£1,254.23
£1,182.12
£178.53
14%
2015
£879.41
£1,265.62
£1,088.53
£386.21
31%
(Source: Plastribution Price Know-how 2015 Review & 2016 Outlook) 4
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contents
PLASTICS &RUBBER
SEPTEMBER 2016
on the cover Polymer production shifting sands in buyer behaviour? Following the recent news that they have secured an exclusive distribution agreement with the Egyptian Ethylene and Derivatives Company (ETHYDCO) to supply the UK and Irish polymer markets, technical experts at Plastribution ask whether, as polymer production increasingly moves away from Western Europe, if buyer behaviour needs to change. SEE PAGE 4
3
36 feature
Controlling the process: How injection moulders can save energy
When it comes to cost savings, reducing energy in the injection moulding process is a key consideration for plastics processors. Serafín García Navarro from AIMPLAS looks at how identification and management of particular aspects of the production cycle can increase the overall efficiency of the process.
EDITOR’S LETTER Once more to Düsseldorf...
42 feature
27 feature
Next month sees the engines fired up once again for the triennial K Show in Düsseldorf, the plastics and rubber industry’s leading trade fair and exhibition. We highlight a selection of the exhibitor news released ahead of the show.
REGULARS
INDUSTRY NEWS mo’s corner Reclamation and Recycling materials BUYERS’ GUIDE SOFTWARE NEWS FROM THE FRONTLINE
K Show: The Preview
Time to take plastics recycling to greater heights?
Stuart Foster, CEO of RECOUP, expresses his concerns over the activities and actions – or lack of them – in 2016 that could potentially shape the next decade or more in terms of opportunities for the UK’s plastics recycling industry.
31 feature
Celebrating 60 years of the IM screw
Screw design plays a fundamental role in efficient injection moulding, keeping manufacturing costs down and delivery times short. 6
55 feature
@Polymerman – Will the typical round of price increases take place again this Autumn?
In this edition of our latest feature looking at some of the key issues affecting polymer prices, Mike Boswell asks whether the industry will experience traditional seasonal pricing patterns, and the factors that influence them.
WWW.BRITISHPLASTICS.CO.UK
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INDUSTRY | NEWS RJG GAINS CPD ACCREDITATION FROM IOM3 FOR POLYMER TRAINING COURSES RJG Technologies has received accreditation for Continuing Professional Development (CPD) for a number of its polymer training courses by the Institute of Materials Minerals and Mining (IOM3). Continuing Professional Development is the updating of knowledge and skills, as well as the development of the personal skills required to successfully fulfill professional, managerial and technical responsibilities throughout a career. “By gaining accreditation of our courses it demonstrates our commitment to providing a platform for continuous learning and thereby provide the industry with a source of relevant training, information, skills and knowledge to enable individuals to remain competent throughout their career journey,” explained Richard Brown, Managing Director of RJG Technologies. “The importance of CPD is often not recognised, but these courses will aid continuous learning and will also help to improve our industry as a whole.”
In addition, RJG says the PAA\ VQ-SET Level 3 Diploma in Polymer Manufacturing Technologies qualification, developed by RJG in partnership with PAA\VQ-SET and Solutions 4 Polymers, has been approved by the IOM3 as meeting the underpinning knowledge to enable successful candidates to register as an Engineering Technician (EngTech). This Diploma is a core element in the Apprenticeship in Polymer Processing delivered by RJG in partnership with regional colleges. The next course of this type is starting on the 26th September in Peterborough.
The CPD-accredited courses are as follows: • • • • • • • •
Module One – Melt Preparation and Plasticisation Module Two – Process Control Module Three – Materials Technology High Performance Moulding Systematic Moulding Decoupled Moulding Master Moulder 1 Master Moulder 2
WWW.RJGINC.COM
The delegates at Ludwigshafen
UK MPS VISIT BASF’S HQ TO HEAR FIRST HAND FROM INDUSTRY A cross-party delegation of MPs visited BASF’s headquarters in Ludwigshafen, Germany, recently on a visit to learn first hand from industry in order to better understand the needs of business. The site at Ludwigshafen is one of the biggest industrial sites in Europe, stretching over 10km2 and employing almost 38,000 people. Over the course of the two-day visit, the delegation of 16 parliamentarians saw a wide range of BASF’s operations in action, which included a full site visit and a tour of their new research and laboratory facilities. They also had the opportunity to meet with senior staff representatives discussing policy issues relevant in both the UK and 8
Germany such as energy, innovation and apprenticeships. The delegation included representatives from all the main political parties and both Houses. This included MP for Cheadle, Mary Robinson, where the sales centre for BASF PLC is located in the UK, Shadow Minister for Small Business, Bill Esterson MP, and WWW.BRITISHPLASTICS.CO.UK
SNP Westminster Group Leader for Transport, Drew Hendry MP. Commenting on the visit Angela Smith MP, former Shadow Minister for the Environment, said “it was an important opportunity to hear from senior staff with expertise in a number of relevant policy areas.” WWW.BASF.COM
POLYPIPE SAYS IT IS “UNAFFECTED BY BREXIT” AS IT DELIVERS STRONG HALF-YEAR RESULTS UK manufacturer of plastic piping and ventilation systems, Polypipe, says there is no sign of orders weakening as a result of the recent referendum vote, as it posted positive half-year results. The company, which operates in the commercial, civils and infrastructure sectors, posted a 31 percent increase in revenue to £223.3million for the six months ended 30 June, as well as an increase of 29 percent in pre-tax profits to £29.9million. Polypipe says after an “excellent start” to 2016, demand from all segments in which it operates has remained strong. It’s recent acquisition of Nuaire, a ventilation systems manufacturer, is “performing well” and has seen some early success in conjunction with Polypipe’s own products.
The company’s results have been unaffected by Brexit, it says, with order intake showing no sign of weakening following the outcome of June 23. Despite the economic uncertainty surrounding the future, Polypipe says the business is well balanced to cope. “We have delivered another record performance in the first half continuing the strong momentum from last year,” commented David Hall, Polypipe’s Chief Executive, who said he is confident the business can “continue to develop and outperform, whatever the market conditions.” Hall added that encouraging comments from UK Government recognising the need to provide stimulus for construction gives it confidence in its outlook and the business plans to continue with development initiatives. WWW.POLYPIPE.COM
Polypipe operates in the commercial, civils and infrastructure sectors (Credit: Polypipe)
K has the future wrapped up
More than one third of global plastics production serves to package and transport foods and consumer goods. One of the biggest challenges in the packaging industry is environmentally appropriate material cycles. K 2016 has the future wrapped up. With some 3,200 exhibitors in 19 exhibition halls on more than 171,000 sqm of exhibition space, the world’s premier trade fair for the plastics and rubber industry will once again be presenting the entire range of products and services that the industry has to offer. Everything that will move the world in the future – with globally unique live presentations of sophisticated production units. Plan your visit now.
CALLING ALL STUDENT DESIGNERS… For those inspired by our winner’s interview in the July/August issue of BP&R, we are pleased to announce that the organiser of the annual ‘Design Innovation in Plastics Awards’ is calling for entries for the 2017 edition. Students registered on design and engineering courses in the UK are invited to design an innovative product, primarily in plastics, that will provide a more comfortable and less stressful travel experience.
The theme is ‘Products For Independent Travel – The Future of Personal Travel’ and every winner in the competition will receive a placement. The full competition brief will be available online in September, the deadline for registration is 9 December 2016 and entries must be submitted no later than 17 March 2017. For more information on the competition email dip.skatz@yahoo.com or alternatively visit www. designinnovationplastics.org
Yo u r Ke y to t h e Fu t u r e
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 23 00 12 info@itsluk.com
k-online.com
www.itsluk.com
A new generation takes shape. s V i s i t u 16 0 a t K 2 l d o r f, sse i n D Ăź m a ny e G r
5 Hall 1 5 8 C Stand
Take the proven and tested, make it even better and explore something new – that is what makes ENGEL and their customers so successful. Following our claim be the first, we will present a new generation of injection moulding machines setting new standards at K 2016. For now, we will entice you with this: We do not compromise on energy efficiency, ergonomics or precision. Do you want to know more? Meet us at stand C58 in hall 15, starting October 19. www.engelglobal.com
FREE FACTCARD LAUNCHED WITH KEY INFORMATION ON 4TH INDUSTRIAL REVOLUTION EEF, the manufacturers’ organisation, and Oracle have published a factcard with the key information UK manufacturers need in order to understand, prepare for and capitalise on the opportunities surrounding the 4th industrial revolution (4IR), sometimes known as Industry 4.0. 4IR is being driven by connectivity, big data and other rapid advances in product and process technology. Eight in ten manufacturers (80 percent) say that this next industrial transformation – which is global - will be a business reality within the next ten years. EEF says this makes it vital that manufacturers are “up-tospeed.” The factcard is designed to encourage manufacturers to think about how they can successfully incorporate new technology into their business strategy to drive growth and productivity. It demystifies how 4IR technologies can improve efficiency
EXPANDED NEW RUBBER TRAINING COURSE GETS GOAHEAD Following a successful approach to rubber manufacturing companies across the country, the Elastomer Training Action Group (ELTAG) has confirmed that arrangements have been put in place to run an expanded rubber technology training course starting in autumn 2016. The suggestion for a new course
EEF and Oracle are helping the UK’s manufactuerers prepare for the 4th industrial revolution (4IR)
and be used in products, the manufacturing process and across supply chains. “4IR will be crucial for UK manufacturing. Manufacturers are aware that it will be a game changer – not just for investment in technologies, but for the cuttingedge, high-level skills required alongside,” explained Ms Lee Hopley, Chief Economist at EEF. “The speed of this new industrial revolution is such that UK manufacturers will need help and support to adjust
and capitalise on its opportunities. Knowledge and understanding will be key, which is why we are collaborating with Oracle and have created this free factcard to help get our sector up-to-speed and to encourage companies to share ideas and best practice.” Manufacturers can download the factcard by visiting the website below.
was proposed earlier this year in order to improve upon the existing model in terms of accessibility to a wider audience. The new model will be held at South Leicestershire College and will be based on block release of six oneweek sessions spread over the year. It will accommodate between 18 and 20 students, who will be taught in two parallel groups. The course is pitched at level three
or equivalent – covering three units towards a BTEC qualification - and is also suitable for others, including graduates, who need to top up their existing knowledge with a full understanding of rubber technology. Although fully subscribed for 2016/2017, companies are invited to register their interest in placing their staff for future courses. “We are delighted that this course is going ahead. Our preliminary research had shown that there was a strong need for a course pitched at this level and the strong response we received to our approach to the industry confirmed this,” explained John Dorken, Co-ordinator for the Group and Director of the British Rubber and Polyurethane Products Association (BRPPA). “The course gives our companies the opportunity to help provide the skills necessary to remain at the forefront in the development and production of high-tech, high value specialised products.” For information on the course, contact jdorken@brppa.co.uk
The new course will be based at South Leicestershire College. Image: (SLC)
WWW.BRITISHPLASTICS.CO.UK
WWW.EEF.ORG.UK/FOURTHINDUSTRIAL
11
D
In this edition of Mo’s Corner – our regular feature that aims to answer commonly asked questions about the manufacture and processing of plastics – we look at the principles behind dry-air dryers.
