Jan/Feb 2018 Volume 20 | Issue 01
BUNTING EUROPE EXPLAINS THE ARGUMENT FOR SEPARATION Cover Story | Page 10
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IN THIS ISSUE Pg 24
INDUSTRY NEWS
COMPOSITES
This past month, the ocean plastics crisis has barely been out the news and both governments and brands have been vocal about what is being done to tackle plastics in the environment. The plastics industry has made pledges of its own, but are both sides in tune?
Composite technology is allowing plastics to do more and more exciting things and there is a lot of movement in this corner of the industry right now.
Bunting Europe has the technology that can aid plastics circularity by ensuring purer streams of plastic to be processed into recycled plastics materials. The expert in magnetic sorting reveals the role it is playing in the circular economy.
Pg 12 RECYCLING The role of recycling and developing systems for difficult-to-recycle plastics is vital. We have technical and exclusive insights from LyondellBasell, AIMPLAS and Impact Solutions - and an open letter from an informed naturalist to the plastics industry.
Pg 20 ADDITIVE MANUFACTURING We deep dive into additive manufacturing for aerospace with champion of 3D printing technology Stratasys.
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art & production robert wood
INJECTION MOULDING COVER STORY
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Volume 20 Issue 01
We have gathered together the injection moulding stories that piqued our interest in recent weeks.
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CHINAPLAS PREVIEW We take a look at what visitors can expect from the world’s second biggest plastics show when it hits Shanghai in April.
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Pg 32 JEC WORLD PREVIEW JEC World is one of the biggest meeting places for the composites industry on the planet - here’s what you can expect from the show in March.
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EUREKA H&M is leading the way for sustainable sportswear launching a line of exercise kit that is manufactured using recycled plastics.
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From The Editor
It’s all come out in the wash It was bound to come to this. The proliferation of plastic waste in the urban environment, in the countryside and in our waterways and oceans is a problem that is only growing, and the malignant nature of plastic as it is broken down into microparticles adds a sinister undertone to the appalling scenes we are confronted with by the mainstream media on a daily basis. The plastics industry’s role in resolving the global plastic waste crisis is well defined. While putting pressure on brands to commit to design for recyclability and improving the overall quality of the recycled plastic materials available to be brought back into the value chain, the plastics industry must also fight an uphill PR battle. Plastic waste is not in the environment because it is plastic,
The plastics industry can help itself, the environment and public wellbeing by adopting sustainable, circular economy practices while also reiterating just why plastics are vital to our modern lifestyles
it is in the environment because it has been inappropriately disposed of. Somewhere down the line, this has been confused by the media. How many times have you read the caption that every toothbrush ever manufactured is still somewhere on the planet? Without opening the ‘incineration for energy exchange’ Pandora’s Box, this is untrue, but that is the problem - the public are being led to believe that the world would surely be better without plastics. The plastics industry can help itself, the environment and public wellbeing by adopting sustainable, circular economy practices while also reiterating just why plastics are vital to our modern lifestyles. I can count on one hand the number of old school plastics industry representatives I’ve met who genuinely believe the mess we make today is somebody else’s problem - these people sadly do exist but are a dying breed. The vast majority of the industry is extremely environmentally-aware and equally appalled at the state of our natural world. This issue of EPPM has a strong sustainability focus, and I hope the efforts being made by some of the companies featured will inspire other plastics processors to do something positive. Rose Brooke, Editor
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INDUSTRY NEWS
Brands up stakes on sustainability Facing media and consumer backlash against plastic packaging, some of the world’s best-known brands have been making promises to appease the mob, but are the brand-owners and multinationals making the right promises for carbon efficiency overall? WORDS | Rose Brooke
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s the War on Plastics wages on, with the plastics industry facing an onslaught of bad publicity as the ocean plastics crisis comes to a head, big brands have set out their store for sustainability prompting both consumers and plastics processors to step in line. The majority of the measures set out by brands directly concern the responsible disposal of their branded recyclable plastic packaging - the central issue surrounding the War on Plastics - while others focus on likefor-like sustainability measures and alternative packaging.
Coca-Cola makes like-for-like recycling pledge The world's best-known brand, CocaCola, has pledged to recycle a used bottle or can for every beverage it sells by 2030, while also making all of its packaging recyclable worldwide. The drinks goliath has called its campaign 'World Without Waste' and acknowledges that food and drinks brands have played a part in the rise of litter in the natural environment.
McDonalds to ban polystyrene packaging International fast food chain McDonald's is banning all its polystyrene foam packaging by the end of this year as
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part of its 2020 Aspirational Goals campaign, which includes making sure 100 per cent of its fibre-based packaging comes from recycled and certified sources. The burger chain announced that it is looking to replace its difficult-to-recycle polystyrene foam packaging with other packaging products in the coming months across its global network.
Last straw for Costa Costa Coffee is removing all plastic drinking straws from its stores in 2018 replacing them with a more sustainable alternative. The company announced that it would be introducing a different kind of straw as part of an on-going effort to find greener alternatives to its existing packaging and takeaway cups.
Pret a Manger rewards sustainable practices Sandwich chain Pret a Manger is doubling its discount to customers who bring reusable cups to its stores. The company is knocking 50p off the price of a coffee to its British clientele if they bring a reusable cup, in a bid to reduce the estimated 2.5 billion coffee cups thrown away yearly in the UK. Previously, Pret offered a 25p discount to customers who brought a cup to refill.
Waitrose to scrap black plastic trays Upmarket grocery chain Waitrose has reacted to growing outrage that black plastic trays - a common sight on the meat counter in supermarkets - are not commonly recycled. Although they can be recycled, many waste management systems lack the sorting technology to filter them into the waste stream. To combat this, the company has pledged not to sell its own-label foods in black plastic after 2019, having already removed 65 per cent of black plastic from its fruit and vegetable offering.
Iceland bans plastic from ownbrand packaging Finally, British supermarket chain Iceland has announced it will be plastic-free within five years, banning plastic packaging from all its own-brand products, instead using paper and pulp trays and bags.
Could anti-plastic propaganda backfire? The plastics industry has articulated its commitment to the plastics circular economy and to sustainable practices in the industry, but has made the point that wiping plastics out is not the answer to the issue of waste - it’s rather a matter of responsible disposal.
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On the Iceland case, the British Plastics Federation released a statement reinforcing the role plastic packaging plays in reducing food waste and ensuring efficient transportation and storage. "Plastic packaging is used because it vastly reduces food waste and is resource efficient," the BPF stated. "If Iceland implements these measures, there is a risk that the weight of the packaging, carbon emissions, food waste and the amount of energy to make that packaging will increase. Growing and transporting food consumes a lot more energy than that used to make the packaging protecting it." Managing Director of Vanden Recycling David Wilson added that an antiplastic packaging sentiment could also backfire, as it does not reinforce the need to recycle plastics and encourage circularity. "There are some [proposals] ... that are suggesting supermarkets should not use plastics for packaging," he stated. "[That's] mixing with a message that could be seen as anti-recycling and that could backfire."
INDUSTRY NEWS
Ampacet makes recycled plastics work harder T he European Commission's revised legislative proposals on waste set clear targets for the reduction of waste and establish an ambitious and credible long-term path for waste management and recycling.
In a circular economy, re-use, repair and recycling become the norm, and waste is a thing of the past. The priority objective is to turn the EU into a resource-efficient, green and competitive low-carbon economy. Ampacet assumes its responsibility and attaches a lot of importance to its sustainable development programme and works constantly on new innovative and “green” solutions. The new Masterbatch Odor Scavenger 1000258-E, the additive Masterbatch Blue Edge 78 (7600078-E), the sustainable Black Masterbatch REC-OBLACK 216 and Ampacet BIORANGE have been specifically formulated to enhance aspect and functionality of post-consumer resin. Black Masterbatch REC-O-BLACK 216 is made from 95+ per cent RECycled and RECOvered post-consumer feedstocks, more precisely from recycled polyethylene carrier resin and carbon black pigment recovered from post-consumer recycling of rubber products like tyres. REC-O-BLACK 216 Masterbatch is designed for rigid and flexible applications. In films, it is suitable for general purpose industrial and consumer goods packaging and flexible infrastructure applications. Odor Scavenger 1000258-E is a powerful wide-spectrum odour absorber that neutralises odours of post-consumer recycled material and keeps them enclosed inside the polymer. This increases the ratio of post-consumer resin by keeping the odour level down and as a consequence it helps to reduce the expenses related to the purchasing of polymers. Recently launched Blue Edge 78 (7600078-E) is dedicated to PET recycled resin that counteracts the unattractive dirty effect in PET postconsumer recycled plastics and enhances bottle brightness with a lighter bluish tone giving it a clearer, fresher look. All in all, Ampacet’s 'green' masterbatch solutions can contribute to the reduction of plastics pollution and to a more sustainable world.
