April 2013
Clear your desk today, call Jan Wynne Jones on 01244 680222 or email janette.wynnejones@rapidnews.com
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editorial editor david gray david.g@rapidnews.com
in this issue
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MACHINERY
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REGULARS: Latest news
SHOWCASE: MOULDS & TOOLING SPOTLIGHT: BLOW MOULDING
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CLASSIFIEDS
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ISSN No - 2052-3912 APRIL 2013 • WWW.EPPM.COM • 3
4 • WWW.EPPM.COM • APRIL 2013
John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience
Clive Maier, Owner and Director, Econology Ltd.
Nigel Brown, Founding MD, Frontier Aerospace
Dr Martin Kay, Chief Consultant, Pira International
Vicki Sayer, Regulatory Manager, Colormatrix
Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre
Pipe Extrusion Recycling Micro Manufacturing Home Appliances
Automotives & Compounds
Mark Bonifacio, President, Bonifacio Consulting Services
Andy Bone, Sales Director, Formaplex
Andrew Smith, Head of Manufacturing, Numatic International
Wire & Cable
Aerospace Biopolymers
Alex Collins, Director, Vannplastics Ltd.
Regulation & Compliance
Andrew McArthur, Engineering Manager, IKO
Jonathon Short, MD, ECO Plastics Ltd.
Jon Herbert, Director, FS Cables
Biopolymers/Materials Science
Simon Chidgey, Director, M&H Plastics
General Industry Insight
Paul Maley, Senior Mechanical Engineer, Selex Elsag
James Goddard, Honorary Lifetime Member, Plastics Pipe Institute
Dr Terence A. Cooper, CEO, ARGO Group International
Ken Braney, 2010-2011 President, Society of Plastics Engineers
Advisor for the German & Scandinavian Speaking Countries
Film & Sheet Extrusion Recycling
Martin Marron, MD, Biffa Polymers
Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb
Education in the UK & Ireland
Construction
Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre
Medical
Barry Assheton, Sales Director, CRDM
Mould Making
John Bunker, Member, Worshipful Company of Horners
Packaging
Omer Kutluoglu, CEO, 2K Manufacturing
Medical
Rapid Prototyping
Blow Moulding
Recycling
Injection Moulding
David Gray, Editor
John Sturgess, Director, MG Stuma
Andrew Feilden, Principle Consultant, Smithers Rapra
Wood Plastic Composites
I try to keep these letters closely related to important developments for the sector. Once in a while though, we do like to blow our own trumpet here at EPPM. In our fifteenth year we are re-launching EPPM.com - one of Google’s highest ranking resources of product and company information for suppliers and processors everywhere. By the time this issue hits your desk, the new website should be live! So what’s new with the ‘new site’? I can promise you it’s a lot more than a facelift. For the first time, we’ve portioned the news into the relevant sections (mirroring the structure of the print magazine) to allow for easier, faster browsing of the specific areas that are important to you. Full of new features, useful buying guides, materials prices, market reports and breaking news, we’ve worked harder than ever to make EPPM.com as powerful a tool as it can be (I did say we’d be blowing our own trumpet!). In online journalism, we’re always told by peers and publishers that content is key. So to offer an alternative angle on our content, we’re also incorporating blogs, properly, for the first time. The new blogs will feature exclusive, informal outlooks on changes in the sector as and when they happen. And here’s your chance to get involved - the comments boxes underneath each blog post are intended for you, the reader, to join the debate. If you’re the type of reader who would love to challenge or explore the views expressed in EPPM, now is your chance! The blogs will be hosted by a range of peers and guest authors, so there will always be something relevant and thought-provoking. In particular for 2013, we are looking forward to receiving a mini-series of guest slots from members of the K 2013 team, giving you an exclusive behind-thescenes look at what’s new for the show this year. One of our most popular resources from the old site the directory - has also undergone radical improvement. Plastrep.com is a new dedicated website purely for the sourcing of your local supplier of machinery, equipment and processing materials. With this new brand we hope to be able to provide key market data to assist with your purchasing decisions. I hope you enjoy the new site; considerable efforts from the entire team at EPPM have gone into making it as useful as possible for you, the reader. Next issue I promise I will turn the spotlight back on the industry!