NORTHEAST PLASTICS MANUFACTURER GETS GOLD FOR ARMED FORCES SUPPORT A County Durham plastics manufacturer is one of only 22 companies in the UK to be recognised for its support of Armed Forces personnel. TA Plastics, based in Spennymoor in the North East of England, was awarded the gold certification in this year’s Employer Recognition Scheme (ERS), which is designed to recognise and thank employers who are supporting Armed Forces personnel and their families. The company has two reservists in its team of 30 staff to whom it provides flexibility in order to accommodate their training or other needs. To qualify for a gold award, employers must not only go through a rigorous boarding process to pledge their support, but also become advocates, encouraging others to do likewise. Managing Director, John 12
ry-air dryers can be categorised as either desiccant dryers or compressed air dryers. Though both designs use dry air, they are each based on different technology. This article details desiccant dryers; compressed air dryers will be covered in the next article (November/ December issue of BP&R). Desiccant dryers are based on a simple principle: hot dry air is passed through the granulate, to release the moisture, which is then adsorbed in a hygroscopic desiccant material called molecular sieve. The desiccant material is insulated, and is usually regenerated at regular intervals or as need dictates. Stateof-the-art dryers are outfitted with two or more desiccant cartridges, or a wheel, to ensure continuous operation and to meet required throughput. A major benefit of desiccant dryers is that they operate on the basis of a defined dew point, independent of ambient air conditions. In most cases, a dew point of -20°C combined with a moderate drying temperature is sufficient to reach the required residual moisture. If the drying temperature is too high, additives can diffuse from the plastic granulate being dried, and become attached to the molecular sieve, causing damage. The air that is dried using the molecular sieve is then heated and fed into the bottom of the drying bin; where it rises up passing through the plastic granulate. The drying bin should be kept full at all times and the
Humphreys, said he was “hugely honoured” to win the gold award, adding that providing support is important to both the Armed Forces and the business, which has benefitted from the new skills brought by the reservists. Congratulating the winners, Defence Secretary, Michael Fallon, said the commitment by companies to support the Armed Forces is “making a real difference to everyone who serves and their families.” James Ramsbotham, Chief Executive, North East England Chamber of Commerce, commented: “I was in the Armed Forces in my early career and know at first hand how important it is to have a positive approach to people who want to serve their country and also have a permanent job outside of the army. TA Plastics are to be congratulated for what they have achieved.” WWW.TAPLASTICS.CO.UK WWW.BRITISHPLASTICS.CO.UK
Interior view of a Luxor dryer with two desiccant cartridges (Credit: motan-colortronic)
drying process time must be complete before removing the first load of material. During continuous operation, the granulate moves slowly down against the dry airflow, from the top of the drying bin to the outlet at the bottom. The process is comparable with that of a counter-current heat exchanger. Heat transfer from the hot dry air to the granulate causes moisture to evaporate off the material. The processed air, now entrained with moisture, is drawn upward out of the drying bin; it is then passed through a filter to remove dust particles. The air then moves through a heat exchanger before reaching the desiccant cartridge, where the moisture is adsorbed by the molecular sieve. Depending on the mode of operation, the dryers can be set to automatically cycle to a fresh cartridge or section of wheel – at regular intervals or based on the dew point – and initiate the regeneration process. This entails passing hot air through the molecular sieve, causing the stored moisture to evaporate and be exhausted. When the process is finished, the cartridge or wheel section is ready for the next cycle. FURTHER QUESTIONS? ASKMO@MOSCORNER.DE
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POLYMERS AND COMPOUNDS | NEWS ABBEY POLYMERS ADDS EN45545 COMPLIANT COMPOUNDS TO PORTFOLIO UK materials distributor, Abbey Polymers, has announced the availability of an “interesting” new compound designed for applications in railway carriage interiors where the new norm EN45545 applies. The company is offering the EN45545 materials, which adhere to a classification system that specifies requirements for fire behaviour of materials and products used in trains, from Italy’s Vamp-Tech, a company with a longstanding expertise in the production of flame retarded engineered compounds that meet the requirements of UL94. Now, however, in addition to its portfolio of V2 and V0 systems based on a number of base polymers, the company has developed materials to meet EN45545 specifications. The key features of EN45545 materials are high oxygen indexes and very low smoke density and smoke toxicity. These compounds are mainly designed for small electrical
Abbey Polymers is now supplying Vamp-Tech’s EN45545 grade materials
components in railway carriages in hazard levels HL1, HL2 and HL3 and risk classes R22 and R23. The EN45545 compliant range available from Vamp-Tech includes PP unfilled, PP 25 percent glass fibre,
PA6 unfilled, PA6 30 percent glass fibre, PA66 30 percent glass fibre and PPA 30 percent glass fibre. WWW.ABBEY-POLYMERS.CO.UK
SO.F.TER. INTRODUCES NEW PA6 GRADE TO LIGHTWEIGHT COMPOUNDS PORTFOLIO Following the successful launch of its ‘Litepol’ polypropylene-based (PP) compound line at Fakuma 2015, SO.F.TER. has introduced new grades based on polyamide 6 (PA6). The Litepol engineering polymers feature hollow glass microspheres that enable lightweighting of plastic parts by up to 30 percent. In the automotive industry — the target market for the Litepol range — potential CO2 emissions savings are as much as 1000 tonnes per car. The company hopes the latest addition to its portfolio will be as well received as the PP grades, which have been approved for use by FCA Fiat Chrysler Automobiles following their launch. In the various configurations currently available, Litepol products enable weight reduction, good strength and shock resistance,
SO.F.TER. has introduced new grades of its Litepol range based on PA6
shorter cycle times and exceptional dimensional stability of the moulded parts. SO.F.TER. says the compounds need no technology investment by users and can be used on standard injection moulding equipment. The ability to use the glass microspheres either alone or in combination with chemically-bonded glass fibre allows for variation of the material properties, enabling users to achieve exactly their required goals WWW.BRITISHPLASTICS.CO.UK
in terms of lightness, mechanical performance and price. Therefore, SO.F.TER says the focus of Litepol is on maximum versatility and adaptability, qualities that make this product range extremely appealing for the automotive industry, especially in consideration of the new limits on CO2 emissions set at 95 g/ km starting from 2021. WWW.SOFTERGROUP.COM 15
ALBIS - Bringing our World Class Polymer partners to you for 50 years
DSM’S BIOBASED POLYAMIDE CHOSEN BY MAJOR GERMAN CAR MANUFACTURER A major German car manufacturer has chosen a biobased polyamide from DSM for the production of a cooling system component due to go into production in the coming months. The part, a recently-developed thin-walled “T” connector for a coolant hose, is produced with EcoPaXX Q-HG6/7, a grade that boasts high hydrolysis resistance and can enable part weight to be cut by as much as 30 percent, compared with polyamide 66 (PA66). The connector needs to withstand high internal pressures at temperatures of up to 135°C, something that is not possible with PA 66. “EcoPaXX offers strength and reliability even in critical areas like the weld lines in complex designs,” explained Thomas Selberdinger, Sales Manager Automotive, at DSM. The grade is one of a portfolio of materials that DSM is expanding for the production of hydrolysis-resistant automotive components across a
BIESTERFELD CREATES DEDICATED DIVISION FOR PERFORMANCE RUBBER COMPOUNDS Plastics distributor, Biesterfeld Group, has announced the creation of a new business division for its performance rubber portfolio. Biesterfeld Performance Rubber GmbH, which started operation on 1 July 2016, aims to further develop the Group’s rubber business strategically, while strengthening its role as a leading European distributor in the sector. “We offer a global distribution network for rubber compounds to our customers and suppliers. In doing so we can draw
T connector in EcoPaXX
wide range of temperatures. For example, DSM is adding to its range of high performance materials with compounds based on Xytron polyphenylene sulfide (PPS), which
on many years of expertise within the Biesterfeld Group,” explained Sascha Hennig, who has assumed management of the new division, along with Peter Wilkes. “We will focus on further expanding cooperation with international market leaders and are able to leverage synergies within the Biesterfeld Group to the benefit of our suppliers and customers,” Hennig added. Wilkes commented: “Our focus is on the distribution of synthetic rubber compounds, of high-quality silicone and fluorosilicone rubbers, carbon black and additives. The current rubber portfolio will be complemented by high performance polymers and additives.” Biesterfeld Performance Rubber will be active in Europe, Biesterfeld has created a dedicated rubber division
16
WWW.BRITISHPLASTICS.CO.UK
is also an inherently hydrolysis resistant polymer; these are intended for applications where very high dimensional stability is part of the requirements. In addition, DSM is introducing a new grade of Akulon polyamide 66 that has very good resistance to water/glycol mixtures used at elevated temperatures in automotive cooling systems. “With the addition of all these new compounds, DSM now has a product pallet that covers just about every application where hydrolysis resistance is needed, whatever the operating temperature,” added Selberdinger. “We are well known for our strength in high-heat polyamides, but a PA66 grade with very good hydrolysis resistance was something that we lacked. I am proud to say that we have now filled that gap. On top of that, our new Xytron PPS compounds will help us to enter even more demanding applications where extreme stability is called for.” WWW.DSM.COM
Latin America and North Africa, with local technical application support available. WWW.BIESTERFELD.COM
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BASF EXPANDS PARTIALLY AROMATIC POLYAMIDES RANGE WITH NEW PPA PORTFOLIO BASF is expanding its range of partially aromatic polyamides with the recent market launch of a new polyphthalamide (PPA) portfolio. The new ‘Ultramid Advanced N’ portfolio comprises unreinforced compounds and compounds reinforced with short or long glass fibres as well as flame-retardant grades. They exceed the properties of conventional PPA plastics, says BASF, thanks to constant mechanics up to 100°C (glass transition temperature: 125°C), outstanding chemical
PETLON POLYMERS TO HELP TAKE RECYCLED GUM FURTHER UP THE VALUE CHAIN A UK-based compounder has signed a joint development agreement with innovative start-up, Gumdrop Limited, to further develop polymers made with recycled chewing gum. Petlon Polymers, based in Lydney, Gloucestershire, will work with Gumdrop, a company previously profiled in March’s issue of BP&R, in order to further develop its compounds made from recycled gum in order to produce a material that can be manufactured into a wider range of goods. “Gumdrop was founded to tackle the global problem of chewing gum waste and we’re the first company in the world to recycle and process chewing gum into a range of new compounds that can be used in the rubber and plastics industry,” explained Gumdrop’s Founder, Anna Bullus. “This exciting new development utilising Pelton’s extensive Polymer knowledge is designed to take the compounds further up the polymer value chain.” This month Gumdrop announced the launch of wellington boots made with recycled chewing gum, as well as educational packs for freshers students starting Universities across the UK to educate them about the importance of anti-littering and recycling. WWW.PETLONPOLYMERS.CO.UK WWW.GUMDROPLTD.COM
resistance and low water absorption as well as low friction and wear. The new product line, which offers processors a short cycle time and a wide processing window, gives customers greater design freedom for technically advanced products, says BASF, especially in terms of miniaturisation and functional integration. “Ultramid Advanced N is BASF’s response to the rising demands on plastics that are employed today under increasingly challenging operating conditions,” says Dr. Melanie MaasBrunner, Senior Vice President, Performance Materials Europe. “Developing specialities such as Ultramid
Advanced N is in line with our strategy to provide our customers with a wide range of solutions. We are committed to offer a broad PPA portfolio and will further launch highperformance plastics in the coming years.” Typical end products for Ultramid Advanced N include small connectors and functionintegrating housings in white goods, consumer electronics and mobile devices, as well as automotive components and structural parts near the engine and the gearbox in contact with hot, aggressive media and different fuels. WWW.PERFORMANCE-MATERIALS.BASF.COM
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Managing Director, David Outen, said that the investments come as the business focuses on cementing its reputation as PVC specialists. “Our core technical team has over 150 years experience of specifying and processing PVC based materials for a variety of applications,” he explained. “The company does not dilute its resources or focus on a range of different polymers but concentrates on the versatility and cost performance of PVC, and we enjoy proving our expertise to our customers.” Outen said Dugdale’s sustained growth over recent years demonstrates the success of the company’s commitment to customer service and the continual focus on development and technical service. The company’s investment is to be fully completed by the end of 2016.
DUGDALE CONTINUES EXPANSION WITH LATEST PHASE OF £2MILLION INVESTMENT West Yorkshire-based PVC compounder, Dugdale Ltd, is finalising the latest phase of a £2million capital investment in the business to facilitate growth and expansion. The latest installation saw a new materials silo and Battenfeld Cincinatti compounding machine delivered and commissioned, with a refurbishing of the premises and the housing of a new laboratory line - equipped with an integral small scale pilot/product proving compounding line - next on the list. The new owners, in place since the 2014 Management Buyout, have grown the Dugdale brand and PVC compound sales through the last three years. Current levels of customer needs see Dugdale formulating an average of 50 new PVC compounds per month.
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LANXESS ADDS TO EASYFLOWING POLYAMIDES AND POLYESTERS PORTFOLIO Lanxess is continuing to expand its range of easy-flowing polyamide 6, 6.6 and PBT compounds (polybutylene terephthalate) following an increase in interest in the benefits that these materials can bring. “We are seeing a strong upturn in the level of market interest in the benefits that these materials open up compared to standard materials in terms of processing, production costs and design freedom,” explained Tim Arping from Lanxess’ High Performance Materials (HPM) business unit. “They are particularly suitable for manufacturing the kind of thinwalled components that are ideal for lightweight construction and the miniaturisation of assemblies.” The latest example of one such product innovation is new Durethan BKV 30 XF (XtremeFlow). The polyamide 6 with 30 percent glass fibre content is the successor of Durethan DP BKV 30 XF and is over 17 percent easier flowing (flow spiral, 8 x 2 millimeters, 280 °C melt temperature). Compared to Durethan BKV 30, another standard polyamide
6 with 30 percent glass fibres, its flowability is 62 percent higher. The new material features a good mechanical property profile that is almost identical to that of its predecessor and Lanxess says it too produces outstanding surfaces. “We think it has huge potential for use in applications such as light but extremely strong mounts and brackets in cars,” commented Stefan Theiler, an expert in the development of polyamide compounds at HPM. Also new are the three polyamide 6 compounds: Durethan BG 30 X XF, BG 30 X H2.0 XF and BG 30 X H3.0 XF. They are reinforced with a 30 percent mix of glass fibres and glass microbeads and Lanxess says they exhibit “outstanding flowability” and an “exceptionally low susceptibility to warpage”. Featuring a good mechanical property profile, their flowability is more than 30 percent higher than that of Durethan BG 30 X, a similar standard polyamide 6. “The compound with H3.0 thermostabilisation has a very low copper and halide content and is customised for natural-coloured and lightly coloured applications in electrical engineering and electronics, such as plugs, plug connectors and fuse boxes. The
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H2.0 material version is aimed at components that are coloured black and are subjected to higher heat loads,” added Theiler. In addition to its Durethan grades, Lanxess is continuing to develop its wide range of easy-flowing Pocan XF polyester compounds. These materials include non-reinforced and reinforced products with flow properties that it says are usually much better than those of similar standard grades and are often more resistant to hydrolysis. “Furthermore, they exhibit an up to five percent reduced density, which means processors can save on material,” explained Boris Neuwald, Product Developer for Pocan at Lanxess. One example of a non-reinforced PBT compound is Pocan B 1205 XF. Thanks to its outstanding flowability, this material is perfect for the trend toward miniaturisation in the electrical engineering and electronics sectors. WWW.LANXESS.COM Comparison of key properties: the improved flowability of the new Durethan BKV 30 XF grade results in a melt viscosity that is only half as high as that of its predecessor Durethan DP BKV 30 XF.
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THERMOFORMING | NEWS RIGID PLASTIC PACKAGING TO FUEL THERMOFORMED PLASTICS GROWTH TO 2021, FINDS REPORT The increasing use of thermoformed plastics, especially in the rigid packaging sector, will be a key driver for growth in the thermoforming market in the next five years, according to a recent report. According to BCC Research, the global thermoformed plastic market is expected to increase from £8.3 billion pounds in 2016 to £10.2 billion pounds by 2021, which corresponds with a five-year compound annual growth rate (CAGR) of 4.3 percent. “In sectors such as food, medical and other packaging, moisture control is often critical and thermoformed products have been used with barrier films to provide excellent packaging materials,” explained BCC Research Analyst, Mel Schlechter. “The concept of ‘thinwalling’ in many packaging applications has been another major driver for thermoformed packaging.” Advances, says BCC, will be driven by above-average growth in
The food sector will be a key market for the use of thermoformed plastic packaging in the next five years
tubs, cups, bowls and lids used in foodservice applications, as well as the packaging of foods such as baked goods, frozen products, fresh produce, meat and dairy products. Opportunities in pharmaceutical blister packaging will also add to the market, as well as the automotive industry. Sheet demand in the auto sector will increase due to the
need for lighter weight and fuelefficient vehicles with instrument panels leading the way in auto interiors along with the potential of plastic windshields and windows. In addition, there has also been increased usage in several exterior auto parts. WWW.BCCRESEARCH.COM
MANCHESTER-BASED THERMOFORMED PACKAGING MANUFACTURER CONTINUES INVESTMENT Manchester-based thermoformed packaging manufacturer, Mister Blister, has invested in its second Illig machine in 12 months as part of an ongoing investment plan. The company, which specialises in tamper-resistant blister packs, purchased the Illig RD 53d automatic roll fed thermoforming machine to facilitate continued growth. The RD 53d features Illig’s ‘Intelligent Control Concept’ (IC), which offers both advanced process optimisation, as well as electric servomotor drives on all movements, enabling reduced cycle times and higher outputs. “It is important for us that we work with suppliers who share our own aspirations for innovation and efficiency, and each new generation of Illig machines gives us an abundance of both,” said Mister
SO.F.TER. has introduced new grades of its Litepol range based on PA6 Mister Blister continues to invest in Illig technology for its thermoformed packaging ranges
Blister’s Managing Director, Gary Briscoe. “Illig are always looking at ways of enhancing their machines and this in turn enables us to push out the boundaries of blister design whilst still maintaining our competitive advantage.” Mister Blister says in order to maintain its high level of designing WWW.BRITISHPLASTICS.CO.UK
and production of packaging for a wide range of industries it will continue to invest in new machinery and equipment. The company has confirmed its next purchase will be an Illig RV 74d, a model released at the beginning of 2016. WWW.ILLIG.CO.UK 21
FRIMO Group GmbH | +49 (0) 5404 8860 | info@frimo.com MPM The Frimo
FRIMO UNVEILS MULTIFUNCTION MACHINE TO GIVE AUTO MANUFACTURERS MORE FLEXIBILITY Frimo has recently developed a new machine for thermoformers that provides more flexibility by incorporating multiple functions for decorating and finishing. The Multi-Purpose Machine (MPM) is designed to enable automotive manufacturers to respond to an everincreasing variety of models, with different interior variants and evershorter model life cycles, by providing a flexible system. Frimo says the MPM replaces the need for separate machines or equipment for vacuum lamination, press lamination, edge folding and groove lamination, as these surface-finishing techniques can now be implemented using one single, compact and modular basic machine. The MPM is designed primarily for small and mediumAdelie’s group procurement manager - packaging, James MacKellar (L) with Kingsmoor Packaging’s managing director, James Hill (R).