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INDUSTRY NEWS
The War on
Europe’s governments have plastic in their sights Decision-makers in Europe have responded to the public and media’s outcry that the level of waste plastic in the environment is too high to ignore, with the European Commission and the British Government committing to preventing plastic from escaping the waste stream. th e nth a fte r me a mo ca the t of n n e o m si the revi a n n o u n ce er e ov h s T r n io s 17 at negoti d target fo hina’s 20 hich reduce lmination of w shock of C cu k, d or an to m ew de ed Fram or mbl fter the maj n, legislators have scra 08 EU Waste rought b g. Both 20 ba in c d ti n ag a as ck , pl g pa p in te scra recycl t on of was ti en ra m wa n ce s rn ife o ol ve ll a pr British go so m e e contain a th in d an er on ov member politick n Commissi e c if ic to anti-plastic sp e f the Europea m n so ea r fo op y tification o e ‘Eur portunit nations. Ra nouncing th s took the op an e o en g re es G t ch n ‘A ee e d ith sp amendm onomy’ an e Ec r th la n January, w , cu a t’ ir e C p en nvironm e E u ro Plastics in a prove the E b e fo re th Im n Strategy for to ea op an ur pl the E 25-year Council and , Future: Our th n o m t ex . ment n lia ar P respectively to e av s h e cte d , both paper tics, a n d wa s ex p timeframes as t pl n imously n re se a fe -u n if le u d ng pass ase out si Albeit with ph – e m n g ro u p sa h the l ca m pa ig astics. ti pl n u ro ic pledged muc m n aled the cling and ba enpeace reve t had re G increase recy ng gi Packa rnmen pean Union’s ritish gove 4, which B bassadors from the Euro 9 19 ve am r ri U be de E s em ie ed The polic ll brief tive of Dec A ec . ir 15 D enting a 20 te m d as le ng W in 2013 an ainst imp ag ts en and Packagi c ti dm as en r cent target with am levy on pl reduced 65 pe introduce a ommissioner was updated to gs e ba ad it would c m ti e European C es wer g on plas high – a sign in o om mmermans to lo Ti as s e an n lin member stat n Fr Europea arges o h the dead on ch it s W el in . t he 18 s gh 20 it u o drag e bags by ave br ation, despit ber states h plastics legisl laws, all mem tic packaging. te le p m co to plas an intention discretional ch 2019. ar M by t xi Bre : ermans said s e aisle e lastics, Timm P fr , c od on ti fo y s r eg la ou p at , gy and our water ng the Str te a hi to tr nc in s , g au k L in c tt to on o Sh egy on is tics ge ’s new ‘Strat -term soluti ust stop plas n Commission ade a “We m The only long . m ea es op ay di ur M E bo a r e es er en ou Ahead of th Minister Th come, and ev te by tish Prime : “In years to plastic was ed ce m u ai d cl Plastics’, Bri re e so sh w lo re using al he e re w w , y d ch cling an at how toda cy d vaunted spee re ke oc sh a challenge le will be ore. This is needlessly.” I think peop m ed uc and od pr to be ns, industry much plastic ic- that citize le st la ck ‘p ta t te us ea ts cr ents m t supermarke voidable plastic governm es gg su to n t ‘a She went o together. to phase ou and pledged free aisles’, stics 2042. the EU Pla packaging’ by also ropean "With u E re a e th e pipped ategy w t tr S en s, ic m re st ce la n m p u anno lk on ew and o The British for tough ta s driving a n e an st o W Fr . p el er e n od th o m to siness Commissi Commission ing circular bu ve tt stainability ti se u va S ’, r, no cs ti in te la as in pl vest as five days s ‘strategy on 30, need to in at s launched it cyclable by 20 nologies th re ch g te in ag ew ck Timmerman n pa r l al ou e . d ak cs an ti m zens da to roplas inister out an agen keep our citi UK Prime M ’ and ban mic t cs ils ti h as w pl e fe us a May sa ees t gl er en in Th m ‘s n ce ro redu st ry was an envi u d gy in te ra r st u o 30 g c said the 20 aging ke e p in P Davor Skrle -leader in man tive." ld ti or pe w m a Croatian ME co as e ak mers m e for Europe su n ov co m t p an el rt h impo g to and recyclin plastic waste s. choice sustainable
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r on Plastic WORDS | John Carlon and Rose Brooke
Plastics industry responds The plastics industry has been quick to respond to the media storm in 2018, with the vast majority of major industry associations making it clear that sustainability is high on the agenda - adding that targets set by governing bodies must be made in consultation with the industry.
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nswering to the cries of ‘what can be done?’ set of ambitious targets from the mainstream and initiatives represent media, consumers ing the plastics industry’s contribution and government, six to achieve a fully circular Eu ropean plastics effi and resource organisations committed cie nt Eu rop e. along with the European Commission to launch a number of Circulari ty As well as suppo platforms to advance the rting the aims set ou recycling of plastic produ t in the European cts Commission’s Pla in Europe. stics Strategy, PlasticsEu rope will strengthen its efforts and collabora tion along the value cha in and with Plastics Recyclers Eu public authorities to del rope (PRE), Petcore iver increasingly sustai Eu rop nable plastics e, solutions. PlasticsE the European Carpet and Rug Association urope has already est (ECRA), European pla ablished three the Polyolefin Circular tforms (ECVM, PCEP ity Platform (PCEP Eu and Styrenics Circular rope), Solutions) to European Plastics Co accelerate innovation nverters (EuPC) and towards more efficient VinylPlus chemical an have adopted a frame d mechanical recycling work of voluntary com . mitments to continue and exp and existing plastics recycling activities and create additional polymer/pro duct- Plastics specific circularity pla 2030 also takes produc tforms. tive
steps to prevent
the leakage of plastic int The organisations have o the environment. set a 50 per cent plastic recycling and reuse by 2040 target to Pla sticsEurope will contin work towards, as well as ue setting up educatio a target for 70 per cent recycling and reu nal projects across Member States se of plastic packaging to increase awareness to be reached through specific platfo on sustainable consumer behaviour. rms involving the whole It will strengthen the plastics value chain: from raw mater industry programme to prevent ial producers, designe pellet loss via Operatio rs, converters, collectors and recyclers n Clean Sweep by increasing the inv to brand owners and spe olv ement of the entire cifiers. value chain, including transport an d logistics. Lastly, Plasti csEurope will launch new research act ivities to fill knowledge PlasticsEurope comm gaps on the most common plastic its items being littered, with a view to identifying solutions. PlasticsEurope also we lcomed the European Commission’s Plastics Strategy and sha res the vision of a truly circular and resource-efficient Europ e by preventing the lea kage of plastic Accelerating resource efficiency waste into the environm ent, promoting recycling and re-use, and boosting innovatio PlasticsEurope is comple n. menting its efforts with other actions aimed at enhancing pla stic s’ resource efficiency by The Strategy aims to accelerating innovation for circulari increase the level of ty. This includes furthe harmonisation across the European Un r research into alternative feedstocks, ion of rules governing more frequent updates environmental and economic aspects of product LifeCycle Inventories and En of plastics. PlasticsEurop vironmental Product De e em phasised pu that such an approach clarations, the blication of extended wa should be maintained wh ste data, new eco-desig en it comes to initiatives put forth by the n guidelines for plastics packaging, and Strategy, which will reduce the standardisation of ind the littering of single use plastics. Th ustrial best practices and methodo ese measures, the org logies. anisation said, should be proportional, effective and harmonis ed at EU level. By mid-2018, PlasticsE urope will have a water “We, the European pla tight action plan and time-based pe stics manufacturers, are rformance indicator tha committed to ensure high rates of reu t can be used to evaluate the achiev se and recycling with ement of the above ob the ambition to reach 60 per cent for jectives. The results are to be monit plastic packaging by 20 ored by an independe 30,” Karl-H. Foerster, Executive Dir nt committee comprising represen ector of PlasticsEurop tatives of academia, e. “This will help achieve our goal of 100 the European Commission, the Europ per cent reuse, recycling ean Parliament, civil an d recovery Pla of all plastics packaging society and sticsEurope. Also, from at European level by 20 40.” 2019, an annual progre ss report will be published. ‘Plastics 2030 - Voluntar
y Commitment’
To fortify its agreemen t further, PlasticsEurop e has published its ‘Plastics 2030 - Volun tary Commitment’, wh ich contains a
“Building a long-term sustainable developme nt requires courage, innovation and concrete actions, ” said Daniele Ferrari, President of PlasticsEurope and CE O of Versalis. “It is in this spirit tha t we designed the ‘Pl astics 2030 – Voluntary Commitmen t’.”
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COVER STORY
Contamination hinders plastic recycling The key to bringing plastic waste back into the value chain lies in the quality of the recycled plastic material - but in order to achieve this, effective separation systems need to be in place. Bunting Europe explains the argument for separation you won’t hear in the mainstream media. WORDS | Paul Fears, Press Office, Bunting Magnetics Europe
T
he environmental impact of poorly managing plastic waste has been in the headlines since the BBC’s Blue Planet II series was aired at Separation is achieved the end of 2017.
using either technology or, more commonly, a combination of separation equipment and human pickers. This is a dirty, difficult, and unpopular environment in which to work.