Plastics for the Environment
Something new for our 15th year
General Industry Insight
“
from the editor
Our Editorial Advisory Board is comprised of a cross-section of the plastics industry, including processors, consultants, technicians and key industry figures.
Dr Gerd Schmaucks, Independent Consultant
cover story
MEUSBURGER: The one-stop-shop for tools and moulds Meusburger, the leading manufacturer of standard parts, launches a groundbreaking new product line: its own change moulds. What's so special about these moulds is that in this case the product developers have accomplished the mighty task of combining the advantages of a change mould with the stability of a standard mould. Change moulds are the perfect solution for the quick and cost saving realisation of prototypes or small series. With the help of positioning wedges the inserts can be replaced very quickly but still in a highly precise manner, with repeat accuracy. Of course, insert changing is also possible with the mould being on the injection moulding machine. The considerable time savings that can be achieved when it comes to refitting result in a great benefit for the customers. Meusburger's change moulds are supplied as modular assembly systems, currently available for three different mould sizes, with three suitable insert strengths respectively. The mould inserts, which are ground and equipped with mounting holes and therefore ready-to-use, are immediately available ex stock in material grades 1.2311 (prehardened steel), 1.2714 HH (43 HRC) and 3.4365 (high-strength aluminium). Alternatively, inserts with machining allowance are available in several hardenable steel
The air-cushioned assembly table by Meusburger offers advantages for tool and mould makers.
The Meusburger change moulds helps to save time and costs
grades. The closed mould frame could also be made of 1.2085 or 1.2312 steel, guaranteeing a very strong mould, whereas similar systems already available on the market show weak points regarding strength. The ejector set is connected with the insert on the moving half thanks to the guiding system. The sophisticated positioning of the guide parts allows maximum space usage. Additionally, the mould frame comes with an anti-misapply protection feature for the mould inserts; cooling holes with O-ring seal recesses and M10x1 threads for the fittings of the temperature regulating system are also included. Furthermore, Meusburger now offers an ejector set coupling that perfectly fits the new change moulds and that enables significant time savings when preparing the injection moulding machine; that again minimizes machine down time. In contrast to other products that only operate hydraulically or pneumatically, this coupling operates fully manually. Another huge advantage is that it can be handled without the need for any tools. Also, the ejector set coupling may be applied independently from the change moulds as well. In other product news, air-cushioned assembly table from Meusburger facilitates operations in repair and assembly work on injection moulding, die casting and punching tools. Last year, the specially designed table was upgraded and CE certified. Using
many air nozzles, an air cushion is created on the underside of the moveable plate supports. This enables light and easy movement of mould halves. Both mould halves are freely accessible without having to reposition or turn them around, enabling efficient operating. Due to its sturdy design, the table will withstand even strong impacts and loads of up to 3,000 kg. In addition, this in-house development provides greater safety for workers and protects valuable tools from damage. As a result, time and costs can be saved throughout the whole production process. The Meusburger assembly table is available in small size (496 x 1156 mm) and in large size (796 x 1496 mm). Since March 2013, this innovation is available with a larger table surface providing twice as much space for moving the mould halves. The air-cushioned assembly table H 4062 is supplied in a complete set including a stand, a tool cabinet and a range of accessories.