sized components such as armrests, console covers and door panels. “The great thing about this is that we have a fully automated solution for tool change, and the system can flexibly process both blanks and material on rolls,” explained Franz Streibl, Key Account Manager at Frimo. “As the smart
UK THERMOFORMER NAMED SUPPLIER OF THE YEAR BY LEADING FOOD GROUP A Somerset-based thermoformed packaging specialist has been awarded the ‘Supplier of the Year’ award by a leading UK food manufacturer. Kingsmoor Packaging (KPL) received the accolade from Adelie Foods Group for its supply of innovative plastic packaging primarily for use with its ‘Food to Go’ (FTG) range of products destined for major UK retailers and coffee outlets. Commenting on why Kingsmoor was chosen for the award, Adelie’s Group Procurement Manager, James Mackellar, said: “The Food to Go category is very demanding with many new projects and frequent
tools have their own PLC on board, a complete product and process change is possible at the touch of a button.” The fully automatic tool change system permits extraordinary flexibility and very short tool changing times, Streibl added. The modular MPM consists of a standardised basic machine, which can be supplemented as required by other components, allowing easy adaptation. For instance, the basic model allows for press laminating and edge folding, and a foil heater would only be required and added if the manufacturer also wanted to use vacuum laminating. Also possible are further configuration stages, for example, in-mould graining, film unwinding and tool change shelves, etc. A benefit of the parallel heating times and substrate assembly is shorter cycle times compared with conventional single-station systems. WWW.FRIMO.COM
product launches across a variety of channels - working with key suppliers like Kingsmoor helps us meet our customer’s requirements.” Kingsmoor has its own inhouse design service and tooling capabilities, which operate in tandem with its production facilities. This, it says, enables the company to fully understand customer requirements and provide a flexible and cost effective single source service. Kingsmoor Packaging’s Managing Director, James Hill, commented: “Knowing and fully understanding their business well means that we can quickly interpret their briefs and design packaging to exact specifications.” WWW.KINGSMOORPACKAGING. CO.UK
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FRIMO Group GmbH | www.frimo.com The detailed facemask, produced using a combination of software, 3D printing and traditional thermoforming
DISNEY COMBINES THERMOFORMING AND 3D PRINTING FOR MERCHANDISE OF THE FUTURE Researchers at Disney are proposing a new method of producing its merchandise that uses a twist on the traditional thermoforming process to create unique, customised items. The key to the new method lies in new, specially designed software, which uses complex algorithms to deform an image to compensate for its application onto a 3D surface. The process works by using this software to design and then distort an image, before it is transferred to a plastic sheet. In combination with a special 3D printed mould, the sheet is then formed to create a faithful replica of the desired product. Disney has released a video
NEW THERMOFORMED PACKAGING OPENS UP NEW DESIGN ADVANTAGES The awardwinning packaging
A new thermoformed ‘twist cup’ with an injection moulded screw lid has won an industry accolade for its unique design advantages. The new packaging solution, which was designed collaboratively between Orkla Foods Norway, RPC
showing the process in action using three examples: a complicated facemask, a tree trunk and a loaf of bread. Such intricate software, able to precisely map the stretch of plastic when applied onto a mould was previously unavailable. Although the concept of printed thermoforming is not new, it is the level of detail that can be achieved with the new software, such as facial features and
expressions, which is being touted as groundbreaking. It is thought that the combined software and hardware manufacturing process will enable Disney to create more advanced merchandise in the future, but is also transferrable to many other industries and applications.
Superfos and RPC Promens, has been recognised in Nordic packaging competition, ‘ScanStar 2016.’ Created using two different technologies and two different resin materials (PET and PP), the packaging is designed to be both lightweight and convenient for use with a range of foods, including cottage cheese and pre-mixed, dressed salads. The product is decorated with high-gloss colour labels on both the pot and lid and the lid is designed to accommodate the pot standing on top, which is both practical and allows for good facing on-shelf. Importantly, end users benefit from a new, easy way to open and close the pack by simply twisting and turning the lid. RPC says this ‘open and re-closure’ mechanism is something special in the fresh
salad segment and serves as a distinguishing feature. In their citation, the ScanStar jury members said the thermoformed packaging “opens up [opportunities] for new shapes and design advantages. The packaging is stackable and easily opened, and it will work well in the shop shelves and in the customers’ homes.” They also commented on the packaging’s good presentation and ease of opening. Kjersti Trömborg, Packaging Developer, Orkla Foods Norway, said the company was “pleased with the recognition” that came with winning the ScanStar accolade and that RPC Superfos and RPC Promens had “done a really good job” in helping it design and develop the new pack.
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RECLAMATION & RECYCLING | NEWS TOTAL LAUNCHES NEW RECYCLED COMPOUNDS THAT “OUTPERFORM VIRGIN MATERIALS” Total has launched a new range of high-density polyethylene (HDPE) compounds with high levels of recycled content that it says offer performance equal to or exceeding that of virgin resins. The new ‘Circular Compounds’ range, targeted at the packaging sector, offers natural-coloured polymer products that Total says cover all the manufacturing needs for blow-moulded bottles and heavyduty containers for household and industrial liquids, with a guarantee of 25 or 50 percent minimum Post Consumer Recyclate (PCR). Total’s initial production capacity for HDPE Circular Compounds amounts to 20 kT, coming fully on stream during the course of 2017. “Total is currently extending the applications of the recycled compounds concept by developing additional new grades, since we believe it will be essential to place the European virgin plastics industry in a new, yet essential role, as ‘circularity enhancer’,” commented Jean Viallefont, Vice President Polymers, Europe, at Total. The composition and
manufacturing process of these Circular Compounds is designed to minimise their environmental footprint, while ensuring outstanding performance and processing properties, just as with any virgin resin. The recycled content originates from post-consumer household waste collected in Western European countries and is recycled by selected partners chosen by Total for their product quality and recycling process capabilities. In its Antwerp plant, Total applies a last deep decontamination step, which transforms the PCR into a completely fragrance-free resin. Finally, the PCR is compounded in Total’s plant with highly technological HDPE virgin products, specifically designed and produced as intermediate resins in order to overcompensate for any lack of performance and consistency of the PCR. The resulting compounds are meant to be fully equivalent to any virgin resin sold in the same application, but Total says in reality they “largely outperform them in all key aspects for their application.” The company believes that for the Circular Economy and for plastics in general, the innovative concept of high performance Circular Compounds allows the recycling
ENTRIES OPEN FOR BEST RECYCLED PLASTIC PRODUCT AWARD A competition deigned to showcase the best products made from recycled plastics is calling for entries. The European Association of Plastics Recycling and Recovery Organisations (EPRO) is inviting companies across Europe to enter its ‘Best Recycled Plastic Product’ and ‘Best Recycled Plastic Product Design’ awards until 10th October 2016. The Awards, which are free to enter, aim to recognise the progression in the applications of recycled plastics, which EPRO says presents an opportunity for the industry to further demonstrate 24
The awards are now open for entries
commitment to the environment and saving resources through use of recycled materials. WWW.BRITISHPLASTICS.CO.UK
Total Polymers Antwerp (Credit : Michel Clinckemaille)
industry and the virgin resin industry to open up new markets for highquality recycled polymers. As a contribution in this area, Total says its objective is to enable downstream industries to rely on recycled materials and to achieve this, it is currently developing additional new grades for a wide variety of applications. WWW.TOTALREFININGCHEMICALS.COM
“It is important that consumers and industry see the development in the recycling of plastics. We see this award as being a vehicle to showcase the innovation within plastics recycling and the many products that are currently being manufactured across Europe,” explained Peter Sundt, Secretary General of EPRO. Winners from the short-listed entries will be chosen at Identiplast 2017, due to take place in Austria on 22nd and 23rd February 2017. Those wishing to enter the awards, or find out further information, can do so by visiting the website below. WWW.BESTPRODUCT.EPRO-PLASTICSRECYCLING.ORG
RECYCLED PLASTIC TAKES ITS PLACE ON RIO’S MEDAL PODIUMS The nearly 2,500 gold, silver and bronze medals awarded to the athletes at the 2016 Olympic Games in Rio last month were hung on ribbon crafted from 50 percent recycled PET. The medal ribbons were one of a number of applications where plastics contributed to the strict sustainability and recycling criteria of the Games. www.rio2016.com
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Emma Bridgewater has called for a compulsory deposit returns scheme for plastic bottles in the UK
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PRESIDENT OF CAMPAIGN TO PROTECT RURAL ENGLAND CALLS FOR PLASTIC BOTTLE RETURNS SCHEME Retailers should pay customers for the return of used plastic bottles in order to cut littering, says the President of the Campaign to Protect Rural England. Writing in the Daily Mail recently, Emma Bridgewater said the introduction of a compulsory deposit returns scheme would incentivise consumers to recycle and would be “immensely popular.” “Ten billion plastic bottles are thrown away every year, littering streets and polluting pristine landscapes alike. I want to see this tide driven back,” she wrote. “The Government has already made important strides in cutting our use of plastic bags. Now we must do something similar for plastic bottles. I am proposing a compulsory deposit system, such as used to be offered on glass bottles, so that customers have a real incentive to return them for proper and safe disposal.” In her comments, Bridgewater, who is best known for her UK-based pottery empire, suggested that the UK should follow in the footsteps of other countries, such as Germany, which already have such schemes in place. She said her passion for the English countryside, and safeguarding its future, had led her to make the call for change.
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BPI RECYCLED PRODUCTS URGES BUYERS TO CHECK REFUSE SACK STANDARDS A UK manufacturer of polythene refuse sacks is urging buyers to look for CHSA certified products to make sure they conform to the highest industry standards. BPI Recycled Products, which supplies 270,000 tonnes of polythene products to customers annually, says that too often buyers of plastic refuse sacks have not received what they paid for – for example, refuse sacks are described as ‘Heavy Duty’ but in reality fall short of the claim on the box. The CHSA (Cleaning & Hygiene Suppliers Association) represents all the major manufacturers and distributors supplying cleaning and hygiene products in the UK. It has driven up standards, says BPI Recycled, making it possible for buyers of cleaning products such as refuse sacks to be sure when they buy accredited products, “what’s on the box is in the box.” “We believe it’s vitally important for buyers to have confidence in the quality of the sacks that they are purchasing and that they don’t fall
foul of misleading their customers,” commented Lorcan Mekitarian, Commercial Director of BPI Recycled Products. “Regardless of which supplier they purchase them from, buyers can easily check with the CHSA the ranking of that particular supplier within the scheme and the number of audits carried out on its sacks. “There are some company-led standards for refuse sacks but none
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of them meet the industry-led CHSA Standards, which have transformed the market. “Other standards don’t have the same stringent criteria, including rigorous independent assessment and auditing, which the industry should be adhering to in order to get the best products into the hands of our customers.” WWW.BPIRECYCLING.CO.UK
BPI is urging buyers to check the quality of their products
INVENTION THAT TURNS WASTE PLASTIC INTO NEW ITEMS AT HOME COULD SOON BE HITTING SHELVES An enterprising student has been recognised for inventing a home recycling kit that enables used plastic bottles to be turned into new, functional items. Josh James recently received a prestigious industry award for his product, ‘Melt’, a toolkit that can be used to transform plastic into handy objects such as plant pots, coasters, cups and chopping boards. The innovation has earned him a top prize at the New Designers Awards 2016, which could now see his product being sold by leading online retailer, Not on the High Street. Melt is an easy-to-use kit made up of tools including moulds, a file and a welding station, which can be used to turn HDPE plastic into objects by cutting it into pieces and melting it in the oven. Once softened into a malleable mass, which acts as a base material, it can then be handcrafted into colourful bespoke items. James said a custom-made plastic cup could be created using just five, four-pint milk bottles. As well as domestic items, he said waste plastic could also be used to create wall tiles, clock faces and even skateboards. “I started melting things and working out the physical possibilities of different materials. It was a shot in the dark but I have always enjoyed materials and experimenting with stuff,” explained James, who created the toolkit as part of his BSc (Hons) in Creative Product Design. “I think the judges liked Melt because it is something no one has really done before and the fact it relates to everyone - the idea that you could use your waste in your house to make some nice things.” The New Designers Awards, which are presented in partnership with leading brands and organisations, recognise the design world’s rising stars, offering winners support as they embark upon professional careers. Awards judges described James’ product as “fantastic, fun and clever”, remarking on its “huge potential.” WWW.NEWDESIGNERS.COM Josh James with a product made using his Melt toolkit
comment
Time to take plastics recycling to greater heights? IN THE FOLLOWING ARTICLE STUART FOSTER, CEO OF RECOUP, EXPRESSES HIS CONCERNS OVER THE ACTIVITIES AND ACTIONS – OR LACK OF THEM – IN 2016 THAT COULD POTENTIALLY SHAPE THE NEXT DECADE OR MORE IN TERMS OF OPPORTUNITIES FOR THE UK’S PLASTICS RECYCLING INDUSTRY.
F
rom uncertain post-Brexit impacts on markets and legislation, company acquisitions and reprocessor administrations, to intensifying packaging scrutiny, collection system reviews and a continued lack of investment in consumer education; plastics recycling is in transition. The EU provided a policy landscape in this sector that was stable and effective for business and environmental development. If a circular economy package is a good idea, we now look to UK Government to make sure a plan is implemented to give us the resource and recycling roadmap we need. The requirement to protect resources and work towards circular economy goals does create an interesting debate over the best environmental approach for plastic packaging. We need to optimise recycling and draw more attention to our design for recycling guidance to maximise the environmental benefit. There is a real need for the circular economy movement to help RECOUP to continue leading the plastic recycling agenda, and ensure circular economy thinking moves beyond recycling. For some time now, the UK has been ahead of the European
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plastic packaging recycling target of 22.5 percent. In 2015, the data shows the UK recycled 891kt, which was driven by UK packaging recycling and recovery targets placed on the producer supply chain. An estimated 60 percent is from household sourced plastic packaging, including bottles, pots, tubs and trays, as reported in the annual RECOUP collection survey. The remainder is mostly films from commercial and industrial sources. By extending the plastic packaging recycling targets to 2020, DEFRA has allowed the time needed to install the necessary infrastructure, alongside changing recycling behaviours and improvements in pack recyclability. The potential for more plastic recycling is undeniable, and RECOUP and its network is determined to work together to take plastic recycling to greater heights. This and more topics will be covered in our annual Plastics Recycling Conference, where the whole of the plastics supply, use and recycling chain will come together to discuss and debate the issues important to the industry and all its sectors.
About the Author
Stuart Foster is the CEO of UK-based recycling organisation, RECOUP. Foster will be speaking at the association’s annual conference at KingsGate Conference Centre, Peterborough, at the end of this month (29th Septmeber). Further details and registration available at www.recoup.org/conference-2016 27
Engineering Passion
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INJECTION MOULDING | NEWS LUXUS CHOOSES BOY MACHINE TO ENHANCE AUTOMOTIVE MATERIALS DEVELOPMENT Technical compounder, Luxus, has purchased new injection moulding machinery from BOY as it looks to develop its range of Hycolene thermoplastics for the automotive industry. The Lincolnshire-based company has invested in a BOY 90E injection moulding machine with ancillary equipment, as well as a BOY 22A, which it says enables it to provide its automotive customers with extra-large test plaques and another mould with complex flow paths. The aim, it says, is to give auto designers a more realistic representation of how a component will look in a specific grain or colour – therefore dramatically reducing the development time required. This investment follows three months of intense trials with BOY to assess the benefits its machinery can bring to the development of Hycolene, Luxus’ high performance thermoplastics (PP) range for lightweight auto interior trim applications. BOY’s 90E machine is required by Luxus to mould extra-large plaques that were previously run on a large 200-tonne machine, while still maintaining the clamp force to prevent flashing and to deliver high precision control and repeatability. Luxus also needed the machines to fit into a small area within its Technical Centre – made possible thanks to their very compact design. “This latest investment is specifically for the continued
NEW BILLION MACHINE FOR EDINBURGH NAPIER UNIVERSITY Edinburgh Napier University has taken delivery of a new Billion injection moulding machine for use in both a teaching and research capacity. The Billion Select 50 tonne all-electric machine replaces a Battenfeld servo hydraulic machine the University has had for more than 25 years.