In January, Theresa May made a pledge to eliminate the UK’s plastic waste by 2042, although the detail of the plan has yet to be unveiled. Less than a week later and the EU ‘declared war on plastic waste’, announcing the intention to ensure that every piece of packaging in the region is reusable or recyclable by 2030. Presently, there is an unprecedented negative feeling towards plastics, however, plastic is and will continue to be one of the most versatile and useful materials available. This versatility is down to the wide range of plastic types, as can be seen
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in any household. Plastic is present in food packaging, mobile phone casings, DVDs, televisions, and many other everyday items that would not exist unless made of plastic. Certainly, product designers need to give recyclability a higher priority and this change in attitude is required for all materials - not just for plastics, which have become an environmental villain. Effectively managing plastic waste is not a new problem for the UK. With the introduction of Material Reclamation Facilities (MRFs) in the 1990s, there was an abundance of segregated materials, including plastics, for which there was no end market. These were stored or exported overseas, and there were reports of warehouses in Germany stocked full of unrecyclable waste materials. This resulted in changes in the EU definition of ‘waste’ that prevented the easy movement of secondary materials within Europe, but this did not address the main problem. The market for materials such as secondary plastics simply did not exist. Advances have been made and there are products being made out of recycled waste plastics (e.g. furniture) and even plastic roads.
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Technology has advanced, but the main problems remain. Complex recycling plants are now able to separate different types of plastic by colour and type, but the process is not perfect. To further complicate the problem, other non-related materials, such as metal and even building materials (e.g. concrete and bricks), contaminate the vast majority of waste plastic packaging.
Contaminated pre-sorted waste Most plastic packaging enters the recycling process as pre-sorted household waste. The specification of what materials are mixed in a single recycling bag depends on the recycling strategy of the local council and varies considerably across the UK and Europe. On arrival at an MRF, the collected materials are then separated into metal, plastic, cardboard, and any other materials defined within the local strategy. Separation of these materials is achieved using either technology or, more commonly, a combination of separation equipment and human pickers. This is a dirty, difficult, and unpopular environment in which to work.
The ability to successfully separate the materials is compromised by the presence of other waste. These materials have been incorrectly added to recycling bags by the consumer or during collection and include used nappies, food waste, paint tins, and other problematic materials. At the MRF, metal packaging (e.g. steel and aluminium beverage and food cans) is commonly recovered using Overband Magnets positioned over the main feed conveyor prior to the picking line. Other materials are manually handpicked and stored separately. Up until recently, the mix of plastic packaging could then be sent to a specialist UK plastic recycling plant or overseas to countries such as China.
Contaminated plastic waste Since 2012, British companies have shipped more than 2.7 million tonnes of plastic scrap to mainland China and Hong Kong. However, this only accounts for two-thirds of all the plastic waste exported from the UK. Plastic waste sent to China is, where possible, commonly hand-sorted into individual plastic types (i.e. removing plastic tops by hand), with all other added contamination removed manually. This involves a huge, low-paid workforce. Similar manually based recycling operations in Europe would be prohibitively costly with unacceptable working conditions. In December 2017, China announced that in early 2018 it will stop importing 'foreign garbage', stating that such waste materials were commonly contaminated with large quantities of dirty or even hazardous wastes. Specialist plastic packaging recycling plants in the UK have been under intense financial pressure for many years. There have been calls for better legislation and Government support, but too many plastic recycling plants open and are then forced to close due to being financially unviable. A typical plastic recycling operation needs a complex system of separation equipment. The plant also needs to be able to adapt to huge variations in the nature of the delivered waste plastic. There are also strict environmental regulations on storing and handling waste plastic. Such plants are expensive to install and operate. Early in the process, ferrous and non-ferrous metal contamination is removed from the waste plastic using Magnetic Separators and Eddy Current Separators. Initially, after the plastic is released from the compacted bale, the waste is fed into a primary shredder. To protect the shredder from damage, an Overband Magnet is suspended across the feed conveyor and removes large ferrous metal. At this stage, the type of ferrous metal contamination found in the plastic is diverse and often surprising. It can include metal packaging mis-sorted at the MRF, heavy lumps of iron that increase the weight of the plastic bale, and metal picked up during
transportation. There have even been reports of car engine blocks. Reasonably sized items of cast iron entering the shredder will cause significant and costly damage and result in the plant being closed until a repair is possible. After the primary shredder, the waste plastic has been reduced in size and many contaminants liberated. This shredded waste plastic is fed onto another Magnetic Separator, commonly a Drum Magnet or Pulley Magnet, to remove liberated smaller ferrous metals. The type of ferrous metal separated at this stage includes steel spanners, nuts, bolts, screws, fine metal wires, springs, iron shards, fine ferrous dust, and chunks of stainless steel. Most of the ferrous metal was not part of the original plastic packaging and has been introduced between disposal and processing. The cleansed plastic waste then passes over an Eddy Current Separator to remove non-ferrous metals. Commonly separated metals include aluminium beverage cans, foils, tubes, and even window frames. After the metal contamination has been removed, the plastic waste moves to the next stage in the plant, which could be the further separation of contamination or sorting by colour or plastic type. The high level of metal contamination highlights the challenges facing waste plastic processors. It was one of many contaminants, not present in the original plastic packaging, that have to be removed. Before UK and EU Government officials make recycling pledges to pacify environmentalists, they need to consider the practicalities and difficulties faced when processing waste plastic packaging. Contamination will always be present, and is one of the reasons for exporting this difficult waste material overseas. Reducing such contamination will make it easier to recycle waste plastic, but there is no clear strategy to achieve this goal at present. www.buntingeurope.com
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RECYCLING
Achieving circularity with collaboration
LyondellBasell has joined forces with waste and water management giant SUEZ to help achieve a plastics circular economy together as a recycling power duo. WORDS | Rose Brooke
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plastics Circular Economy will be achieved faster if stakeholders collaborate. This is the message behind the joint venture between chemicals giant LyondellBasell and waste and water management juggernaut SUEZ, which was SUEZ will be bringing the announced late last year (November raw waste material then 27th 2017).
they will be sorting it and we will apply our technical and application knowhow to upgrade this waste into a material we want to position as prime recyclate
LyondellBasell agreed to purchase a 50 per cent stake in Quality Circular Polymers (QCP), a high-standard plastics recycling company in SittardGeleen, Netherlands. The facility is capable of converting consumer waste into 35,000 tonnes of polypropylene and high-density polyethylene (HDPE) per annum as of this year.
The deal makes LyondellBasell a 50/50 partner in QCP with SUEZ and marks the first time that a major plastics company has joined forces with a leader in waste management to contribute to circular economy objectives. Senior Vice-President of Olefins and Polyolefins Europe, Asia and International for LyondellBasell Richard Roudeix believes the
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partnership demonstrates LyondellBasell's position as a champion of circularity and inter-sector collaboration. "We need to take on responsibility and work with the value chain to find a solution," he told EPPM. "We are joining forces with [SUEZ] because collecting and sorting waste sorting is not one of our strengths and we feel it is much more appropriate to join forces with a specialist. So SUEZ will be bringing the raw waste material then they will be sorting it and we will apply our technical and application knowhow to upgrade this waste into a material we want to position as prime recyclate. The same quality as a prime product."
Matching expertise The partnership with SUEZ has a strong foundation of shared values. Roudeix explained that whenever LyondellBasell enters into an agreement many factors have to be taken into account such as due diligence checks and other business parameters, but sharing a similar culture is just as important. In the deal with SUEZ, these twin sentiments were a bonus for LyondellBasell, as it meant teaming two leaders in their respective fields while sharing their passion for circularity.
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"Circularity in plastics requires a combination of solutions and we need to work along the value chain," said Roudeix, who also serves as chairman of Cefic’s Climate Change and Energy Programme Council. "We need to work with designers in order to make the plastic part recyclable, we need to educate the consumer to make sure that people are aware of the environment, and we need to work with the brand owners so they take that into consideration. I am convinced that I do see Europe more at the forefront of evaluating what by working with the full value chain we will be able to fix the problem."
This mission includes tackling the thorny issues of resolving how we deal with difficult-to-recycle plastics at end of life, as well as doing away with less sustainable methods of getting rid of rubbish including incineration and landfill.
A key player in fixing the problem of plastics at end of life entering the correct waste streams, or languishing in landfill or the environment, is the brand owner and Roudeix acknowledged that it is this vital cog in the value chain that is putting pressure on the rest of the industry to help them find the solutions their environmentally-aware customers are looking for.
He explained that in time, he is confident mechanical and chemical recycling technologies will be advanced enough to do away with incineration but for now, incineration is part of the waste management ecosystem.
could be future business models for circularity
"We are the largest producer of polyethylene and polypropylene in Europe, so we have the knowledge and the technology that will hopefully dig up the solution," said Roudeix. "That is one of the reasons why we have been targeting this operation, because it is exactly in line with our core competencies."
"Provided we are able to develop the technologies in terms of mechanical or chemical recycling on a large enough scale that it is economical, we can live without incineration but today these technologies are not yet developed," the expert noted. In the meantime, the LyondellBasell partnership is part of the solution to bringing more plastic waste back into the value chain, and keeping it out of the natural environment.