Meusburger Tel: +43 5574 67060 Email: sales@meusburger.com Web: www.meusburger.com
APRIL 2013 • WWW.EPPM.COM • 5
MACHINERY
Thermoforming more productive with updated machine range The third generation RDM-K automatic roll-fed thermoforming machines from Illig, a specialist in the field, are designed for the high-volume production of cups in diverse shapes and sizes from thermoplastic material stock. RDK series machines also rely on roll-fed material but produce bowls, trays and hinged packs used, for example, to preserve food in transport and on supermarket display shelves. At Chinaplas, an RDM 70K with a 680 x 300 mm² forming surface will be shown making APET cups at a rate of almost 45,000 per hour using an 18-cavity mould. APET will also be the material processed by an RDK 80 IC (forming surface 756 x 565 mm²) in making trays in a 10-cavity mould at 50 cycles per minute. The “IC” suffix denotes machines featuring the new “Illig Intelligent Control Concept”. This control system has been designed to help the operator to make full use of the servomotor-driven thermoforming units. With the development of its RDM-K
machines, Illig says it has driven up productivity while reducing costs and further boosting the quality of the thermoformed parts. The use of servomotors for all machine motions raises the speed of each function, subject to a velocity profile adapted to the given process stage. At the same time, the third generation RDM-K automatic thermoformers need less forming air – compared with their predecessor, air demand is reduced by up to 50%. This results in a more dynamic forming air build-up. The user should benefit from faster moulding and a closer reproduction of cavity contours. Productivity could potentially be boosted by 30% and over, with a simultaneous increase in quality and substantial energy savings, claims the group. The precision and repeatability of the RDM-K automatic pressure forming machines is said to be noticeable from start-up. The RDK machine’s productivity (up to 55 cycles/minute) delivered through consistently servomotor-driven and processcontrolled operating sequences, is supported by the new IC (Illig Intelligent Control Concept) control technology. This operating system
comprises mutually compatible control modules, thus making the machine simpler to operate, accelerating start-up of new moulds, eliminating ambient influences through appropriate process control, and boosting process stability and process quality. One such module is ThermoLineControl, a feature that enables machine components on the production line to be centrally accessed and programmed at the forming station. The module also provides structured help functions for optimising processes and reducing setup times. One newly added capability is referred to by Illig as “dynamic process optimisation”. The operator, claims the group, no longer requires an “expert understanding” of interdependences between operating parameters – these are computed automaticallly for each station on the line. When settings are changed, the cycle rate is re-calculated and adapted immediately.
For enhanced process stability, a compensation control system now adjusts for the effects of changing ambient conditions during the production run. Until now, the inevitable heat-up of the machine frame in the course of thermoforming operations would lead to temperature irregularities (temperature drift) in the material web. Another new module, called sas-up (selfadaptive start-up), provides a start-up mode with a lower cycle rate and process-optimised settings, thus reducing material consumption in the start-up phase when a new mould is put into service. The intelligent control (IC) concept is rounded out by its ability to integrate the production line into Illig's NetService – with the benefit of providing an Internet-based review of all line components, fault diagnosis, and fast troubleshooting where problems are due to machine settings. Illig Web: www.illig.de
New system for high-volume plasma coating of automotive PC glazing components SABIC Innovative Plastics has partnered with Ulvac Inc, a leader in massproduction vacuum technologies, to launch a new system called ‘Ulglaze’ for high-volume production of plasmacoated polycarbonate (PC) components for automotive glazing applications. The Ulglaze machine has been developed as part of a two–year collaboration between SABIC and Ulvac. Optimised for SABIC’s Lexan resin and Exatec plasma coatings, the process is said to enable automotive OEMs and tiers to mass produce lightweight, durable and aerodynamic glazing components – like rear quarter and side windows, backlight windows, rear spoilers and sunroofs – that deliver performance and aesthetics over the life of the vehicle. SABIC states the availability of this technology marks a significant milestone in enabling automakers to take full advantage of PC glazing to create lighter vehicles for improved fuel 6 • WWW.EPPM.COM • APRIL 2013
efficiency and performance. “Ulvac studied Exatec plasma coating technology and found that it offered significant advantages in the processing time and performance it gave us,” said Hisaharu Obinata, Chief Executive Officer, Ulvac. “In fact, we found that the Exatec plasma coating process is at least 30 times faster than other plasma coating technologies used for PC glazing. We then validated the process and plasma coating through the creation of the Ulglaze machine. SABIC’s coating technology, together with Ulvac’s extensive experience in developing automotive equipment for a broad range of applications enabled our team to develop a system that promotes high productivity and reliability.” “With the availability of this highvolume coating technology, PC glazing is now ready to play a much larger role in automotive design and make a greater contribution to improved fuel