Luxus’ Managing Director, Peter Atterby (left), with BOY UK Managing Director, Bob Wilson.
development of our high performance Hycolene thermoplastics range, since auto designers are increasingly requesting extra-large test plaques and complex mould flow paths which are not widely available,” explained Peter Atterby, Luxus’ Managing Director. “We have also, therefore, purchased two moulds from specialist manufacturer, Senior and Dickson, to fit the new machines. One is a flat grained plaque, the other is a mould designed to show the flow path of materials in a ‘real world’ application.” Bob Wilson, Managing Director, BOY UK, commented: “We are pleased that Luxus has invested in BOY machinery to deliver large test plaques. Our patented clamp unit is known for its ability to mould large
tools and a considerable surface area. Its two-platen design allows for the production of large plaque tools on the very smallest of machines, in fact, the clamp force was reduced in Luxus’ trials to some 600kn (60 tonnes without any adverse effect).” Wilson added that the 90E also helps with demanding test component pieces too, like the glove pocket component for example. “The machine’s servo-motor pump drive means it has a dynamic reaction to the hydraulics and movements on the machine, when used with the Alpha control system and the clamp design. This means that these components are more controllable to produce even under the most difficult conditions,” he concluded. WWW.BOY.LTD.UK
The purchase represents a significant investment by the University, which is the only centre in the UK that offers professionally accredited BEng, BEng Hons and MSc programmes in Polymer Engineering. WWW.BILLION.FR
versity Napier Uni Edinburgh hine ac e new m receiving th ) A R (Credit: SP
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technical comment
Celebrating 60 years of the im screw
T
echnology-wise, little has changed since Demag Plastics Group (Ankerwerk Nürnberg) developed the first reciprocating screw for IM machines in the 1950s. During this SCREW DESIGN PLAYS decade, post World War II, manufacturers in all sectors A FUNDAMENTAL ROLE switched from producing metal IN EFFICIENT INJECTION components using plungers MOULDING (IM), KEEPING to the mass production of MANUFACTURING COSTS plastic products. In response, DOWN AND DELIVERY TIMES Anker built the world’s first single-screw IM machine in SHORT. HERE, JAMES HINES, 1956. It was a milestone PROCESS AND TRAINING moment, giving moulders ENGINEER AT SUMITOMO more precise control over the (SHI) DEMAG, TALKS ABOUT speed of injection and enabling THE SIGNIFICANCE OF THE materials to be mixed before SCREW PATENTED IN 1956, injection. Just as it did 60 years ago, AND HOW THE ACTUAL the screw continues to perform SCREW DESIGN AFFECTS four key roles - consistently THE PROCESSING OF feeding and melting the resin, POLYMERS AND IMPACTS pumping fluid steadily and THE QUALITY OF MOULDED mixing resin homogeneously.
COMPONENTS. The general-purpose screw
Although there are several variations in injection moulding screw design, about 95 percent of applications today are catered for by the ‘general-purpose’ (GP) screw. Also known as the universal screw, the advantage is
within a narrow processing window. GP screws are very flexible and can be used with most engineering plastics and in a variety of shot sizes and cycle times without destroying the properties of the polymer. It is also the least expensive screw design to manufacture. The primary disadvantage is that, for some materials, part quality and productivity rates will be lower, compared to more advanced injection moulding screw designs. GP screws are compression screws, comprising three zones - feed, transition and metering. The ratio split of the screw length is roughly half, a quarter and a quarter respectively. For that reason it’s often called the 50/25/25 screw. In the feed zone, solid plastic pellets are conveyed from the hopper to the transition zone where they are compressed by a change in screw geometry. This compression forces the pellets to melt through shearing the action of pushing up against each other. The metering zone then conveys the melt to the front of the screw for injection into the mould cavity. In the transition zone, material is compressed by the change in the depth of the screw channels from the feed zone to the metering zone. The ratio of the change in depth is called the compression ratio. Typically, the length of the transition zone in a GP screw is four to seven times the screw diameter. A non-return valve is fixed at the tip of the screw stopping the melted resin from back flowing into the screw during the injection stage. There are a variety of non-return valve designs available for use with different materials.
The world’s first single-screw IM machine was built 60 years ago in 1956. The screw technology used then continues to apply today.
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Approximately 95 percent of all applications use the GP screw (pictured centre featuring standard screw tip assembly). More specialist application screws pictured either side.
Screw geometry
Screw geometry - the length to diameter ratio (L/D) - is another vital consideration for moulders and can impact performance. Longer screws will produce a better quality melt and, consequently, better quality parts. High-performance screws with a screw length of up to approximately 26D may be used for high-speed machines (e.g. for packaging materials). Yet, long screws are not advisable for processing thermally sensitive material grades, since over-long residence times can result in thermal damage to the material. The L/D ratio for PP and PE is typically between 20:1 and 30:1. To increase the economic efficiency of the IM process, there’s a current trend towards larger shot volumes and higher mass flow rates for the same size of plasticating unit. It can be accomplished at low cost by lengthening the metering stroke. However, larger shot volumes can result in the effective screw length being shortened, potentially resulting in unmelted material and inhomogeneous temperatures, so the benefit can impact quality.
up less material and consequently the residence time in the plasticating unit is shortened. Double flight screws also deliver a high quality melt at fast rates and can be used to produce technical PP and thin wall parts in PA (nylon) that do not plasticise well using barrier screws. The double flight design ensures the plastic is fully melted before it reaches the compression zone. Once the screw and barrel start to wear, part quality will start to suffer, so serious consideration should be given to using a heat-treated screw and barrel, as these provide longer life than non-heat-treated parts. When working with high temperature specialist materials, we coat them to stop the material from degrading and sticking to the screw. We do the same for lens manufacturers using clear PC, acrylics or CR39 diallyl phthalate where clarity is the key to minimise the degradation. A full, comprehensive whitepaper about the importance of screw design, and variations in technology can be viewed by visiting Sumitomo (SHI) Demag’s website.
About the author
James Hines is Process and Training Engineer at Sumitomo (SHI) Demag Plastics Machinery UK Ltd, based in Buckinghamshire. He has got 20 years experience in the plastics industry, during which time he has built a wealth of knowledge in the automotive, telecoms and pharmaceuticals industries.
Barrier and double flight screws
Barrier screws provide better quality melt at a faster rate and come in different designs with varying flight depths and channel widths. Shallow-flighted screws pick
Screw design plays a fundamental role in efficient injection moulding (IM), keeping manufacturing costs down and delivery times short.
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Engineering Passion
PENTAGON PLASTICS INVESTS £95,000 IN NEW HAITIAN MOULDING MACHINES Horsham-based injection moulder, Pentagon Plastics, has invested £95,000 in new injection moulding machines as it continues to enhance and improve its manufacturing facilities. The company, which has invested significantly in new machinery and equipment over the last two years, has most recently taken delivery of two new machines from Premier Moulding Machinery.
The first, a MARS MAII 900/300 Universal, is a 90 tonne hybrid moulding machine that replaces an older hydraulic one of similar capacity; this, says Pentagon, will deliver “a good rate of energy saving to the business over the coming years”. The second machine is a ZERES ZE1200/430, which comes as an addition to the current plant machinery and takes Pentagon’s on-site machine count from nine up to 10. The new 120 tonne press, it says, will help cater for the increasing mid-range production demand, especially
in the medical moulding sector. “The repeatability of the newer breed of hybrid and electric machines will mean parts stay correct from the beginning of the run until the end, and with close process monitoring software any discrepancies are flagged up straight away,” said Graham Fooks, Mould Shop Manager at Pentagon. Going forward, Fooks says having the extra machine will help in many ways. WWW.PENTAGONPLASTICS.CO.UK
The new Negri Bossi machines are the latest investment by Icon Plastics
ICON PLASTICS MAKES £200,000 INVESTMENT IN NEW MACHINERY AND ROBOTICS Precision injection moulder, Icon Plastics, has expanded its workforce and manufacturing capabilities following a £200,000 investment in new equipment. The Tees Valley business says the investment comes in order to meet the demands of its growing client base across industries including medical, construction, defence and automotive. The latest purchase has seen the installation of two new Negri Bossi Canbio ST machines, bringing the total number of plastic injection moulding machines at the Eaglescliffe site to 27. “Over the last 12 months, we have invested more than £400,000 so that we can continue accommodate our recent contract wins,” explained Operations Director, Phil Walker. “The new Negri Bossi machines are a major upgrade for Icon. They are more accurate and efficient than our previous machines thanks to their synchronous motors, technology more often seen in industrial robots. This means we are more productive than ever, allowing us to increase our client base, expand our workforce and future-proof the business.” The new machinery investment has resulted in Icon recruiting additional staff, bringing the total overall to 56, including the appointment of a new Operations Manager and three Line Operators. WWW.ICONPLASTICS.CO.UK 34
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CASE STUDY: HOW INJECTION MOULDING EXPERTISE IMPROVED PRODUCT DESIGN IN A ‘FLASH’ UK-based manufacturer, Fern Howard, has worked on a project to redevelop the design of a USB data stick alongside memory and storage products giant, Integral. Integral, a UK company established at the beginning of the PC era in 1989, was one of the first to produce memory cards and
USB drives for the fast growing digital market. It now supplies thousands of drives to customers around the world. In order to be highly responsive to an ever changing demand for its products, Intergral worked with Fern Howard to develop an injection moulded USB stick that could be both produced and assembled at short notice whilst being robust
The USB stick design can be seen worldwide, utilised by a number of well known companies
TRADE MOULDER INVESTS IN NEW MACHINES FOR ENERGY EFFICIENCY AND CONTROL A UK trade moulder has purchased two new Romi injection moulding machines as it looks to achieve greater process control as well as reducing energy usage. Suffolk-based Skar Precision Mouldings invested in a Romi EN 300 and an EN 70 model as direct replacements for two existing machines to produce a range of components for sectors that include medical, engineering, point of sale and retail. “Seven of our 40 plus machines are Romi models and we know the machines will do what they say they will do and that they are robust and will work across a wide range of thermoplastic materials,”
commented Paul Denny, Operations Director at Skar. “The two new machines replace a 1986 Sandretto and an ageing Arburg and will give us greater control and reduce our energy usage. The capital cost and running costs were very convincing.” The Romi EN series comes in models ranging from 70 to 2000
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The redevelopment of the USB stick design
enough to withstand being in bags, drawers or desks. The result, a two-piece design, fixed together using only mouldedin latches, meant that immediate demand could be met by premoulded cases kept in stock and hand assembled on demand – but it also meant that same design was suitable for bespoke printing and branding for third-party retailers. Now producing in excess of 10,000 units a day, these flash memory cases can be seen across the world, often carrying the livery of well-known companies – but all produced using the same tool and design. Final printing is also carried out in Fern-Howard’s Alton factory in Hampshire and the units can be printed in any number of standard colours alongside specially commissioned finishes. WWW.FERNHOWARD.COM
tonnes and features a Siemens servo pump system. Romi says the range is popular because of high uptime, good repeatability and low energy consumption. WWW.ROMIUK.COM d in a Skar has investe chine ma 0 30 EN mi Ro
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Engineering Passion technical comment
controlling the process: how injection moulders can save energy
T
he injection process is one of the main manufacturing techniques for the production of plastic parts and consists of six key phases: mould closing, plasticisation, filling, WHEN IT COMES TO COST packing, cooling, mould SAVINGS, REDUCING opening and removal of the ENERGY IN THE INJECTION part. During the process, MOULDING PROCESS IS A KEY CONSIDERATION FOR other peripheral equipment plays a part in order to help PLASTICS PROCESSORS. IN achieve process stability THE FOLLOWING ARTICLE, and ensure homogeneity SERAFÍN GARCÍA NAVARRO, in the characteristics of HEAD OF THE DESIGN AND the manufactured parts. INJECTION MOULDING These include dryers and DEPARTMENT AT AIMPLAS, dehumidifying dryers, mould temperature controllers, WRITES FOR BP&R ON mills/grinders and dosing HOW IDENTIFICATION equipment. AND MANAGEMENT OF Nevertheless, around PARTICULAR ASPECTS OF 60 percent of the energy THE PRODUCTION CYCLE consumption in the injection moulding process can be CAN INCREASE THE OVERALL assigned to the machine and EFFICIENCY OF THE PROCESS. its functions, and it is here that processors should really focus in order to maximise savings.
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Essential Energy
We must bear in mind that the energy needed to inject a part depends on several factors. Take peripheral equipment for example. The greater the amount of energy needed for such equipment, the higher the consumption will be. In addition, the type of material being processed will affect the processing temperature and, therefore, the energy needed. Materials with high melting temperatures require more energy from the electrical resistors in the plastification cylinder. The cycle duration must be taken into consideration too, as this determines the time the pump or engine is working. Longer cycle times request a longer working duration of the pump or engine and therefore are more energy-intensive. Finally, one must consider the design, shape and size of the mould, which of course has an impact on the size of the injection moulding machine. The bigger the machine, the bigger the clamping force and therefore the more energy needed for the process.
Figure 1. on Distributi ergy of the en tion p m u ns o c n. in injectio Source: tic SKZ Plas in Institute , Wurzburg Germany
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www.kraussmaffei.com Injection moulders can save energy by optimising areas of the manufacturing process
The six injection phases
If we look in detail at the energy requirements for each of the six phases of the injection process identified at the beginning of this article, we can better understand how each aspect uses power. Firstly, the recovery of the screw (the movement associated with the screw’s turn allows the material to advance and contribute to the previous plastification needed in the injection process) represents about 50 percent of the injection machine’s energy consumption. The mould opening and closing movements, and the removal of the part, consume about 10 percent of the total energy. The injection process represents around 10 percent of consumption, and 17 percent is used for the proper functioning of the electrical resistors that enclose the plastification cylinder and guarantee that the material keeps the optimum processing temperatures for injection. Finally, in the cooling and packing phases, the energy consumption amounts to around 16 percent of the total consumed by the machine.
Methods to reduce energy
In view of the theory relating to the injection process and the functioning of injection machines, different methods have been developed to minimise the energy losses and achieve greater global efficiency in the process. These include, for example, installation of insulating sleeves in the cylinder (for reduction of start-up time, energy consumption, stability of working temperatures); installation of speed controllers to adjust the electrical engine’s speed (they improve the process control, reduce the demand of the hydraulic systems and the engine’s wear); and also mould design with conformal cooling to cool the part quickly and uniformly (reducing the cooling time and, therefore, the cycle time). Given these strategies and premises relate to the functioning of the injection cycle, processors must consider a number of questions. Firstly, is the process stable and consistent? By controlling all the process variables, we will get indicators of which lines we must follow in order to reduce consumption. Secondly, do we have the optimum parameters for the part being manufactured? It is essential to avoid movements or functions that do not have a direct effect on the part’s quality. Next, have we optimised the injection cycle fully? By reducing the cycle times, we also reduce the usage times of the different sub-systems responsible for controlling the temperature and cooling the parts. Also, is there a plan or methodology to improve the rejection level? By minimising the rejection level, we optimise the use of the injection machine and reduce the energy consumption used by other peripheral equipment.