Finding the solution Europe in particular is home to consumers that are motivated by recycling and the need to be green and Roudeix believes the region is world-leading in its mission to achieve plastics circularity.
"We are excited because we are convinced the combination of both a leading waste management and a leader in polymer technology will be successful for the future."
"We need to find a solution that is workable, and today we don't have an active solution, however I am convinced we will find one," the expert stated. "There will be a combination of solutions, so I do see Europe more at the forefront of evaluating what could be future business models for circularity."
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RECYCLING
Characterisation and analysis of recycled plastic materials according to European standards The use of plastic waste, its recycling and transformation into new products requires quality assurance of the material. For that purpose, there are European standards that describe the analytical methods for the characterisation of the plastic wastes and of the recycled materials after their transformation process. WORDS | Eugenia Núùez Calzado, AIMPLAS
C
urrently, European countries recycle around 45 per cent of generated municipal waste. Germany is at the forefront with 66 per cent of waste recycled, while Spain achieves half this amount (33 per cent). A large amount of municipal waste is formed by plastic materials, most of it from single-use packaging materials. Sources of plastic waste can also be found in the industry, including manufacturers and processors of plastic materials. Some types of plastics, in particular thermoplastics (PP, PE, PS, PVC and PET), are suitable for recycling. After the waste collection from sources, these materials are subjected to sorting, washing and a classification processes to sort fractions composed mainly by just one type of plastic. Such fractions can be used in the manufacturing of new products, as long as they meet the specifications defined for each application. In order to assure the quality of recycled plastic materials, there are European standards that have to be met. Within the standards on characterisation of recycled plastics, specific standards are found for each family of plastic material suitable for recycling (PS, PE, PP, PVC y PET). In each standard, the required and optional characteristics for each type of plastic are set.
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When determining characteristics related to the composition of the recycled plastic material, a series of combined identification techniques can be used, such as thermogravimetry TGA, calorimetry DSC and spectrophotometry FTIR
Required and optional characteristics for the different families of recycled plastics
When determining characteristics related to the composition of the recycled plastic material (impurities, contaminants, foreign polymers), a series of combined identification techniques can be used, such as thermogravimetry TGA, calorimetry DSC and spectrophotometry FTIR. The determination of certain substances requires the previous transformation of the sample, including grinding and melt-mixing, besides the preparation of standardised specimens to determine the mechanical and thermal properties. On the other hand, standards UNE 53972 and UNE 53978 for PP and PE respectively, describe codes for classifying and marking the recycled plastic materials according to established ranges in certain characteristics.
Marking according to UNE 53978 and UNE 53972 standards for PE and PP. MARKING
Required and optional characteristics for the different families of recycled plastics (cont.).
In the case of polystyrene, the required and optional characteristics are the same for General Purpose Polystyrene and High Impact Polystyrene (HIPS), with the exception of impact resistance, a mandatory characteristic only for HIPS. That is a characteristic also required in polypropylene recycled materials, since this plastic is used in applications in which a good impact behaviour, specially at low temperatures, is needed. In general, the characteristics related to processing (Melt Mass Flow Rate) and the mechanical properties are significant in polyolefin recycled plastic materials (PE, PP) and PS.
PE - (R) – Shape – Color – A / B / C / D - UNE 53978 Characteristic
Classification
Shape
Grinding Densifying Pellet
Color
N: Natural C: Any color N, C, or NC: Black, Color or Carbon Black
A = Class
Class I: various sources, without specific application Class II: selected source, hollow items, extrusion applications, high thicknesses Class III: selected source, hollow items, extrusion applications, low thicknesses Class IV: selected source, hollow items, extrusion applications, high thicknesses
B = Group, depending on the density
G1: r ≤ 0.921 G2: 0,921 < r ≤ 0.936 G3: 0,936 < r ≤ 0.954 G4: r > 0.954
C = Type, depending on the Melt Mass Flow Rate
T1: IFM ≤ 2 T2: 2 < IFM ≤ 10 T3: IFM > 10
D = Category, depending on the deformation at break (only Classes II and III)
Class II C1 and C2: Strength = 10 C3: to be specified Class III C1: Deformation ≥ 350 C2: to be specified
PP - (R) – C / T / I / Color - UNE 53972 Characteristic
Classification
Color
N: Natural C: Any color N, C, or NC: Black, Color or Carbon Black
C = Class
Class I: Injection Class II: Profile extrusion Class III: Other specific processes
T = depending on the Melt Mass Flow Rate
T1: IFM ≤ 5 T2: 5 < IFM ≤ 15 T3: IFM > 15
C = Type, depending on the impact strength
I1 (high resistance) ≥ 8 kJ/m2 I2 (medium resistance) ≥ 3 kJ/m2 and < ≥ 8 kJ/m2 I3 (low resistance) < 3 kJ/m2
The standard methods described in this paper comprise a guide to tackle the characterisation of different recycled plastic materials. However, there is always the possibility of adjusting to a greater or lower degree to those methodologies described in the standards, according to the agreement reached between the supplier and the customer and the final application of the recycled plastic material. www.aimplas.net
In the case of PET, the content of water, the PVC content and the fine particle content are required characteristics. In order to determine the content in PVC and polyolefins in PET flakes, the standard UNEEN 15348 refers to its Annex C, in which the methodology to be used for such determinations is described. Optional characteristics such as colour determination by colorimetry, alkalinity or intrinsic viscosity (in solution), are particular to PET recycled materials. PVC is a material with special characteristics. Stiffness is a required characteristic and properties like slipping, the recommended type of processing and the thermal stability are optional characteristics.
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Milliken presents NX™ UltraClear™ Polypropylene – the right choice for thermoformed food packaging When you weigh up all the benefits, there is a strong case for choosing NX™ UltraClear™ PP to achieve attractive and sustainable transparent thermoformed food packaging with excellent functionality. The days of thermoformed polypropylene (PP) applications with a milky appearance are gone. Milliken’s pioneering Millad® NX™ 8000 clarifying agent has removed PP’s transparency obstacle. The resulting highclarity NX UltraClear PP combines significant performance, economic and sustainability benefits for sheet extruded/thermoformed food-packaging applications. Such applications today require diverse properties – lightweight; stiffness and impact strength; transparency; sealing effectiveness; hot fill, retort and microwave ability. NX UltraClear PP now is an attractive alternative to other glass-clear materials such as A-PET and PS for many sheet extruded/ thermoformed applications, while also offering sustainability and recyclability advantages.
Glass-clear transparency In addition to setting a new clarity standard for PP, Millad NX 8000 can give PP applications a glossier aspect than normally possible with standard nucleated PP.
Lightweight & productivity gains With significantly lower density than other
plastic options, NX UltraClear PP reduces part weight and allows thermoformers to produce more trays per kg or to use less material.
Stiffness & impact strength Using a ribbed or improved design allows NX UltraClear PP to achieve the same stiffness as A-PET at the same thickness and at a lighter weight than similar PET applications.
Sealing in freshness
Photo courtesy of Knauf Industries.
Standard PP sealant films offer good sealing performance despite any residue on tray edges and exteriors. For the best seal strength, we recommend PP trays sealed with polyolefin films.
Hot filling, retort & microwave ability NX UltraClear’s excellent heat resistance makes it suitable for hot fill and for microwaves. This, plus good cold-temperature performance, fulfills food packaging ‘s “fridge to microwave” concept.
Recycling & sustainability The market for recycled PP in a wide range of products makes the material a good circular-economy choice. PP also consumes the least amount of energy during production and has low carbon dioxide emissions, and thermoformed NX UltraClear PP monomaterial applications are easy to recycle.
For thermoforming and sheet packaging, NX UltraClear PP offers glass-clear clarity and benefits such as easy seal and impact and heat resistance.
This new choice for converters and brand owners is ready to be explored. Open your eyes to the benefits and visit chemical.milliken.com or email Eurochem@milliken.com for more information.
© Copyright 2018. All rights reserved. Millad is a registered trademark of Milliken and Company. NX and Milliken are trademarks of Milliken & Company. Please Note: As each customer’s use of our product may be different, information we provide, including without limitation, recommendations, test results, samples, care/labeling/processing instructions or marketing advice, is provided in good faith but without warranty and without accepting any responsibility/liability. Each customer must test and be responsible for its own specific use, further processing, labeling, marketing, etc.
RECYCLING
BOSS level recycling Separation technology will be key to establishing the long-term resilience of the recycling industry. Separating polyolefins has been a tricky process in conventional facilities, but Scotland’s Impact Solutions has taken on a new plant to use its own innovation to separate PP from PE.
There is now a need in the UK market after the Chinese market closed down, where before it would have been cheaper to hand-separate under their relaxed labour laws, it is not feasible to do hand separation over here.
WORDS | John Carlon
G
iven the pressure the European recycling sector is under since China banned scrap plastic imports at the New Year, it looks like many recyclers are playing catch-up with the vast mountain of waste staying on the continent. Well prepared though, is Impact Solutions, which proposes a simple yet radical solution to speedily separate household waste plastics – its BOSS system.
"Impact Solutions is now offering a solution to that problem, taking in the mixed rigid plastic and setting up our new technology to separate the PE from the PP. "The machinery is based on differences in density between the plastics - there is a sink-float part to the process, which is really to get rid of any impurities such as heavy metals.
"We are taking commissioning loads and spending January educating suppliers on our ideal materials. "There is now a need in the UK market after the Chinese market closed down, where before it would have been cheaper to hand-separate under their relaxed labour laws, it is not feasible to do hand separation over here.
"Only both PE and PP float, so what we did is made a technology called Baffled Oscillation Separation System. "The difference is the force put through the water, the same concept for if you had two flotation devices in one hand and one in the other, the movement would differ across devices depending on the water’s force.
The roots of Impact’s BOSS machinery come from a request by a customer to separate HDPE and polypropylene bottle cap regrind. Rudimentary sink-float principles were embellished by ‘shoogling’ paddles in a densitycontrolled solution. Impact made the system in a self-contained unit, with a recirculating flow of water through the machine. David Walsh, Manager of Impact Solutions’ new facility in Newcastle-upon-Tyne, told EPPM about the company's journey to become a plastic separation specialist.
The landfill risk "The facility will recycle plastic from councils and household waste recycling centres, on their behalf. They are collecting mixed rigid plastics, the polyolefins PE and PP, which today are very hard to recycle because they are mixed, so those operating on behalf of the councils stop collecting them as they are too difficult. Now especially with the Chinese market closing - the risk is they will stop collecting the polyolefin, and it will all go straight to landfill.
"Similarly, with plastics the PE and the PP have different densities, so when you apply the sink float with a force throughout the water, some of the plastic will rise but the heavier stuff will fall. "It really depends on our technology to separate the two. Happily, it’s quite successful and we’ve achieved more than 95 per cent in the purity of polyolefin - we get very pure plastic. Which can then go straight to polymer companies for recycled products. "The facility in Newcastle has been built from the ground up - it was a bare floor when we went in and we have specified the lot ourselves, moving in last September. Now we are doing everything necessary with traditional recycling equipment for washing and separating impurities, then preparing it by shredding it twice. We now have it in full production, taking in more or less raw material from the HWRCs.
Market demand "The facility is specialising in polyolefin, we could set it up for other plastics but with BOSS you have to apply a force appropriate to the plastic you’ve taken in. We try and aim for one plastic that we are taking and make sure that’s mostly what we’re getting.
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"I think from that point of view, people have now accepted that China is shut for plastic. Having certainty of supply, means manufacturers can run their business properly and we don’t have to worry about exchange rates. "In the short term, Europe is not totally able to deal with the issue - I don’t think there is space, and it will lead to a reduction in recycled materials. A lot of the recyclate will go to incineration rather than landfill, and then once our technology is developed we can deal with it through recycling. "We are opening four new plants, with our first in Newcastle then more this year in Birmingham, Liverpool and London. We are all hoping these will come through in the next couple of years, and our machinery is ready to go where it is needed. In Newcastle, we have eight people working on each shift and starting up we have one shift in operation with the second starting soon."
www.impact-solutions.co.uk
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RECYCLING
Out of sight, out of mind no more: An open letter to the plastics industry Naturalist and author Sarah Roberts believes the plastics industry can put pressure on brand-owners to help consumers close the plastics circular economy loop, as the ocean plastic crisis reaches boiling point in the media. WORDS | Sarah Roberts, Naturalist and Founder of This Is Creature
T
he biggest culprit of plastic pollution is people. 'Out of sight, out of mind' is human nature and for too long we have become used to burying our waste without a second thought. We are living in a consumerist world, where if something breaks, it’s less effort to replace it rather than fix it, and as the global population rises and our consumption of natural resources is more rampant than ever, our Plastic advances in technology processors have have separated us even a duty to help further from the natural world that we are a part make it easy of. As a result, we don’t for consumers often come face-to-face to recycle their with our negative impact on the ecosystem. plastics and the
environmental impact and the lifecycle of each material should be openly disclosed
I have seen everything from microplastics, fishing lines, bags, straws, and tampon a p p l i ca to rs, ri g ht through to clothing and whole appliances dumped in rivers, streams and oceans. The problem is not limited to water sources though and there needs to be a focus on cleaning up farmland, woodland and even the urban ecosystem. But is the answer to live 'plastic free'? Google solutions to plastic pollution and you’re likely to be greeted with the '#plasticfree' campaign. And with celebrities, conservation groups and the media all pumping it out en mass, an ordinary member of the public could be forgiven for assuming this may actually be a viable option. However, most advocates often neglect to highlight our unequivocal reliance on this material as a society in every aspect of our lives. I wonder how many of these plastic-free backers are willing to turn down drips, injections or pills packaged in speciallydeveloped polymer packaging?
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the world they are growing into, but at the same time, children have a great ability to educate and spread the message to adults. This is a huge environmental issue that needs everyone on board.
We all know that plastic waste is an environmental problem, but what isn’t clear to the public is how we must learn to live with it. This is where the plastics industry needs to take up the baton. We are not in a position to eradicate plastic, but new technological advances in how plastic can be recycled and how it can be made from different sources should be shouted about. Plastic processors have a duty to help make it easy for consumers to recycle their plastics and the environmental impact and the lifecycle of each material should be openly disclosed. The more facts we can give consumers, the more pressure brands will be under to make environmental choices and as a result, the more sustainable the industry as a whole will become. Equally, there needs to be more investment in advanced recycling systems and in the development and testing of non-petrochemical feedstock materials. In my career, I have delivered public talks and workshops from nursery, right the way up to retirement homes. I’m an ambassador for one of the largest environmental social media campaigns for 18-30 year-olds, (see www.ladbible.com/trashisles/ welcome) with plans to deliver more college and university talks later this year. My intention in writing 'Somebody Swallowed Stanley' and creating a lesson plan for primary schools, is not just to get plastic higher up the curriculum, but to find a fun way of communicating with children, parents and teachers too. We have a duty to educate the next generation about
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We want to inspire future scientists, so along with product designer Drew Kendrick and members of the plastics industry, I have developed an interactive lesson plan and practical experiment to highlight the importance of the safe disposal of plastic and demonstrate different types of plastic on the market. The experiment uses characters from the book, which has been used and approved by teachers, the media and conservation groups including Surfers against Sewage and The Wildlife Trust. I am currently looking for sponsors and partners to put 'Somebody Swallowed Stanley' and our speciallydesigned science lesson, into every primary and special school in UK. Right now, the plastic industry is under a barrage of bad press and has been scapegoated by the media. If you would like to support this project and demonstrate your company's commitment to preserving the environment, please get in touch via sarah@thisiscreature.com. A problem of this size requires collaboration from all sectors.
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ADDITIVE MANUFACTURING
Deep diving into additive manufacturing for aerospace Stratasys has been cultivating its relationship with the aerospace industry for many years. Eric Bredin, Vice-President Marketing EMEA for Stratasys, sat down with EPPM to unpick the complex process of getting a 3D-printed part airborne. WORDS | Rose Brooke
V
anguard of the additive manufacturing industry Stratasys has seen its 3D printing technology take off in the form of in-flight parts on aeroplanes, and in June 2017 the company conquered additive manufacturing in aerospace by launching its Fortus 900mc Aircraft Interiors Certification Solution. There is much more to additive manufacturing for aerospace than getting parts approved by the OEM for installation in a working aircraft. Eric Bredin, Vice-President Marketing EMEA for Stratasys, set out just what it takes to get a Stratasys-printed machine into the lower stratosphere. “In general, aerospace is a very interesting segment as it’s a market in which we have a lot to play with,” he explained. “What we are trying to influence is concept design right through to production and there are many areas in this industry where we can be very active.”
Prototyping, production and maintenance Naturally, 3D printing has a home in prototyping for aerospace, and Bredin explained that prototyping remains a growing business for the AM pioneer, but Stratasys is trying to engage with the entire aerospace ecosystem to show how the technology can bring efficiency and innovation to a high-accountability industry. This is where the Fortus 900mc Aircraft Interiors Certification Solution comes in, as it facilitates the 3D printing of FAA and EASA-certified aircraft interior parts, allowing aerospace manufacturers to certify more parts for flight quickly. The system is based on the Fortus 900mc Production 3D Printer, which is optimised for producing FAA and EASA-certified parts. The solution includes ULTEM 9085 resin, a lightweight and strong thermoplastic that meets regulations for flame, smoke and toxicity in aerospace. The innovation is undergoing a qualification programme under FAA oversight at the National Center for Advanced Materials Performance (NCAMP), which is part of the National Institute of Aviation Research at Wichita State University, leading eventually to the first-of-its-kind NCAMP qualification of a 3D printing process. “Stratasys is looking into four different areas where we deploy our technology in aerospace; so service, software, materials, and hardware development go very much into the vertical aerospace segment,” Bredin stated. “And when you get into the specific development of end use production parts there has been many years of development together with key players.”