Other factors, such as periodically checking the mould operation, should also not be overlooked. A proper maintenance of the mould will ensure effectiveness in the part cooling. In addition, is the correct injection machine being used (configuration, size, screw type)? The size of the machine should be proportionate to the injection capacity and closing force needed. Do not overlook peripheral equipment either. The proper use of peripheral equipment optimises a machine’s operation. Next, is there a maintenance procedure in place for injection machines and peripheral equipment? Ineffective operation of this equipment will result in energy losses during its use. Another important factor is whether energy saving is systematised in long machine stops (by reducing the temperature profile)? By having a procedure for starting and stopping, processors can ensure greater efficiency through the avoidance of non-productive downtime of the equipment. Finally, can the time be reduced by process automation? Obviously, any processes – both before or after the injection of the part – that can be automated will reduce the energy consumption related to the end, and finishing of, the parts.
Automation and process control as energy saving tools
Savings here are based both in energy cost savings and time saving. For this reason, there are some concepts to be considered. These include, firstly, increasing the overall automation of the manufacturing process. This results in a better process control and minimises associated losses. Secondly, integrating manufacturing phases. The ‘onestep’ concept contributes to a reduction of the number of finishing lines and post-processing (such as the use of IML or multi-component technologies, for example). Next, consider the adequate use of peripheral equipment as a tool to improve the control in the entire productive process and, finally, have we made the most of the cycle time? For instance, in the injection process, we must keep in mind aspects such as dwelling time and pressure, cooling time, etc.
Conclusion
The injection moulding manufacturing process is one area of production where, if the points highlighted in this article are considered, can result in significant energy savings for processors. If each area is addressed, then processors will have an adequate strategy to achieve reduced energy costs in manufacturing processes. WWW.AIMPLAS.NET
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THERMOPLASTIC ELASTOMERS | NEWS
STRINGENT SAFETY STANDARDS SEE TPE MAKE A SPLASH AT BATH TIME The safety, regulatory compliance and aesthetic aspects of PolyOne’s thermoplastic elastomers (TPE) have made them the ideal choice for the production of a new bath tub for babies. Hong-Kong based Karibu Baby Ltd. chose GLS Versaflex TPE and OnColor colourants from PolyOne for the production of its new, portable and folding bath specifically designed for babies and children.
The Karibu bathtub is designed for the space limitations of city living and for convenience when travelling. The patented foldaway design enables easy storage without sacrificing a fullsize tub for infants. Extra leg support with non-slip material makes this bathtub usable on any flat surface, and a built-in hook allows it to be hung for drying or storage. Designers chose Versaflex TPE to mould the folding portion of the tub and provide a non-slip surface on the bottom of the tub legs. The material’s soft, grippy feel improves
The new folding baby bath produced with PolyOne’s GLS thermoplastic elastomers and OnColor colourants
TPE CHOSEN FOR WOUND HEALING MEDICAL DEVICE TPE has been chosen for a high profile medical device that uses cold plasma to promote wound healing through deep stimulation. The ‘PlasmaDerm’ device, manufactured by Germany-based Cinogy, uses Thermolast M TPE from Kraiburg for the sterile sensor pad which comes into contact with a patient’s skin during the treatment process. The material surrounds a ‘spacer’ placed on the skin, which creates an even space over the entire surface of the wound for generation of the cold plasma. The device is the first of
its kind to use cold, or non-thermal, plasma, which is used to promote wound healing and fight multiresistant pathogens. “Our process is used for treating open wounds, which is why it is of essential importance to us that the contact material of the sensor pad comply with all relevant medical certifications and can be used in direct contact with the human bloodstream,” explained Dr. Dirk Wandke, Managing Director of Cinogy. “We are therefore pleased to have found Kraiburg TPE as a development partner who shares our high quality standards.” The individual sterile pads
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comfort and enjoyment for the child while enhancing safety. Because the TPE bonds well to the polypropylene (PP) substrate, the tub withstands repeated folding and unfolding. The colorants provide bright, appealing aesthetics to please children and parents, and help the product stand out from the competition during the purchasing decision. Karibu switched from a local supplier to PolyOne to obtain an advanced TPE made without bisphenol A (BPA), phthalates, or heavy metals. The material is also compliant with U.S. Food and Drug Administration (FDA) food contact requirements and the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) European regulation. “Karibu’s top priority is providing customers with the highest-quality and safest products for their babies,” said Mr. Yeung Yiu Fai, Karibu General Manager. “We chose the PolyOne solution for our new Mega foldaway bath because the PolyOne TPE and colourants meet the most stringent global standards and provide peace of mind to parents. They also provide an enjoyable sensory experience and exceptional durability.” WWW.POLYONE.COM
produced using the TPE are single use items, which conform to medical safety and regulatory standards.
The PlasmaDerm medical device
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POLYMAX TPE LAUNCHES TPES WITH LOW COMPRESSION SET FOR SEAL INDUSTRY PolymaxTPE has introduced two Styrenic TPE grades engineered to deliver low compression set performance specifically for gasket and seals applications. The two new grades, P32-010 and P32-011, can replace TPV elastomers in a variety of sealing applications, including gaskets, seals, valves, home appliance products and food packaging requiring high resilience for seal integrity. The stand-out feature of the new products, says Polymax, is their low compression set at elevated temperatures. Measurements show that the compression set of the 60 shore A P32-011 TPE has 16 percent at room temperature, 26 percent at 70°C and 38 percent at 100°C for 22 hours; and the 40 shore A P31010 has 20 percent compression set at room temperature, 27 percent at 70°C and 48 percent at 100°C. “The development of new TPEs with low compression set for the seal industry reflects the focus of PolymaxTPE on R&D and its
MARKET FOR BIOBASED AND RECYCLED TPES “EMERGING FROM THE SIDELINES” Hexpol TPE says interest and end-use applications for biobased TPEs is growing
The market potential for biobased thermoplastic elastomers (TPE) is “emerging from the sidelines” as advances in both technical properties and functionality are being made, says a manufacturer of TPEs and complimentary compounds. Elasto, part of the international HEXPOL TPE Group, says the company has seen growing interest from customers in a number of end markets for its ‘Dryflex Green’ range of biobased TPE compounds since it launched the compunds at the end of last year. “Since we launched the Dryflex Green TPEs to the market at the end of 2015, we have seen just how diverse the requirements are for
TPE for seals and gaskets
strategy of working proactively with customers,” commented Dr. Martin Lu, CTO of PolymaxTPE. In addition to the low compression set performance, P32-010 and P32-011 are said to offer excellent tear strength, cold temperature flexibility, low odour, stability at high temperature and weather resistance. The raw materials used to manufacture these two grades are compliant with food contact regulations. These materials can be used in stand-alone injection
moulding, extrusion applications, or bonded with polypropylene substrates. “The new addition of P32-010 and P32-011 will provide a lowcost alternative to TPV in gaskets, stoppers, flexible connectors, and sealing for food, beverage caps and closures requiring durable sealing performance,” explained Tom Castile, VP sales of PolymaxTPE.
biobased products,” explained Klas Dannäs, global R&D coordinator at Hexpol TPE. “While some of our customers have already adopted a ‘green’ strategy and are well on the road to developing sustainable products and practices, others are keen to ‘go green’ but are uncertain what this means and what the options are. Our role is to guide our customers to a greater understanding of the possibilities and limitations of biobased TPEs,” he added. The Dryflex Green range includes several series with amounts of renewable content to over 70 percent (ASTM D 6866) with hardnesses from 50 to 80 Shore A. Elasto says the products display mechanical and physical properties comparable to TPE from fossil-based raw materials and offer flexibility and tensile properties with a soft-touch feel. They can be processed using traditional polymer technologies such as injection moulding and extrusion. In addition to its biobased range, Elasto says its range of TPE compounds based on post-consumer recyclate (PCR) is also gaining in popularity. The Dryflex PCW TPE materials were developed to address demands in the automotive industry, which is obliged to use increasing
quantities of post-consumer waste and operate under the European ELV Directive to ensure recyclability at the end of each vehicle’s life. The Dryflex PCW compounds contain recyclate consisting of polypropylene drawn from automotive mouldings, which are cleaned and re-ground and rubber tyre crumb from both OEM and after-market tyres. Apart from the obvious benefit of recycling, the material exhibits other advantages when compared with virgin materials including sound reduction properties. The compounds are being used in automotive applications such as mud flaps, sidesteps and anti-drag lips. “Waste can sometimes be seen as a dirty word, however, improved utilisation of waste streams will be critical when pursuing sustainable development objectives. In the circular economy waste will be a resource, it will be a way to meet growing demand while reducing demands on finite raw materials,” commented Dominic Philpot, Managing Director at Elasto UK. Hexpol will be showcasing its ranges of biobased and PCR TPEs at the K Show in Dusseldorf next month.
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K Show: The Preview
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ext month sees the engines fired up once again for the triennial K Show in Düsseldorf, the plastics and rubber industry’s leading trade fair and exhibition. The show, which this year takes place from 19-26 October, is renowned for its ability to draw industry-wide interest, setting an important stage for exhibiting companies to prepare new launches across machinery, materials, auxillaries and supporting applications and technologies. This year is set to be no different. Testament to this, over the following pages we have chosen to highlight a selection of the exhibitor news released ahead of the show, to give you an early insight into the latest products, polymers and processes of interest. During the last edition in 2013, automation and robotics dominated where machines were concerned, with automotive the key driver in
the materials halls. This time, Industry 4.0 and the notion of smarter, connected ways of working throughout process, supply chain and logistics, is the most prominent theme – with its cost saving and streamlining benefits hard to ignore. Materials-wise, lightweighting and smart materials continue to drive innovation across a number of markets, not least automotive, but also aerospace, E&E and packaging. The upcoming K Show will feature 3,100 exhibitors across 19 halls, with visitor numbers expected in the region of 200,000. Whether the numbers will topple the last edition, which saw 218,000 bodies through the door, remains to be seen. However, many exhibitors insist that quality, not quantity, is the key metric. WWW.K-ONLINE.DE
MATERIALS
Thermoforming Machinery
3M PRESENTS “PLASTICS FOR THE FUTURE” WITH NEW FLUOROPOLYMERS
AMUT COMI TO PRESENT NEW GENERATION OF ACF SERIES THERMOFORMING MACHINES
3M Advanced Materials is showcasing its latest plastics materials for future megratrends at K 2016, including fluoropolymers and glass bubbles for energy saving and lightweight construction. During the show 3M and its subsidiary, Dyneon, will demonstrate the effective use of fluoropolymers in fuel cells, where they can live up to the unique and aggressive chemical and temperature conditions and provide specialised electro-chemical properties, thereby increasing their performance and extending their lifetime. In addition, it will demonstrate how, used as a binding agent, 3M Dyneon Fluoroplastic THV extends the lifetime of batteries, which is of particular relevance to the automotive industry, amongst others, as the high performance plastic offers very good barrier properties and withstands very high temperatures. Finally, it will showcase lightweighting applications through the use of 3M Glass Bubbles iM16k.
FIND THEM - HALL 5, STAND B10 WWW.3M.COM
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AMUT COMI, the thermoforming division of AMUT Group, is to present a new generation of steel rule cutting thermoforming machines at K 2016. The new ‘ACF 820’ machine combines the characteristics of Amut’s V and F series, creating a model said to have high levels of standardisation, repeatability, durability, flexibility and increased high-speed performances. The new range of machines is suitable for handling a wide range of thermoplastic materials and to produce many items, including trays, lids, fruits and vegetables boxes, flowerpots, clamshells, nursery trays and plates. The ACF machines can be integrated with a T-IML system (In-Mould Labelling for the thermoforming sector), based on a side entry robot to load labels inside the forming mould in order to decorate the articles. The use of steel rule cutting moulds makes this T-IML even more competitive compared to the existing T-IML systems.
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Materials
Extrusion Machinery
Arburg to showcase 27 machines but keeps an “ace up its sleeve”
BASF to launch new gold effect pigment
Arburg has teasingly said that despite the 27 machines it will have operating on its stand - it is “keeping an ace up its sleeve” for K 2016. The 27 exhibits will cover injection moulding, additive manufacturing and ‘Industry 4.0’, and will incorporate a variety of industry-specific solutions from automotive to packaging and medical. The company will demonstrate a machine from its latest series, the ‘Golden Electric’, which is an all-electric, entry-level option that combines standardised components with proven technology. At K 2016, an Allrounder 470 E Golden Electric with a clamping force of 1,000 kN and a size 290 injection unit will be used to produce a technical part. Arburg Managing Partner, Michael Hehl, said the company’s exhibit would cover “something for every plastics processor.”
BASF will introduce its new ‘Dragon Gold’ effect pigment, the newest member of its Lumina Royal product family during K 2016. The new Lumina Royal Dragon Gold EH 0908 is a brilliant greenshade, gold mica effect pigment that offers the highest lightness and strongest sparkle in styling for yellows and greens. BASF says it extends the colour space potential of high chroma shades for packaging, consumer electronics, household appliances, sporting goods and other speciality applications. “Lumina Royal Dragon Gold provides attractive shades, especially in combination with yellow pigments or in black reduction,” explained Marc Dumont, Head of Marketing for Pigments for Plastics at BASF. “Our customers will be able to formulate new looks of greenish gold hues with exceptional sparkling and brilliance.”
battenfeld-cincinnati to launch new series of single screw extruders
Find them - Hall 13, Stand A13 www.arburg.com
Find them - Hall 5, Stands C21/D21 www.basf.com
Injection Moulding
Conveying Systems
Materials
BOY showcases standard machines with multifunctional features
Conair’s latest vacuum conveying system to make European debut
BOY’s stand at K 2016 will feature its largest number of injection moulding machines at an exhibition so far. The company’s exhibit will address networked machines in keeping with the theme of Industry 4.0, as well as individual automation solutions. It will also showcase its machines’ multitasking capabilities - where standard models with multifunctional features – some with individually tailored automation solutions or packages for optimising set-up times – are the focus. This, says Klaus Geimer, Deputy Managing Director at BOY, comes as a result of rising demand from the industry for machines of this type. BOY will continue to showcase its expertise in microinjection moulding, with a BOY XS producing parts of a micro rotary engine with a shot weight of only 0.08 g using an 8 mm screw. Finally, it will also display printing of 3D mould inserts on a BOY 25 E. Different mould inserts with different geometrical parts will be printed during the trade fair.
Conair’s patent-pending R-PRO dense-phase vacuum-conveying system developed to minimise pellet fracturing, ‘angel hair’ and equipment wear will make its first appearance in Europe at K 2016. Other innovations on display will include a new FLX-128 Plus conveying control, a new Mobile Drying/Conveying (MDC) system with standard colour touchscreen control interface, and several examples of equipment from Conair’s new MedLine range of clean-room-ready auxiliaries. The new MedLine family includes 40 different models and 170 different configurations for moulding and extruding medical products and the MedLine display at K will include the MicroWheel dryer, the MedLine TubeLoader and the TB-45 TrueBlend gravimetric blender.
Covestro debuts in-process coating for greater freedom of design in vehicles
Find them - Hall 10, Stand J59 www.conairgroup.com
Find them - Hall 13, Stand A43 www.dr-boy.de
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WWW.BRITISHPLASTICS.CO.UK
battenfeld-cincinnati will be introducing a newly-developed series of high-performance single screw extruders: the solEX NG series. This latest development features a completely new processing unit offering a lower melt temperature and up to 15 percent energy savings, thanks to the system needing less drive energy and less heat discharge. The solEX NG series not only complements the wide range of battenfeld-cincinnati single and twin-screw extruders, but also the portfolio of solutions for large-diameter pipe extrusion. The solEX NG extruders, with high outputs and excellent melt processing capacities, are ideally suited for PO pipe lines with diameters of up to 2.6m.