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Getting 3D-printed parts off the ground Getting a 3D-printed part onto a plane is a long and sophisticated process and Stratasys has to prove that additive manufacturing technology could bring improved lightweighting, more functionality, better cost and time-to-market. “Within the plastic environment we see a lot of applications in cabin interiors where there’s a lot of potential now,” Bredin said. “We started a few years ago looking at working with some of the key aerospace manufacturers to see how our additive manufacturing technology can fit their needs. We explored qualifying the parts and going through the certification process.” This process is long and stringent, beginning with the certification of the materials, the certification of the process, and then finally the certification of the part. All of this has to be in compliance with the European and US aerospace authorities. As well as prototyping and end-use parts - where additive manufacturing for short-run productions comes into its own where replacement components are concerned - Stratasys is also assisting the aerospace manufacturing process in the intermediate phase of production, namely tooling. “Tooling is still a big area where we see the benefit of using the technology to manufacture a part,” Bredin explained. “You can already see [its success] reflected in automotive.” He added that 3D printing can also be put to use when working with composite materials such as carbonfibre to assist with lightweighting, while the technology is being developed with what may yet be possible in mind - future-proofing its capabilities. “You think about using carbon fibre as a very interesting material which is combining light weight and a very strong resistance,” Bredin said. “Plane manufacturers today are looking at wings that are going to be made with carbon fibre because you can make it thinner, lighter, stronger ... and they are running through extensive tests. Now we are not in a position yet where we can direct manufacture carbon fibre parts for this application but step-by-step we are supplying material that can be loaded with carbon fibre.”
Expanding solutions into the ecosystem “That’s what we as a company are looking at,” Bredin explained. “The focus we have on very specific applied adoption of our additive manufacturing solution means ‘deep diving’ with some
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key customers such as Boeing and Airbus, who want solutions customers can develop into and that can be expanded into the whole vertical community.” Stratasys’ additive manufatruing solutions for aerospace have to prove the production of parts with repeatable characteristics and consistent quality to ensure they are airworthy, but once the benefits of the technology have been The focus we have on very harnessed, the 3D printing solution specific applied adoption of brings advantages to the supply chain, enabling low-volume, customisable our additive manufacturing production that is lightweight, lower solution means ‘deep diving’ cost and more efficient.
with some key customers who want solutions they can develop into
“There’s a lot of work to be done with key users,” said Bredin. “Helping the industry in developing the right application, the right material, the right software, the right hardware is critical for them to become even more competitive and more advanced. It’s a very conservative business, and at the same time you still need to go through the steps of validation the certification. “You have to provide a confidence level as a manufacturer that you have something solid that has been proven and certified, and you can then build the whole strategy in terms of going to the next step of adoption.”
Putting together the right team Interaction between Stratasys and the aerospace industry has to be holistic and include the whole ecosystem. A relationship with the manufacturer begins with development, through to production and maintenance. “We need to have that focus so we can prove to people in charge of a particular strategic business unit that we have the resources and a good understanding of what we can do with the technology and how to get it done,” Bredin stated.
“It has taken some time to convince people about additive manufacturing, but the good thing about working with a company like Airbus is they can put together the team of people who can understand how they could incorporate a different design, challenge the way you work on a concept and take advantage of additive manufacturing.” When teams like this are put together, it takes up to 18 months for them to gain a full understanding of the technology and its parameters, and consultants and designers are outsourced to bring specialist competencies to help redesign and define what is eligible and what is not eligible for in-flight application. But ultimately it is this expert team that will find the selected parts that bring the return on investment advantage of choosing additive manufacturing technology over conventional manufacturing. “It is a step by step process but of course we have people like Scott (Scott Sevcik, Stratasys Head of Aerospace, Defense and Automotive Solutions) who are bringing a different level of expertise when you discuss and engage with the user. We need to bring people who have a holistic understanding of what is required. It’s not just taking a file, which has been designed using a conventional method, sending it to a printer, and printing it. That’s too simple and that’s not reality. You need to have a good understanding of what can be done differently, and unless we have the technical consultant it’s difficult to articulate to him what the additive manufacturing technology could do differently for them.” This conversation with the manufacturer always begins with setting out Stratasys’ four pillars of service, software, materials and hardware, and the Stratasys Fortus 900mc Aircraft Interiors Certification Solution provides an extra layer of confidence for the aerospace industry. “This is where we have an important play as a company,” Bredin said. “We know additive manufacturing solutions and we have the expertise to go deep into these vertical understandings of customer requirements, whether healthcare, automotive, aerospace or anything else.”
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www.stratasys.com
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ADDITIVE MANUFACTURING
Artec makes Europac 3D Gold Standard partner to resell scanners Europac 3D, a scanning specialist in the North-West of England, has received Gold Partner Status for ‘exceptional product knowledge’ with US scanner maker Artec 3D. Artec will supply Europac 3D with its Artec Leo, the fastest professional 3D scanner available.
Andaltec makes torso replica to aid child’s tumour surgery Andaltec, the Spanish 3D Technological Centre for Plastics, has designed and printed an exact replica of a young patient’s chest, to allow a surgeon to prepare a less invasive and more effective surgery to remove a tumour near her heart.
John Beckett, Managing Director of Europac, said: “Artec have put us through our paces to gain this accreditation and we are delighted that our hard work has paid off and we have now achieved ‘Gold Standard Partner’ status.
The chest was scanned by ultrasound to make a 3D model and print a complete piece replicating exactly the patient’s ribs, heart and tumour.
"We are now officially a trusted reseller of Artec products and customers can be rest assured that with our exceptional knowledge of not only the products such as the Leo scanner, but the company too that we can provide them with in depth information and advice on which products are best suited to their applications."
Miguel Ángel Jiménez, Head of Andaltec’s Prototype Department, said: “Once manufactured, the model was sent to the medical team to carry out a real-scale planning of this delicate operation, which comprised entering through the girl’s ribs to remove the tumour.”
www.artec3d.com
www.andaltec.org
One small step for 3D printing, one giant leap for adidas Global sportswear brand adidas is taking its Futurecraft 4D trainers with 3D-printed midsole - to the mainstream market. Sportswear giant adidas has unveiled its much-anticipated Futurecraft 4D shoe, which features a 3D-printed midsole manufactured using Carbon’s Digital Light Synthesis technology. The trainer was first previewed in 2017 and is now hitting the shops, becoming available to Sneakersnstuff, Packer and KITH in New York City, while adidas’ Executive Board Member, Global Brands Eric Liedtke hits Silicon Valley, joining the Carbon Board of Directors. “I am excited and honoured to join the Carbon Board,” said Liedtke. “The unparalleled work we’ve done together to make Futurecraft 4D a reality is a proven example of the vital role digital 3D manufacturing can play in opening up endless opportunities and creativity in the future.” The Futurecraft 4D midsole material is a blend of UV-curable resin and polyurethane, a stiff elastomer that can be additive manufactured into a lattice structure to create a high-performance midsole that offers durability while being aesthetically pleasing. The development of the Futurecraft 4D has been on-going for two years, with adidas targeting 100,000 pairs delivered by the end of 2018. In order to meet this, the highest volume production application for 3D manufacturing to date, the shoe harnesses Carbon’s rapid 3D printing technology and programmable resins to deliver an insole built on a library of running data. www.carbon3d.com
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COMPOSITES
The rise of the composites Composite materials are on the rise with the overall market growing at a rate of 100 per cent per annum. With more and more manufacturers becoming aware of the innovative solutions composites have to offer, including decking and fencing companies, the appetite for composite products is growing. WORDS | Charles Taylor, Sales Director of Wood Plastic Specialists, Composite Prime
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omposite materials are the ideal solution for a number of projects where a durable, low maintenance product is required. Being lightweight, as well as strong, is a key feature of a quality composite material – ideal for when a robust, yet easy-to-handle product is required, such as an external door or fencing solution. The strength of wood plastic composites comes from the plastic content; HDPE (high density Polyethylene) is often chosen for its superior toughness. The molecular structure of HDPE allows it to have a much higher tensile strength, while maintaining its flexibility. These benefits have ensured composites have flourished, particularly within the gardening sector. From summerhouses and cladding, to decking and fencing, wood plastic composites are becoming the go-to option. Not only are they durable, they are often splinter-free, slip resistant and low maintenance. Compared to alternative options on the market, such as timber, the benefits of wood plastic composites heavily outweigh those that hardwood has to offer. Once combined with a recycled reinforcing plastic, the humble hardwood can be transformed
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Taking Composite Prime as an example, there is the equivalent of more than 3,000 recycled plastic bottle caps per square metre of decking, combined with wood flour that is FSC 100 per cent certified timber from responsible sources. This shows a commitment to sustainability and sourcing materials that are environmentally friendly; a pledge all manufacturers and suppliers should make to the industry to ensure the forest sector is protected. At a time where plastics are under huge scrutiny, the rise of composites could provide a much-needed lifeline for the industry.
into the perfect outdoor material. Timber decking on the other hand, can often be difficult to maintain and requires a lot of upkeep. Along with this, it’s prone to rotting, warping and splitting, which are difficult issues to resolve and often result in having to completely replace the deck. If you opt for a composite solution, it’s considerably more durable and lowmaintenance. So, after taking the garden sector by storm, what’s next for composite materials?
Other industries such as dental, automotive and construction, all use composites on a daily basis. Alongside this, they’re making waves within the building and manufacturing industries. As quality wood plastic composites use recycled HDPE they also satisfy the green credentials that a number of architects and specifiers look for when identifying building materials that adhere to the BREEAM assessment used by The Green Guide. The guide offers designers and specifiers advice on how to make the best environmental choices when selecting construction materials.
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www.composite-prime.com
Charles Taylor is the sales director of Composite Prime and established the company in 2014 alongside director, Domenic Harrison. Combining their expertise in the timber and polymer plastic industries the company creates innovative products for the decking and fencing markets.
COMPOSITES
TeXtreme enters aeronautics project with SAAB Leader in composites technology TeXtreme has entered into a project with SAAB to increase its understanding of the integrity of complex composite structures in aeronautics. TeXtreme is embarking on a fouryear project to explore the thin-ply effect on bolted multi-material joints with a focus on bearing strength with Swedish aerospace and defence company Saab.
composite structures. The methods should be applied in a timely and cost-effective manner in industrial applications. Development of further reinforcement methods for bolt joints is also included.
The project focus is to increase the understanding of the impact of material behaviour on structural integrity of complex metal composite structures within aeronautics. The goal is to develop reliable and accurate methods and models that can simulate the mechanical behaviour of bolted
TeXtreme revealed that the project's aims are to compile an analytical methodology for confidential and cost-effective certification of both civil and military hybridbolted aircraft structures. Furthermore, the project is expected to contribute to the development of sustainable and environmentally
friendly design solutions with efficient material utilisation. To begin with, the team will begin to identify structural mechanical phenomena and conditions relevant to a large-scale industrial application. These phenomena will then be studied and modelled at detail later on where improved
design solutions and methods are developed and returned to the industrial application. Current analytical and experimental methods will form the basis for the development of the improved methods. www.textreme.com
KraussMaffei appoints Philip Zimmermann new Head of BU Composites/Surfaces for Reaction Process Machinery All change at KraussMaffei as the plastics technology giant appoints a new Head of BU Composites/Surfaces for Reaction Process Machinery to further composites' suitability for series production. On New Year's Day, Phillip Zimmermann became KraussMaffei's new Head of the Composites/Surfaces Business Unit for Reaction Process Machinery, taking over from Erich Fries. Zimmermann, who studied mechanical engineering at the Technical University of Ingolstadt, has been employed in the Reaction Process Machinery division at KraussMaffei since 2012. In his new position as Composites/Surfaces BU Manager for Reaction Process Machinery at KraussMaffei, Zimmermann will be further establishing composite technologies' suitability for series production â&#x20AC;&#x201C; like the T-RTM process or Wetmolding â&#x20AC;&#x201C; and the implementation of cost-effective surface technologies. "We are delighted to have acquired the services of Phillipp Zimmermann, an international experienced composites expert from our own ranks, for the post of Manager of the Composites/Surfaces Business Unit," said Nicolas Beyl, President of the Reaction Process Machinery segment at the KraussMaffei Group and Managing Director of KraussMaffei Technologies. "Due to his outstanding personal and technical skills, he will help to strengthen and expand this important business unit for Reaction Process Machinery at KraussMaffei." "We thank Erich Fries for setting up the Composites/Surfaces Business Unit in the last five years and thus establishing Reaction Process Machinery at KraussMaffei as a leading provider in fiber composites and surface technologies." www.kraussmaffeigroup.com
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COMPOSITES
Stork IMM appoints Chudleigh Sutch Asia-Pacific distributor Stork Injection Moulding Machines (Stork IMM) has appointed Chudleigh Sutch as its exclusive distributor in Asia Pacific. Based in the Netherlands, Stork specialises in high-speed injection moulding machines. “In 2018 Stork will celebrate its 50th anniversary, and by partnering with Chudleigh Sutch we see this as the perfect springboard to expand and grow our presence in the important Asia Pacific region,” said Erik de Graaff, Director Sales and Marketing for Stork IMM. “With their deep industry knowledge and experience in the market, coupled with Stork’s unique range of high-performance machines, we are excited about the prospects for growth in the coming years.”
Hennecke introduces COLOURLINE with MULTICONNECT technology
www.storkimm.com www.chudleighsutch.com
With the new COLOURLINE MULTI-CONNECT Hennecke introduces a machine system that takes surface finishing to a new level. Based on CLEARMELT technology users can now process even abrasive colour systems with no problems. The intelligent MULTI- CONNECT plug-and-play system allows fast and clean colour changing and thanks to the consistent modular system structure, users also benefit from a production capacity that can be expanded virtually without limit. The COLOURLINE with MULTI-CONNECT technology is now opening up new horizons for the automotive industry and consumer goods industry. www.hennecke.com
New Manager for ENGEL ITALIA ENGEL has appointed Dr Matteo Terragni to take over its management of the sales and service subsidiary ENGEL ITALIA. “We are very happy at being able to organise the change in management with a long-term view, thus ensuring a high degree of continuity for our customers,” said Dr Christoph Steger, CSO of the ENGEL Group. “With Dr Matteo Terragni, we have gained a very experienced injection moulding expert, who has already done a lot of work with ENGEL. We know each other well, which will contribute to a smooth transition for our customers as well as the ENGEL ITALIA team.” Today, ENGEL ITALIA has more than 30 employees and is supporting in excess of 1,000 active customers. www.engelglobal.com
Arburg Tech on Tour Arburg is hosting 15 exclusive events for its customers in its Technology on Tour road show. The German injection moulding giant’s first stop was Heilbronn in September 2017, and the final event will take place in Munich in July 2018. True to the company’s “Wir sind da.” brand promise, Arburg seeks proximity to its customers and personal dialogue, despite the general trend towards digital communication. The Technology on Tour agenda includes a presentation on Industry 4.0, which examines the digitalisation of production and innovative solutions. Among other items, it outlines new possibilities for added value by means of efficient production of small-volume batches and customer-specific one-off parts, requirements concerning the smart machine, smart production and smart services in the smart factory, as well as the analysis of the gathered complex data and functions of assistance systems. www.arburg.com
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Netstal adds power outage manager module for PET-LINE Moulding machinery maker Netstal is offering a 'Controlled Production shutdown during Power outage' option for PET-LINEs. The CPP option was developed for challenging industrial
environments
with
unreliable power supply. Stefan
Kleinfeld,
Product
and
Application Manager at Netstal, said: "Our new solution increases the robustness of the PET-LINE system during brief power outages and reliably prevents the occurrence of short shots." In the case of momentary power failures, the system will provide enough power to continue operation of the current cycle. If the outage lasts longer, then sufficient power is provided to reliably and controllably shut down the cycle. Preforms are fully injected and demoulded, meaning short shots do not arise. Meterage for the next shot is stopped and the entire system is controllably brought to a halt. Kleinfeld said: "All axes are returned securely to their end position. As soon as the power returns, production can be simply started up again. The new CPP option is an addition that is particularly cost-effective in harsh industrial environments. Even brief power failures or fluctuations in the grid lasting milliseconds can represent a considerable cost risk for manufacturers." CPP is now available as a sales option for all new Netstal PET-LINE systems.
www.netstal.com
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industry 4.0 From automation and smarter machines, to predictive maintenance and increased efficiencies, NPE2018: The Plastics Show covers everything driving Industry 4.0â&#x20AC;&#x201D;bringing together all of the machines, technology, products and solutions advancing plastics manufacturing today. Make plans to attend and discover new ways to maximize your operations and achieve success.
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CHINAPLAS 2018 new Young Tech Hall offers instant access to freshest tech As CHINAPLAS 2018 is set to be ever more vast than previous outings, the new Young Tech Hall will give up-and-coming enterprises and technologies a platform to help them stand out from the old school. WORDS | John Carlon
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HINAPLAS is evolving in response to the needs of industry, by launching a ‘Young Tech Hall’ for the 2018 outing at the National Exhibition and Convention Centre (NECC), in Hongqiao, Shanghai.
The Young Tech Hall is a comprehensive exhibition hall, which will gather together new exhibitors from diverse fields. CHINAPLAS is set to achieve a massive show scale this year, with 340,000 m sq of exhibition area, though its scale could be a double-edged sword – as it takes a longer time for visitors to search for specific types of products in mind, especially from new exhibitors.
Strategic platform
New theme zones
The show has formed the Young Tech Hall as its solution. Ada Leung, General Manager of Adsale Exhibitions, explained: “The Young Tech Hall is introduced to help visitors locate exhibitors and products by further segmentation. It’s a win-win solution. New Chinaplas exhibitors can seize the opportunity to strategically market their brands and new products to Shanghai, while Chinaplas itself can draw in new blood, fresh energy, and more advanced technologies.”
On top of the Young Tech Hall, the mega show has been divided into 18 different theme zones to facilitate successful sourcing of buyers. The ‘3D Technology Zone’ and ‘Thermoplastic Elastomers and Rubber Zone’ are two new theme zones to debut at CHINAPLAS 2018.