Find them - Hall 16, Stand B19 www.battenfeld-cincinnati.com
Covestro will be showcasing the prototype of a new design for a steering wheel cover using its DirectCoating/DirectSkinning technology at K 2016. This development features a wide range of colours, surface structures and tactile properties that can be reproduced on the same component from a single mould using DirectCoating. The coated component is produced in a twocomponent mould using a two-stage process in an injection moulding machine. Having undergone injection moulding in the first cavity, the plastic substrate is then transferred to a second cavity that is one coating layer thickness larger. The solvent-free coating system is injected into this mould via a RIM (reaction injection moulding) mixing head. This creates a polyurethane-coated component with outstanding properties that requires virtually no post-processing.
Find them - Hall 6, Stand A75 www.covestro.com
www.motan-colortronic.co.uk
Extrusion Machinery
Materials
Plastics Processing
DAVIS-STANDARD TO EXHIBIT HIGHSPEED EXTRUSION TECHNOLOGY FOR EFFICIENCY AND THROUGHPUT
DSM to launch brand new generation of ultra-high performance polyamides
ENGEL to premiere decorating technologies and showcase technical moulding
Davis-Standard will promote the benefits of highspeed extrusion technology at K 2016, with a running demonstration of its high-speed extruder for demanding processes, where rates and energy savings significantly impact profitability. Advantages such as better product quality, less machine volume for reduced changeover time and a wider processing window are just a few reasons high-speed extrusion is a cost-effective option, says Davis-Standard. The company’s 75mm, 40:1 extruder offers processing versatility due to a favourable surface-to-volume ratio when compared to conventional extruders. The high-speed model offers energy savings of 10 to 15 percent when compared to traditional systems. Additionally, the screw speed and drive unit can be adjusted to accommodate different processing conditions.
Royal DSM will launch a brand new range of high performance plastics at K 2016. DSM opened the era of high temperature polyamides with its Stanyl PA46 in 1986 and has since broadened its platform with ForTii and ForTii Eco, based on PA4T. At K 2016, it is launching a new generation of ultra-high performance polyamides, which it says will accelerate the rate of replacement of die-cast metals in automotive and industrial applications. In addition, it will also showcase applications from other industries, including a water faucet-mixing valve in a glass-reinforced compound of DSM’s EcoPaXX bio-based PA410, which reduces the risk of part failure and leakage in long-term use while in contact with hot and cold water.
Engel will showcase its “most challenging applications” targeted at the automotive, teletronics, technical moulding, packaging and medical industries at K 2016. This will include the premiere of its ‘Decoject’ decorating process for automotive interior components with the addition of ‘In-Mould Graining’ (IMG), the company’s latest development. At its exhibition stand, ENGEL will present the DecoJect technology in a fully automated production cell for the first time. On an ENGEL duo 5160/1000 injection moulding machine, sample parts simulating large door panels will be produced. In order to demonstrate the new technology’s broad spectrum of capabilities, the parts exhibit different structures, including a sophisticated leather grain. This exhibit will be one of several demonstrating Engel’s latest technologies for high-end moulding applications.
Find them - Hall 16, Stand A43 www.davis-standard.com
Find them - Hall 6, Stand B11 www.dsm.com
Find them - Hall 15, Stand C58 www.engelglobal.com
Recycling Machinery
Materials
Injection Moulding
EREMA to launch ‘Recycling 4.0’, which it will demonstrate using trade fair waste
ExxonMobil to add new grades to Exceed XP performance polymers
Husky to make global debut of next-generation closure moulding machine
EREMA will demonstrate the first example of an extensive Smart Factory package for both recyclers and producers at K 2016. Working around the theme of ‘Careformance’ the company will demonstrate its own take on Industry 4.0 – ‘Recycling 4.0’ – in action at K using on-site waste. Careformance consists of four components, with EREMA’s ‘Intarema’ system, which is based on counter current technology, forming the basis. In addition to the machine data already available, the exhibit at K will show how specially integrated sensors – called the ‘QualityOn’ package – can be used in future to record and evaluate MVR (Melt Volume Rate), colour and moisture. The QualityOn package enables recyclers and producers to make their recyclates with consistent quality in accordance with customer requirments and document them transparently using online data acquisition and analysis.
Find them - Hall 9, Stand C05 www.erema.at
ExxonMobil will use K 2016 as a platform to expand its portfolio of ‘Exceed XP’ performance polymers, with the addition of new grades. “Since its launch in April, Exceed XP has been exceptionally well received in the market. Customers report that these polymers provide an unprecedented level of performance, and we expect these new grades to broaden this impact,” commented Cindy Shulman, Plastics and Resins Vice President at ExxonMobil. ExxonMobil will also display the recently introduced ‘Enable 40-02’ performance polymers for compression packaging and geomembranes, as well as a range of low viscosity ‘Vistamaxx’ performance polymers for home and consumer products and an array of other applications. Additionally, a ‘TechTalks’ series at the ExxonMobil pavilion will feature industry experts discussing a range of topics including ExxonMobil innovations, market and industry insights and sustainability benefits of polymers.
Husky Injection Moulding Systems will launch its next generation system for high output beverage closure moulding, HyCAP4, at K 2016. The latest generation of the HyCAP platform, which was first launched in 2009, features engineering advancements, including several new capabilities and features for enhanced machine and mould integration. Combined, Husky says these enhancements allow HyCAP4 to deliver new levels of performance and productivity, as well as significantly more energy savings. The system is also equipped with intelligent features that make it easier to use, with simplified controls for faster process set-up and improved repeatability. With these advancements, Husky says system owners can look to HyCAP4 to deliver improved returns and increased opportunities.
Find them - Hall 13, Stand A61 www.husky.co.uk
FIND THEM - PAVILION FG04 www.exxonmobilchemical.com
WWW.BRITISHPLASTICS.CO.UK
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Kongskilde your conveying specialist
Kongskilde offers complete systems for conveying and handling large volumes of plastics materials generated from today’s production lines. These systems ensure a high efficiency, significant savings and an improved working environment.
Kongskilde UK Tel. 01263 713291 mail@kuk.kongskilde.com www.kongskilde.com
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Thermoforming Systems
TPEs
Plastics Processing
ILLIG TO DEBUT LATEST IML-T DEVELOPMENT AND FLEXIBLE HANDLING SYSTEM
KRAIBURG TO LAUNCH NEW FLAME RETARDANT COMPOUNDS
KraussMaffei presents expanded APC software and new data systems
Illig will be focusing on the performance of in-mould labelling in thermoforming (IML-T), hygienic production and enhanced productivity through technical optimisation, as well as the systematic expansion of automation. For the first time in its latest stage of development, Illig will showcase its IML-T thermoforming line, ‘IC-RDM 70K’, together with its IML unit, ‘RDML 70b’ for the flexible decoration of cups of nearly any geometry. Also making its debut at the K stand will be a flexible product handling system. Adapted for the Illig ‘IC-RDK 54’, this combination is said to accelerate production for enhanced productivity. Visitors will also get to see the latest in Illig mould-making technology with new moulds on display.
Kraiburg TPE will use K 2016 to mark the launch of it’s FR/AD1 series of flame retardant compounds. The new series of TPEs, which will sit within its ‘Thermolast K’ portfolio, were developed specially for applications in the construction industry, where they are used to ensure flexible cable installation in flush-mounting boxes. The material is flame retardant in accordance with UL94 and is included in flammability class V0. In addition, it features excellent adhesion with ABS and PC in two-component injection moulding. The flame retardant compounds are highly elastic and are free of latex, PVC and halogen. Other product highlights from Kraiburg TPE at K 2016 will include materials for drinking water applications as well as under-the-hood automotive applications.
Find them - Hall 6, Stand 6C58-03 www.kraiburg-tpe.com
KraussMaffei is presenting a range of both new and expanded software and process optimisation solutions for plastics processors at K2016. Within the theme of ‘Plastics 4.0’, its own take on Industry 4.0, the company will focus on intelligent machines, networked production processes and interactive services. Part of this is its new, expanded APC control system, known as ‘APC Plus’. The expanded function of the APC system, which detects and counteracts process fluctuations caused by changing ambient conditions or fluctuating viscosity, makes it suitable for multi-component injection moulding and processing silicone, as opposed to just thermoplastic processing it was compatible with previously. The enhanced version provides numerous new, intelligent features, such as taking into account the specific behaviour of the raw material.
Extrusion Machinery
Conveying Systems
Plastics Processing
KraussMaffei Berstorff launches new BPCTouch control system
Maguire to introduce new vacuum loading system for simpler operation
Milacron to showcase integrated portfolio over two booths and PET machine makes EU debut
KraussMaffei Berstorff will exhibit its new BPCTouch control system at K 2016. The new system features state-of-the-art technology for easy control and configuration and supports Plastics 4.0. From now on all twin-screw extruders in the ‘ZE BluePower’, ‘ZE UTX’ and ‘ZE Basic’ series will be equipped with the BPCTouch control solution. This system, says KraussMaffei Berstroff, substantially enhances ease of use and reduces set-up times during compound changes. It offers benefits in terms of cost-effectiveness and flexibility, especially for compounding companies facing the challenge of processing a continuously increasing variety of compounds in ever-smaller batches. In addition, KraussMaffei Berstorff will exhibit its new ZE 42 BluePower twin-screw extruder at K 2016.
Maguire will introduce a new vacuum loading system for conveying pellets and regrind from storage to single or multiple blenders. The system is said to be simpler to operate than standard systems and consists of autonomously controlled receivers that are fully 80 percent shorter than conventional material loaders and receivers. Named LoPro, the low-profile receivers protrude only 200mm above the lid of a blender, providing a low centre of gravity that minimises potential sway on fast-cycling processing machines. “Maguire has designed the LoPro system to be affordable, easy to use, readily installed in existing production facilities, and even adaptable to a third-party vacuum system,” said Frank Kavanagh, Vice President of Sales at Maguire. “Its simplicity alone will enable more plastics processors to obtain the productivity benefits of an automated loading system.”
Milacron says it will illustrate how its new integrated approach can benefit plastics processors. Tom Goeke, CEO of Milacron, said the show is an opportunity to “demonstrate what is new”. Innovations on display include the European debut of its M-PET 300, a servohydraulic PET system, which combines key components across Milacron’s product portfolio in a single cell. It will also display it’s ‘Klear Can’ metal replacing packaging system, as well as its new Elektron Evolution injection moulding machine and new Uniloy All-Electric Shuttle Blow Moulding Machine. The company will be displaying its Advanced Plastics Processing Technologies (APPT) featuring Milacron, Ferromatik and Uniloy product branded injection, PET, blow and extrusion offerings in Hall 15 Booth C06. Milacron’s Melt Delivery and Control Systems will be in Hall 01 booth A39.
Find them - Hall 10, Stand A26 www.maguire.com
Find them - Hall 15, Stand C06 Find them - Hall 01, Stand A39 www.milacron.com
Find them - Hall 3, Stand A52 www.illig.de/en
Find them - Hall 15, Stands B27/C24/C27/D24 www.kraussmaffeiberstorff.com
WWW.BRITISHPLASTICS.CO.UK
FIND THEM - HALL 15, STANDS B27/C24/C27/D24 WWW.KRAUSSMAFFEI.COM
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Moretto to announce global availability of moisture analysing technology
Negri Bossi starts yearlong 70th anniversary celebrations with ‘Project ELE’ premiere
NETSTAL TO DEMONSTRATE “WORLD’S FIRST” 128-CAVITY PIPETTE TIP PRODUCTION LINE
Moretto will demonstrate a working example of its ‘Moisture Meter’ system at K 2016, as it announces global availability of the resin moisture analyser. At Moretto’s stand there will be a working display of the system installed on a running injection moulding machine producing a standard medical device. With this instrument it is possible to certify the production of plastic parts, and, when installed directly on the processing machine, it measures the actual moisture content of the plastic granules. No calibration is required, says Moretto, with the operator needing only to select the polymer to be treated before the Moisture Meter works to establish how much water remains in the process resin. In addition, Moretto will present several exclusive solutions at K 2016, including ‘XD 10’, a high performance mini-dryer; ‘DGM’, a continuous batch gravimetric dosing unit; and ‘EXA’, a conveying system for up to six stations.
Negri Bossi will kick-off a year of celebrations marking 70 years of manufacturing injection moulding machinery at K 2016. The company says its stand will “tip its hat” to the past, whilst presenting ideas, developments and innovations that will help shape the future of injection moulding. On the stand will be the first showing of its new generation of all-electric machines, known as ‘Project ELE’. With both improved physical specification and performance this completely new product is designed to have a wider appeal in areas such as packaging and medical. The machine has the new Tactum multi-touch controller, with features such as remote access, in built camera and gesture navigation thanks to the introduction of ‘multi-touch’ technology. The machine also features Negri Bossi’s new ‘Smart Flex 2’ locking unit with a different toggle geometry designed to be coupled specifically with electric closing.
On the joint stand of the KraussMaffei Group, Netstal will produce medical pipette tips on an all-electric ELION 2800-870. In the world’s first mould with 128 cavities from Tanner Formenbau, the pipette tips will be produced with a cycle time of just 5.6 seconds, which corresponds to a daily output of around 2 million units. The medical part will be a 0.38 mm and have a part weight of just 0.26 g, which Netstal says will enable it to demonstrate moulding to the tightest of production tolerances. The production process will be automated by a system that does not require a larger footprint than a comparable 64-cavity system, enabling manufacturers to double their productivity in the same space.
Find them - Hall 11, Stand H57 www.moretto.com
Find them - Hall 15, Stand B22 www.negribossi.com
Materials
Plastics Processing
Plastics Processing
Solvay to introduce two new PA6.6 grades for automotive and E&E
Sumitomo Demag to “demystify Industry 4.0” and hold world premiere of new IntElect platform
Wittmann Battenfeld presents trade fair debut of latest B8 control system
Solvay will introduce two product offerings in its ‘Technyl’ portfolio at K 2016. These include a new series of heat performance polyamide 6.6 (PA6.6) for thermal management applications and an innovative PA6.6 range with a specified and controlled halogen content tailored to fit sensitive electrical and electronic applications. Lightweighting will also be a key focus of Solvay’s exhibit and it will display example applications for high-performance polymers for metal replacement in today’s down-sized, turbocharged automotive engines, as well as its growing ‘TegraLite’ material technologies, which aim to reduce fuel consumption, increase efficiencies and accelerate development of cost-effective, lightweight solutions for the aerospace industry.
FIND THEM - HALL 6, STAND C61 WWW.SOLVAY.COM
Sumitomo (SHI) Demag team will aim to put Industry 4.0 into a practical context for plastics processors. Under the banner ‘Electrified 4.0’, five machines will be actively running on the stand, demonstrating the production of packaging, caps and closures, pharmaceutical, automotive and in-mould decorated (IMD) plastic components and how these can work together with other processes and technology to form a ‘smart factory’. In addition, K 2016 will be the world premier of a new IntElect platform, plus three injection moulding partnership installations developed in collaboration with Sepro, Yushin and ONI. UK Managing Director, Nigel Flowers, said the company’s presence at K will provide “practical examples” of Industry 4.0.
Find them - Hall 15, Stand D22 www.sumitomo-shi-demag.eu
WWW.BRITISHPLASTICS.CO.UK
Find them - Hall 15, Stands B27/C24/C27/D24 www.netstal.com
Wittmann Battenfeld is making its latest control system the highlight of its exhibit at K 2016. The new Unilog B8 system will be shown on every single machine exhibited at the trade fair in order to demonstrate its new features, which include greater operator control, ease-of-use and memory functions. The additional features of the B8 feed into Wittmann Battenfeld’s overall K show theme of “be smart”, where the concepts of Industry 4.0 are demonstrated across its machinery and equipment. In terms of machinery on display, the company will showcase its new EcoPower Xpress, a high-speed, all-electric injection moulding machine primarily aimed at the packaging sector. At the show it will be running in conjunction with an IML unit, complete with robot. There will be several other machines running, as well as Wittmann’s portfolio of auxillary equipment.
Find them - Hall 16, Stand D22 www.wittmann-group.com
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EXTRUSION | PRINTING | CONVERTING
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W A N T Z E N AGENCY FOR UNITED KINGDOM AND IRELAND Suite 26 · 70 Churchill Square · Kings Hill, West Malling/Kent ME19 4YU · Great Britain Phone: +44 1732 781089 · Fax: +44 1732 887195 · info@wantzen.co.uk · www.wantzen.co.uk
PLASTIC ELECTRONICS | NEWS
COVESTRO FILMS LIGHT THE WAY FOR SMART ELECTRONICS Covestro has created a luminous dress to showcase how its latest materials developments can be used with LEDs to produce smart and functional clothing for a number of end uses, such as pedestrian safety or health monitoring. The dress is lit up by light-emitting diodes (LEDs), but uniquely these are not positioned on a panel or strip, but on a piece of soft fabric. At the centre of the development is an electronic system that is responsive to movements without losing its functionality. The system that lights up the dress comprises a flexible and formable film made of thermoplastic Formable electronic systems can also be directly laminated onto textiles, as in the case of the luminous dress.
polyurethane (TPU). The TPU is the substrate for the printed copper circuits, which are arranged in a meandering pattern and can, therefore, also be bent and stretched. To manufacture the smart circuits, copper films are first laminated onto the polyurethane films. The printed circuits are produced in a subsequent structuring operation featuring highly
effective adhesion. The coated films are then shaped as required using conventional thermoforming. “The films are resistant to standard etching and imaging processes,” said Covestro Film Expert, Wolfgang Stenbeck. “Formable electronic systems can also be directly laminated onto textiles, as in the case of the luminous dress.” The smart circuits meet a whole range of customer needs and are therefore ideal for applications in a variety of industries. Compared to conventional electronic components, they offer greater design freedom and reliability while enabling more sustainable products due to the reduced use of materials. For example, the technology opens up an extremely wide range of options for smart textiles alone. Besides fashion items, such as the luminous dress, freely formable electronic systems are already in use in underwear, where they monitor heart rate and breathing. They assist patients with therapy and help athletes monitor their training. Freely formable The production technology was electronic systems developed as part of various projects open up new funded by the EU Commission, possibilities for the including ‘STELLA’ and ‘TERASEL’. design of fashion items, The dress will be on display on automobiles, buildings, Covestro’s stand at K 2016 next as well as in consumer month. electronics, to mention only a few examples.
BASF LAUNCHES POLYAMIDE GRADES FOR SENSITIVE AUTOMOTIVE ELECTRONICS BASF has developed a special portfolio of polyamide 6 and 66 grades that help prevent electrical corrosion damage to circuits used for microelectronics in sensitive automotive applications, such as control units and sensors. The different Ultramid EQ grades (EQ = electronic quality) are extremely pure, which means they have hardly any electrically active or corrosion-generating contents, yet still offer good resistance to heat aging. They are subject to special quality tests that cover raw material selection, the production process and the analysis of the halogen content. Available globally, the portfolio
consists of uncoloured and black grades with glass fibre contents of 30 and 35 percent, which are also lasermarkable. BASF says Ultramid EQ has already proven itself in a range of applications under harsh conditions. All Ultramid EQ grades have an organic heat stabiliser with a very low halogen content of less than 1 ppm. BASF says this prevents halogens like iodine or bromine from damaging metal wiring, ions from reacting with the metals and undesired electric currents from arising. In addition to the specified formula and complex production process, all Ultramid EQ charges are checked carefully. This ensures that the manufacturing process does not introduce any halogen contamination to the material. The relevant certificate is provided to customers if desired. The new Ultramid EQ portfolio is also well suited for use in electric and hybrid WWW.BRITISHPLASTICS.CO.UK
WWW.COVESTRO.COM
Specified polyamide Ultramid EQ for sensitive automotive electronics
vehicles with elevated AC and DC voltages. WWW.BASF.COM
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A lamp from the new Orion range
CASE STUDY: CONDUCTIVE POLYMER SUCCESSFULLY REPLACES METAL IN LED SPOTLAMP Sylumis, a manufacturer of LED lighting systems based in Lieusaint, France, has successfully replaced metal with a thermally conductive polymer solution from PolyOne in a new, larger model of its ‘Orion’ range of LED spot lamps. Sylumis says that replacing metal with the Therma-Tech conductive polymer enables it to manufacture the lamps more efficiently and with more innovative designs. “The transition from metal to a speciality engineered polymer solution maintained the high quality of our Orion spot lamps, enabled us to set new industry standards for innovative design, and led to more efficient manufacturing that helps us save energy during production,” explained Jean-Luc Berthet-Bondet, Director at Sylumis. With 32.4W of power, this new addition to the Orion range of LED spot lamps offers significantly more
LANXESS INTRODUCES NEW POLYESTER COMPOUNDS FOR LED CHIPS Lanxess has developed four new compounds for light-emitting diode (LED) housings and sockets. New Pocan TP 555-911, -991, -912 and -992 are based on polycyclohexylenedimethylene terephthalate (PCT), a polyester used by the company for the first time. The mineral- and/or glass-fibrereinforced compounds achieve very high light reflection levels of 93 to nearly 96 percent (at a wavelength of 450 nanometers). Used as a material for the LED housings, they reflect the light of the LEDs almost completely, says Lanxess, keeping brightness losses to a minimum. “What is so special about the new products is their good reflection behaviour, which diminishes only minimally over time under standard LED operating conditions. That is a major advantage over high-melting polyamides, which eventually yellow from exposure to heat and light, causing their light reflection and thus the brightness of the LEDS to
lighting performance than the 9W and 18W models already offered. PolyOne supported the design and production engineers at Sylumis with thermal simulation and mould filling analysis to help the manufacturer optimise the geometry, heat transfer and manufacturability of the heat sinks. The Therma-Tech conductive formulation selected for these LED lamps outperforms aluminum, the material traditionally used in heat sinks, with a 25 percent increase in heat exchange surface area and a nine percent reduction in weight. The speciality polymer solution from PolyOne meets relevant safety standards, including a UL94-V0 flame class rating at 3mm thickness, and
drop noticeably,” explained Thomas Malek, New Business Development Manager for lighting technology in Lanxess’ High Performance Materials business unit. Another advantage of the four innovative products, says Malek, is their very high temperature of deflection under load. “They can easily withstand temperatures of 240 to 280 °C like those commonly encountered in lead-free vapour phase soldering,” he continued. Vapour phase soldering without lead is used frequently to connect the LED chips electrically. The new polyester compounds support a stable manufacturing process and can be injection moulded in a wide processing window despite their high filler content. “Thanks to the good flow properties, the chip housings and sockets can be designed with thin walls and slim dimensions,” Malek added. Processing temperatures are significantly lower than with high-temperature polyamides and the mechanical properties of the compounds lend the LED chips
WWW.BRITISHPLASTICS.CO.UK
offers Sylumis significant production efficiencies via injection moulding in place of metal forming. “We have a wealth of experience in metal replacement projects, and Sylumis tapped into this knowledge to make its Orion LED lamp project a great success,” said Holger Kronimus, VP Europe and General Manager, Speciality Engineered Materials, Europe, for PolyOne. “Transitioning from metal to speciality engineered polymer solutions helps our customers meet their goals for efficient manufacturing, innovative design and weight savings.” www.polyone.com
The properties of the four new PCT compounds are tailored for use in housings, sockets and other LED chip components. Photo: LANXESS AG
good durability. For example, the elongation at break is between 1.5 and 1.8 percent and the tensile modulus between 4,200 and 7,000 MPa. This makes the materials ideal for LED applications requiring better mechanical properties. WWW.LANXESS.COM
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ooth ll 10, B
G42
Following the recent UEFA Euro 2016 Championships, the impressive Allianz Riviera Stadium in Nice, France, features on the front cover of a new brochure from VinylPlus celebrating the prominent role played by PVC in the construction of modern sports venues. Published by VinylPlus, the European PVC sustainability programme, ‘Vinyl in European Stadiums’ charts the path to sustainable development for PVC and how the use of vinyl combines environmental responsibility and architectural greatness in present-day sports complexes. “This brochure showcases how PVC’s versatility can combine demanding architectural and technical design requirements with sustainable objectives,” explained Brigitte Dero, VinylPlus General Manager. The brochure covers advances in building materials and techniques, spanning the centuries – from marble used in classic amphitheatres of Ancient Greece to the comprehensive contribution made by PVC in today’s sports arenas. The Nice stadium, seating 35,000 people and completed in 2013, is among several case studies that VinylPlus says highlights PVC’s advantages as a modern, versatile and sustainable material for such large public venues. A transparent PVC tensile fabric membrane for the façade allows daylight through, making the building appear open and inviting, while a PVC roof was chosen for its acoustic qualities. According to the stadium’s Architect, Marco Punzi from Wilmotte and Associés, extensive use of PVC enabled “stateof-the-art design with environmental stewardship”. He explained: “For us, PVC was a natural choice. It allowed us to design a fifth-generation that functions well and is aesthetically pleasing. PVC was used throughout the building, since it is long-lasting and can be recycled.” WWW.VINYLPLUS.EU
@POLYMERMAN ON PRICES Will the typical round of price increases take place again this Autumn? IN THIS EDITION OF OUR LATEST FEATURE LOOKING AT SOME OF THE KEY ISSUES AFFECTING POLYMER PRICES, MIKE BOSWELL ASKS WHETHER THE INDUSTRY WILL EXPERIENCE TRADITIONAL SEASONAL PRICING PATTERNS, AND THE FACTORS THAT INFLUENCE THEM.
The first issue is oil price and, whilst polymer price has become increasingly independent as the supply-demand balance for polymers has come to dominate pricing, the trend of oil price and its impact on both feedstock and energy costs is still of influence. As shown in Graph 1, the cost of Brent Crude has been enjoying a steady increase since early August and has once again exceeded the $50 per barrel threshold, although much of this increase is depending upon a forthcoming OPEC meeting and the speculation that supply might be cut in order to support price. The second issue relates to the typical price relaxation that occurs over the summer months. Whereas typically in Southern Europe demand decreases as factories shut for holidays – an effect seen in Graph 2 – which, for the purposes of discounting the effect of the devaluation of the GBP versus the Euro, is presented in € per tonne. The third issue is that of demand from processors and, whilst in the UK there may be some recovery from the postBREXIT hangover, demand is brisk as supply chains are replenished
400.00 380.00 360.00 340.00 320.00 300.00 280.00 260.00 240.00 220.00
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Price per tonne €2,200.00 €2,000.00 €1,800.00 €1,600.00
PE Basket
€1,200.00
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PP Basket
Brexit Impact
graph 3
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1.2500 1.2000 1.1000 01/06/2016
So it appears that in September there is the potential for UK polymer buyers to experience the twin effects of increasing prices and currency devaluation. Beyond September, attention will pass to the K-Show, which presents a tremendous opportunity for buyers and sellers to meet and ultimately determine the future direction of prices. And so, it appears that we could be about to enter another period of uncertainty within which supplydemand balance and exchange rate will be pivotal in determining price, with at least some influence from crude oil and feedstock costs.
Who is @polyerman?
1.4500
1.1500
of the £ versus both the $ and € took its biggest hit immediately after the BREXIT vote, further weakening has taken place, as shown in Graph 3. More importantly, however, it is taking time for the exchange rate effect to take hold as both factors, such as pre-June 23rd inventory and forward currency deals, become absorbed, leaving sellers little choice other than to pass through increases.
Attention turns to K Show
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GBP
Aug 2015 Sep 2015 Oct 2015 Nov 2015 Dec 2015 Jan 2016 Feb 2016 Mar 2016 Apr 2016 May 2016 Jun 2016 Jul 2016
So what can we expect this September?
graph 1
Brent Crude per Tonne
02
A
way from exceptional situations, such as the severe disruption in supply starting in February 2015, there is a kind of underlying rhythm that applies to polymer pricing. Typically, in September, there is a call from polymer producers to increase prices across a wide range of standard polymers including PE, PP and PS. The strength and duration of the rally depends upon a range of fundamentals and typically lasts anywhere up until November, at which point attention is focused on aligning inventory prior to the seasonal December holidays.
01/07/2016
and the demand for packaging for seasonal goods starts to take effect. The fourth factor, which is unique to the UK, is that of exchange rate. Whilst the value
01/08/2016
“So, it appears that we could be about to enter another period of uncertainty”
WWW.BRITISHPLASTICS.CO.UK
Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group. He has a broad knowledge of both materials and the issues affecting the wider industry, with over 20 years experience in the field. @polymerman is the title used for announcements made via his Twitter account.