The Young Tech Hall, which will house over 350 new exhibitors in an exhibition area of 20,000 m sq is a comprehensive exhibition hall. The new hall will present additives, colour pigments and masterbatch, testing equipment, die and moulds, extrusion machinery, injection moulding machinery, smart manufacturing technology, plastic packaging and film technology. Henan Yinjinda New Materials will launch laser low temperature shrink film for glass bottles at CHINAPLAS 2018, the first display of this film technology in Asia. The product is laser anti-counterfeiting and it can cover containers. It is flexible when printing on metallic products compared to product of the same kind, reducing customisation cost. It is half the price of dry washable label.
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Customisation and small-batch production are gaining momentum nowadays. High-end manufacturing, like aerospace, automotive, medical and consumer products, is in urgent need for 3D printing (additive manufacturing) solutions to expedite development cycle and reduce R&D costs. CHINAPLAS will set up a “3D Technology Zone” to group together the vendors and providers of 3D printing technologies. Confirmed exhibitors include Autodesk, ZWCAD, Hong Cheng, Hanbang 3D, dMac and more. More 3D printing solutions can be found in other theme zones. Some of the advances exhibits that will be displayed are highlighted below. Guangdong Hanbang 3D Tech brings HP Jet Fusion 3D Printing Solution to CHINAPLAS 2018. The solution reinvents how we prototype and produce functional parts, delivering quality output up to 10 times faster at half the cost. Clariant will make a global launch for Exolit flame retardant Polyamide 6 3D printer filaments at CHINAPLAS 2018. It is made of premium grade Polyamide 6 with good fluidity and blended with Exolit OP 1230 to achieve UL V-0 level flame retardancy.
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Low-carbon economy With the advent of a low-carbon economy, light, energy-saving thermoplastic elastomers with a wide range of applications have a promising prospect. Thermoplastic Elastomers and Rubber Zone, a new theme zone to the Chemicals and Raw Materials Zone, will gather about 50 suppliers to demonstrate their latest products and solutions. Confirmed exhibitors include Huntsman, Momentive, SIBUR, Top Polymer, Dawn, Huafon, Shin-Etsu, CPMC, Chinasound, KRAIBURG, Kraton, MIRACLL, LCY CHEMICAL, COIM and others. CHINAPLAS 2018 is going to be an arena of innovations, covering Asian and world premieres of new technologies. A myriad of other new products is also going to be found in the Asia’s premier and the world’s sophomore plastics and rubber trade fair. CHINAPLAS 2018 will be relocated to the NECC in Hongqiao, Shanghai, PR China, and run from April 24-27, 2018. For walk-in visitors, 50 Yuan and 80 Yuan will be charged for a one-day pass and a four-day pass respectively. Visitors who pre-registered before February 11th, 2018, can enjoy admission discount at 50 Yuan for a four-day pass. They can receive a visitor badge in advance to enjoy express entry on-site.
Colloids Colloids is once again exhibiting at Chinaplas to promote its extensive range of high quality black, white and coloured speciality masterbatches, compounds and additives, including electrically conductive, engineering polymers and environmentally friendly, sustainable product grades. All Colloids products aim to provide both added value processing benefits, such as higher throughput rates, as well as improve the quality and functional performance of finished products, such as anti-static, heat and chemical resistance. This year, the Colloids stand will be focusing on key industrial markets and applications, such as automotive, electrical & electronics (E & E) and high pressure plastic pipes for gas and water utilities. In particular, the stand will be showcasing a new range of specialty coloured and black masterbatches being launched at Chinaplas 2018.
8.2 E75
www.colloids.com
www.chinaplasonline.com
The HP Jet Fusion 3D Printing Solution reinvents how we prototype and produce functional parts.
Brückner Maschinenbau German film stretching line market leader Brückner Maschinenbau will present its latest concepts for the production of added-value plastics films. For any kind of oriented film development, it is essential to perform all trials on completely reliable and accurate lab-stretching equipment. With more than 40 installed units, Brückner’s KARO IV has set a worldwide standard as the laboratory stretching machine. The new KARO 5.0 generation comes with a series of extended features which will be introduced for the first time at Chinaplas. Brückner is also introducing the A 5.5 m line concept – the most powerful and efficient battery separator film technology on the market - and the unique LISIM simultaneous process – applied to wet battery separator film production for the very first time.
2L 91
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www.brueckner-maschinenbau.com
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JEC WORLD PREVIEW
JEC World 2018:
Composites in the French Capital JEC World 2018 takes place in March in Paris, and it is innovation that is driving the growth of this exciting composites technology event.
L
eading composite technology exhibition JEC World 2018 will be taking place at the Paris Nord Villepinte Exhibition Centre from March 6th-8th, bringing a world of composites and innovation together.
will focus on the topics of Biocomposites, Recyclability, Sustainability and 'Make It Real', which focuses on solutions to societal concerns.
JEC World 2018 follows on from a successful outing in 2017, which smashed previous records. Over the three-day event, the show welcomed 40,607 visitors - a ten per cent increase in professional visitors year-on-year - as well as a 78 per cent increase in international visitors from 113 countries. The exhibition floor features numerous international pavilions, while the scope of companies exhibiting represents every region of France.
Winning strategy
Spotlighting trends and innovation One of the reasons why JEC World continues to gather momentum is because the event is constantly reinventing itself and adapting to modern trends - much in the same way composite technologies are evolving into new applications every week. The JEC Awards will shine the spotlight on the 30 biggest innovations in composites, driving the technology and numerous industries forward. Three days of conferences and technical presentations aim to enrich delegates' experiences and understanding of composites in a contemporary manufacturing industry. Moreover, the Startup Booster brings the biggest startup competition in composites to the show, shining a light on new talent and innovation. The biggest trends affecting the composites sector are to be presented as Planets, where OEMs and suppliers come to see the newest trends facing the industry. In 2018, these planets
"Each year, new products and services are offered to Exhibitors and visitors," said Anne-Manuèle Hébert, Show Director of JEC World and European Show. "For instance, in 2017, the Startup Booster competition, the new planets, the electronic devices and the giant LED screen on the VIP Club, are some of our novelties and improvements that refined customer experience.” Frédérique Mutel, JEC Group President & CEO, added: "JEC Group’s strategy towards end-users is a winning one as we welcomed more architects, creators, developers, designers, style engineers and trendsetters. We are very happy with the participation and the enthusiasm the composites professionals expressed. We are grateful and are committed to go further. "We strongly believe in collective intelligence and all our operations aim at involving the Golden Triangle: industry, research and economic authorities such as regional or national entities. It is certainly part of our success, both for JEC Group and here for JEC World." www.jeccomposites.com/events/jec-world-2018
JEC
Paris, World 20 March 1 Paris 6-8, 2 8 Nord V illepin 018 te Exh i
bition Centr e.
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EUREKA SERIES
Race to recycled plastic fashion The fashion and sportswear industries are leading the way when it comes to utilising recycled plastic materials in new collections. H&M and GRN are just two retailers that are trying to make a difference. Words | Rose Brooke
S
ustainable and fair-trade fashion is a growing part of the clothing market and the mechanical properties of recycled polyester and elastane are ideal for performance activewear, as global retailer H&M has proved.
and swimming clothing to reduce its carbon footprint and prevent plastic materials from being wasted at end of life. Co-founder of GRN Pete Lillie was quoted by Climate Action as saying: “We decided to offer ... sports clothing that was technically advanced and ethically sourced. Our initial offering was a cycling jersey made from 100 per cent recycled plastic bottles and a range of bamboo t-shirts.”
The Sweden-headquartered high street mainstay launched its latest sportswear collection made with sustainable materials in January 2018, with each piece of clothing in the portfolio consisting of predominantly recycled elastane and polyester, offering the wearer comfort thanks to the garments’ quick-dry technology, ventilation and innovative Blending function with ‘seamless’ knitting. sustainable thinking The collection is targeted at women and includes hoodies, tops, leggings and sports bras for training, running and yoga.
and fashion in this way is the way forward
“By bringing together the functional and feminine, the aim is to give customers a stylish, conscious sports collection,” said Petra Smeds, Head Designer of Sportswear at H&M. “Blending function with sustainable thinking and fashion in this way is the way forward.”
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GRN is not ignorant to the side issue of microfibre pollution caused by microscopic fibres of synthetic fabrics breaking away from the yarn and being ingested by marine animals, and the company has stated that it is investing in research for synthetic yarns that are less prone to shedding.
“We’re part of a growing number of innovative companies trying to tackle this issue head on but it’s going to be some time before any company is truly able to say ‘our clothing has no impact on the environment’,” said GRN CEO Rob Webbon.
H&M is a retailer that stands by its sustainability pledge, with the brand aiming to become completely circular by 2030, but it isn’t the only fashion retailer exploring recycled plastics materials for activewear.
Until then, the retailer advises to buy well and buy once, as cheaper synthetic materials are more prone to shedding than higher quality materials, to wash sportswear at a lower temperature in a laundry bag and only if it really needs to be cleaned, and to patch and mend activewear rather than throwing it away.
GRN Sportswear, which is based in Bristol in the UK, is reprocessing plastic bottles and abandoned fishing nets for its cycling, triathlon
about.hm.com/en/sustainability.html www.grnsportswear.com
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