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MATERIALS | NEWS TEAM GB’S WOMEN WIN HOCKEY GOLD ON DOW’S ARTIFICIAL TURF
Team GB during their gold-winning hockey finals match on the artificial turf pitch (Credit: Getty Images / Tom Pennington)
Team GB’s women took gold in the Olympic hockey finals in Rio last month on a pitch produced using polymer technologies from the Dow Chemical Company. Building on the success of the London 2012 Olympic Games experience, the innovative artificial turf solution based on Dow’s polyethylene (PE) and polyurethane (PU) technologies was the official playing surface for hockey competitions during the Rio 2016 Olympic Games, at the Deodoro Olympic Park. Dow worked once again with Polytan STI, a global manufacturer and supplier for outdoor and indoor sports surfaces, to deliver what it describes as “a higher performing, more reliable and faster artificial
Team GB’s Hollie Webb (left) faces the opposition during the Olympic women’s hockey finals (Credit: Getty Images/ Tom Pennington)
turf” for the world’s best hockey players in Rio. Dow and Polytan worked together on London 2012’s Riverbank Arena, which helped set the new standard for hockey’s most important competitions. The pitch was produced using specific high-performing materials formulated together in multiple layers. The surface system is designed to deliver enhanced durability for increased pitch life and a consistent field-of-play. The production of synthetic turf is a highly elaborated process. The system begins with the production of the masterbatch and the yarn for the turf. The subsequent tufting and backing process provides a strong turf bind, even when the surface is wet. For the upper surface layer, the polymer yarn provides wear resistance and energy absorption,
combined with softness and speed. The complete turf system, including embedded shock pad properties, provides stability, durability, shock absorption and force reduction properties for the benefit of the players and the game. “The solution we developed together is durable, low maintenance, stays consistently flat and fast from game to game, and requires no watering - compared to natural grass,” explained Ana Carolina Haracemiv, Global Marketing Director, Dow Packaging and Speciality Plastics. Now the Games have concluded, the artificial turf pitches will become home to the Brazilian national team, as well as Rio’s citizens, as one of the main legacy projects for the city. WWW.DOW.COM
PERSPEX MAKES PROJECT POP WITH COLOUR Perspex acrylic has been used to produce two design-led sculptures at a community health centre in Scotland. The two vertical totems, located in external courtyards at Kilsyth Health Centre in North Lanarkshire, feature colourful overlapping panels fabricated from Perspex acrylic sheet. An assortment of Perspex solid, translucent and transparent colours were chosen by the designers of the totems, Civic Architects, who said the colours “mimic the coded, specific patterns of our DNA profiles as individuals within a community.” CAD drawings designed by Civic Architects provided fabricators, QD
View of sculpture in West Courtyard
Plastics, with a variety of messages to be CNC cut into the materials, linking the sculpture to local places and thoughts. The vertical structures relate to the architecture of the courtyards and are designed to WWW.BRITISHPLASTICS.CO.UK
encourage visitors to “look into the sky for contemplation and reflect changing emotions.” WWW.PERSPEX.COM
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SCHOOLGIRL CREATES SUPERABSORBENT POLYMER FROM ORANGE PEEL TO COMBAT DROUGHTS A 16-year-old schoolgirl from Johannesburg has created a superabsorbent polymer (SAP) made using orange peel and avocado skin in order to help solve South Africa’s drought crisis. Kiara Nirghin recently won Google Science Fair’s ‘Community Impact Award’ for the Middle East and Africa
with her project, entitled ‘No More Thirsty Crops’. The project saw Nirghin develop a polymer that could store reserves of water a hundred times its own weight, in order to help create reservoirs that could be utilised by farmers for watering crops in times of severe drought. The low-cost, biodegradable and chemical-free superabsorbent polymer uses polysaccharide naturally found in orange peels and
Kiara Nirghin has created a superabsorbent polymer (SAP) made using orange peel and avocado skin
Kiara Nirghin (Credit: Google Science Fair)
organically cross-linked with sunlight. Oil found in avocado peels is then used in emulsion polymerisation of the solution. “Kiara found an ideal material that won’t hurt the budget in simple orange peel, and through her research, she created a way to turn it into soil-ready water storage with help from the avocado,” Andrea Cohan, Programme Leader of the Google Science Fair, told CNN. Nirghin will now be issued a mentor from Google who will help her develop and test her polymer, with a view to commercialisation. WWW.GOOGLESCIENCEFAIR.COM
RECYCLABLE MANNEQUINS MADE FROM POLYPROPYLENE FOAM ARE NO DUMMIES An Italian manufacturer has created a mannequin manufactured from polypropylene foam to create a recyclable, lightweight and more cost-effective product. Mannequin producer, Lideimmagine, used ARPRO, an expanded polypropylene bead foam material developed by JSP, for its new range of ‘Livelymen’. The new range has been designed to satisfy the needs of a contemporary market and has already been welcomed by a range of major retailers for their window displays.
Historically, mannequins have been made from fibreglass, which cannot be recycled. The new ARPRObased models, however, are fully recyclable and provide a simplified and shorter production process. Alessandro Fongaro, Chief Executive at Lideimmagine said the company’s goal was to create “lightness, versatility and flexibility” in the new mannequins. “This has been achieved, largely due to ARPRO and thanks to the cooperation with JSP and the moulder, IES,” explained Fongaro. The Livelymen mannequins produced using ARPRO
“The innovative product has allowed us to look to the future in a very positive fashion and we are already working on other exciting products that will allow retailers to make much more of their mannequin displays.” Bert Suffis, ARPRO Innovation Manager for Europe, Middle East and Africa, said: “Retailers no longer have to put used mannequins in landfill sites. This new range of costeffective and sustainable solutions is a great example of innovation to solve an industry-wide issue. ARPRO’s simplicity of use makes it possible to achieve the required durability, weight and production speed to make a real difference for retailers. This represents a great opportunity for retailers to enhance their in-store displays with state-ofthe-art mannequins.” JSP has recently announced that it is set to increase capacity due to the material’s increasing popularity across a number of sectors. The additional 10.5 kt/a of capacity, which will be on-stream in 2018, will be located at its existing site in Cheb, in the Czech Republic, taking the ARPRO capacity in EMEA to 37.0 kt/a. WWW.ARPRO.COM WWW.LIDEIMMAGINE.COM/HOME/EN
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WWW.BRITISHPLASTICS.CO.UK
BUYER’S GUIDE
PL Machinery BG 2015_Layout 1 2
MATERIALS
DEHUMIDIFIERS
Whatever your ancillary needs – we have the solution
MASTERBATCH
Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
HEATING EQUIPMENT
BLACK & WHITE MASTERBATCH Compounding
Recycling
Moulding
Film
Pipe
Conduit
Whitelands Mill, Whitelands Road Ashton-under-Lyne, OL6 6UG, UK Tel: +44 (0)161 308 2550 Fax: +44 (0)161 343 2026 E-mail: aml@abbeymb.com Web: www.abbeymb.com
Telephone: 01582 883666 Email: sales@plmachinery.com Web: www.plmachinery.com
MOULD RELEASE
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.bransoneurope.eu
induction heating for platens and tools
pulse staking H.T.E Engineering 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
Accurate colour systems for the PVC and additives industries t: +44(0)1942 254006 e: sales@astropol.uk.com www.astropol.uk.com
ultrasonic welding
MF Induction Heating
CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd
T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.
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
HOT RUNNER SYSTEMS hot runner controllers
DRYERS Motan Colortronic Ltd
Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk
MACHINERY & EQUIPMENT colour masterbatch
ANCILLARIES
InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)
PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk
MATERIALS HANDLING AND STORAGE gravimetric/volumetric blending
Telsonic UK Ltd
Motan Colortronic Ltd
12a - 15 Birch Copse Technology Road, Poole, Dorset BH17 7FH T: 01202 697340 F: 01202 693674 E: info.uk@telsonic.com W: www.telsonic.co.uk Blog: telsonicuk.wordpress.com Call: 0161 624 2114
Eclipse Buyers Guide_Layout 1 07 Email: sales@colourmaster.co.uk www.colourmaster.co.uk
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.
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
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
vibration welding
FOR SALE
Branson Ultrasonics
158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu
DRYER HIRE Hire from one month Monthly rolling contract Opportunity to purchase
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
Range of models Preventative Maintenance Visits
We have prime, reprocessed, regranulated, pulverised in various grades / colours flexible PVC compound for sale. We also buy flexible PVC and associated raw materials, redundant stocks / scrap for reprocessing. Please send us your detailed enquiries / offers. Vinyl Ltd Tel: 01625 500912 Email: vinyl_ltd@mail.com 59
BUYER’S GUIDE SCREWS & BARRELS
MACHINERY & EQUIPMENT LABORATORY MACHINES
Magnetics Separators Metal Detectors Eddy Current Separators
Bunting Magnetics Europe Ltd European Design & Manufacturing Facility
Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk
TRAINING
for
ulders injection mo c.co.uk www.rjgin
11 )1733 2322 P. +44 (0
Northbridge Road Berkhamsted Hertfordshire HP4 1EH, UK Tel: +44 (0) 1442 875081 Email: sales@buntingeurope.com www.buntingeurope.com www.magneticseparation.co
TransXL International Ltd
/magnetic_separation_and_metal_detection/
Contact: Carlton Hicks
NOZZLES & NOZZLE TIPS Engineers to the Plastics & Rubber industries, specialising in the following: Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd
MATERIALS HANDLING AND STORAGE hopper loaders
SECONDHAND AND RECONDITIONED
PRINTING MACHINES pad
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
thermocouples
Cooper Plastics Machinery
EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
MIXING, FEEDING & DOSING 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
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
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DM Machinery Ltd
Unterfeldstraße 3 4052 Ansfelden / Austria Phone: +43 (0)732/31 90-0 Fax: +43 (0)732/31 90-71 sales@erema.at www.erema.at
CHOOSE THE NUMBER ONE.
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
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
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
FOR SALE
in Plastic & Rubber
BILL CARRINGTON
Regular quantity of Nylon/Polyester mixed fibre based in bales of 300400 kilos per bale. Contact 01253 736963
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
STATIC CONTROL
Tel: 01420 88645
www.projet3d.co.uk
SERVICES MOULDFLOW ANALYSIS
Arrowquint Ltd
Unit 2 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
Injection
Moulding
Trainingancy Consultow fl & Mold c.co.uk www.rjgin
RECYCLING SYSTEMS
3D Printing
211 )1733 232 P. +44 (0
8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 850610 F: 01525 218008 E: cooperplastics@googlemail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, fly knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.
3D PRINTING
Ray Ran Test Equipment Ltd
Kelsey Close, Attleborough Fields Industrial Estate, Nuneaton, Warwickshire, CV11 6RS T: 024 763 42002 F: 024 766 41670 E: Polytest@ray-ran.com W: www.ray-ran.com
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
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
WWW.BRITISHPLASTICS.CO.UK
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
BUYER’S GUIDE
SERVICES SOFTWARE
PRINTERS
Gammadot Rheology Testing & Consultancy Services
printers of plastic mouldings Total Print Ltd
Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry
PARTS & SERVICE
TESTINg/CONSULTANCY
Component PRINTERS
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
TO ADVERTISE IN THis SPACE CONTACT LISA MONTGOMERY 01244 680222
TAMPO.SCREEN.FOIL
c.co.uk www.rjgin
211 )1733 232 P. +44 (0
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
SOFTWARE DIRECTORY A listing in the Software Directory costs £160 per programme per year. Call Lisa on 01244 680222 for details. real time production monitoring, scheduling and process monitoring Epicor Mattec Real-time MES (Microsoft Windows™ PC Servers & “Web Based”) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Modules: Production Monitoring, Process Monitoring, “Drag and Drop” Scheduling/Planning, “Family Moulding”, Preventative Maintenance, Bar Coding/Parts’ Trace-ability, Operator Visual Aids, Process Parameter Profiling, E-mail/Public Address System Alerts, Stand-alone “Drag and Drop” Scheduler, Stand-alone SPC “Machine Analyzer”, Machine Energy Monitoring, KPI Dashboards, Visual Manufacturing (Large LED Displays), Automatic Data Import/Export Functions (For Integration with Epicor ERP & Other Manufacturing Systems/Software Packages). 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. intouch T: 01604 646144 E: enquiries@ intouchmonitoring.com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages. ProHelp EPM (for Microsoft Windows™ PC Servers) Mattec Ltd T: 01909 561544 F: 01909 560675 E: a.jewell@mattec.com Real-time Modules: Production Monitoring, ‘Drag and Drop’ Scheduling/Planning, Preventative Maintenance, Bar Coding/Parts Traceability, Operator Visual Aids, Process Parameter Profiling, Pager/ Tannoy Alerts, Stand-alone ‘Drag and Drop’ Scheduler, Stand-alone SPC Machine Analyzer, Automatic Data Import/Export Functions (for integration to Manufacturing Systems and other software packages). SYSCON – PlantStar Tel: +44 (0)7747 014545 E: ianh@syscon-intl.com W: www.mtec-services.co.uk W: www.plantstar.org
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. Browserbased software and hardware, and wireless Ethernet technology make for highly versatile and configurable systems providing information wherever needed. Standard systems include realtime alarms, downtime & reject analysis, capacity scheduling , ERP integration and more. With options including SPC/SQC, Labour tracking and Scheduling, Family Tooling, Materials traceability, barcoding. New QuickShot entry level system, provides real-time data collection & reporting, plus drag & drop scheduling and much more for less than £500 per machine!
enterprise resource planning Epicor ERP Manufacturing Software (For Plastics’/Rubber Processors) Epicor Software (UK) Ltd T: +44 (0)1344 468 468 E: info.uk@epicor.com Epicor ERP software for the polymer converting industry covers the full range of back office operations from on-line and off-line sales and quotations to production planning, inventory management and finance through to logistics, warehousing and distribution. Available on-site, hosted & SaaS it seamlessly integrates with Epicor Mattec Real-time MES to provide a single system that offers a complete quote-to-cash solution for the plastics’/rubber industries.
WWW.BRITISHPLASTICS.CO.UK
Process Optimisation Software RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E ingo@rjginc.co.uk Zero Defect Moulding – What’s your target? • Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.
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cumbersome, clinker-built wooden boats that were as much a struggle to put into the water as they were to row. Now, the sport is dominated by sleek, narrow lightweight boats - carbocraft - which cut through the water with almost effortless ease, significantly cutting record times. The oars (“blades” to the cognoscenti) are also now made from lightweight carbon fibre reinforced materials. Rowing today is almost a technological experience compared with the ungainly heavings of the past. The same is true of other sports. The footballs used are a complex combination of polymeric materials, sports shoes designed to win a few more vital seconds on the track are based on plastics, and rackets have a much lighter weight due to carbon fibre reinforced plastics. It’s reasonable to expect that the sports in which the UK excelled in recent weeks will prompt a surge of interest in the population. In turn, this could stimulate a higher demand for those products – hopefully with British brand names – not just in the UK, but also overseas. Sporting success certainly does matter to the plastics industry. In a different vein, but still linked to water, the end of August saw the House of Commons Environmental Audit Committee publish its report on the use of plastics microbeads in cosmetics. This rightly highlighted the key elements necessary to tackle the potential effects of microplastics in the environment, such as prevention in the first place and international collaboration. Once it had been highlighted that water treatment plants were unable to filter out microbeads, the BPF, alongside other leading associations, started to encourage companies to move away from their use in cosmetic products. We’ve been pleased to see a large number of cosmetics manufacturers committing to phase out microbeads completely. We believe that the focus should now be placed on addressing litter behaviour and improving the current waste management infrastructure to make sure all used plastics are efficiently collected for recovery. Once again, we emphasise that plastics in the seas is an issue that will not go away. The area that we can influence is preventing pellet loss from plants. Companies are exhorted to sign up to the principles of Operation Clean Sweep. For details of this please refer to the BPF website. WWW.BPF.CO.UK
ASSOCIATED ORGANISATIONS
ike most BP&R readers, I spent much of the last few weeks watching the box and marvelling at the accomplishments of our sports men and women as they hauled in the magnificent total of 68 medals at the 2016 Olympic Games in Rio. Many congratulations to them! In these uncertain times, when IN THIS MONTH’S EDITION OF HIS economic considerations are REGULAR COLUMN, PHILIP LAW, to the fore, some people may DIRECTOR-GENERAL OF THE wonder, “so what”? Is this something British politicians BRITISH PLASTICS FEDERATION can take to Brussels and (BPF), MARVELS AT THE UK’S throw on the negotiating table, SPORTING SUCCESS AND WHY saying “we have a tremendous TEAM GB’S MEDALS TALLY sporting spirit in this country MATTERS TO THE PLASTICS so you’d better give us a great deal?” INDUSTRY MORE THAN YOU Well, not exactly, but the MIGHT IMAGINE. Olympic success does have quite a strong commercial impact, not least on the plastics industry. British sporting success could be taken to illustrate a fierce competitive spirit and a national determination to win across the board – not just in sport. It can certainly be reflected in our business temperament. It adds to our image of an industry that is determined to be more efficient in its manufacturing than anyone else, one which offers unique innovative products that others cannot and one which goes that extra mile in providing better service than the competition. That is something that our negotiating counterparties should take heed of in Brussels. The Plastics Industry itself was incredibly well represented in the Olympics by an extraordinary range of equipment made from plastics. I’m certainly aware of this when it comes to rowing, more so than any other discipline, as I am part of a fairly siginficant rowing fraternity in the UK plastics industry This includes not only myself (John O’Gaunt RC) our BPF Vice-President, Bruce Margetts of Bericap (Lincoln RC), Peter Donnelly, formerly Akcros (Agecroft RC) and former BPF President, David Williams (Northwich RC). I’m sure all will tell you how the sport of rowing has changed remarkably thanks to the introduction of carbon fibre reinforced plastics material. I started my rowing career in 1968 training in heavy,
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