economy, reduced emissions and increased vehicle range,” said Amanda Roble, Lead Executive, SABIC’s automotive PC glazing unit. “With this machinery, automakers can take full advantage of PC glazing technology and integrate it into their vehicles. To help accelerate this momentum, SABIC and Ulvac will continue to collaborate and invest in R&D to further improve the machinery and process technology to produce plasma-coated Lexan resin parts for vehicle windows.” In addition to automotive glazing, the Ulglaze system is said to be a candidate for use in consumer electronics display applications (touchscreens, monitors)
The Ulglaze Machine, Developed as Part of a two-year collaboration between SABIC and Ulvac and electrical components, semiconductors and solar cells. SABIC Web: www.sabic.com
MACHINERY ROUNDUP Vacuum resin dryer offers simple operation and low costs A resin dryer, which is claimed to feature a new design may advance the concept of vacuum drying, making operation simpler and more reliable than with previous vacuum systems, according to its manufacturer Maguire Products, Inc. The new Maguire VBD Vacuum Dryer now incorporates the use of gravity to move material through vertically arranged stages of the drying process, with the discharge of material from one stage to the next, controlled by slidegate valves. This eliminates most moving parts, in particular the three-station indexing carousel mechanism of the Maguire LPD vacuum dryer introduced in 2000. It also removes sealing gaskets, which can be worn and compromised by resin dust, and with perforated screens, which require cleaning. “The VBD Vacuum Dryer provides
trouble-free, low-maintenance service, along with the same operator-friendly software and controller used with great success on the LPD dryer, and with the same five-year warranty,” said B. Smith, Marketing and Sales. “The savings in energy and startup time in comparison with conventional desiccant systems enable the processor who switches to the new VBD dryer to pay back his investment in a matter of months.” The first model in the new-generation system is the VBD-1000 Vacuum Dryer, with a throughput capability of up to 455kg per hour. The unit is 4.9m tall and has a footprint of 2.1m x 1.1m. It can be configured for mounting on the shop
floor or on a mezzanine. A series of smaller VBD dryers, starting with a throughput of 45kg per hour will be introduced in coming months. The cost savings achieved with vacuum drying result from a reduction in energy consumption of more than 60% in comparison with desiccant dryers; elimination of the need to regenerate desiccant; and reduction in startup time as a result of a drying cycle that is only one-sixth as long. In addition, resin is exposed to elevated temperature for as much as 80% less time than with the desiccant dryer, which means less processed-in stress. Vacuum-drying in the new VBD dryer is
a multi-stage, continuous batching operation carried out in three heavily insulated, stainless steel-lined vessels arranged vertically. High-speed slidegate valves for dispensing material from one vessel to another have an accuracy per dispense of +/- 4 grams and are of the same design widely employed in other Maguire equipment. The system uses ambient air that is circulated by a blower whose variable-frequency drive saves energy. Maguire Products Inc. Tel: +1 610 459 4300 Email: info@maguire.com Web: www.maguire.com
Parallel gripper works economically and with versatility Based on customer specifications, automated gripper supplier AGS Automation Greifsysteme Schwope has devised a versatile and cost-effective solution which is now offered as standard equipment. In many cases, it replaces the parallel gripper (PAG) and reportedly goes beyond it in terms of function. The user can take the simpler gripping fingers with adapter jaws, screw on the new prismatic bracket and prismatic connector (parallel or angled) – and secure all components to be prismatically clamped. This enables the freedom for individual adaptation and can grip mouldings of all types and sizes, both externally and internally. Furthermore, the PreciGrip component combination offers a high degree of adjustment and adaptation possibilities, and may cut costs by 50%, claims the group. AGS Automation Greifsysteme Schwope GmbH Tel: +49 2204 96810 0 Web: www.ags-automation.de APRIL 2013 • WWW.EPPM.COM • 7
MACHINERY ROUNDUP New static control bar for labelling, packaging and converting
Meech has launched the latest addition to its static control range, the Hyperion 971, which it says is ideal for use in labelling, packaging and converting applications. “The decision to update our range of static elimination equipment is a direct result of customer feedback,” explained Business Unit Director for static control, David Rogers. “We pride ourselves on being flexible and having the capacity to respond rapidly to change.” “A lot of the companies that employ our equipment work in dusty environments. The airborne contaminants build up on ionising bars and cause a drop in performance. The bars need to be designed to minimise the effects of the contamination and to help reduce the amount of cleaning required.” Featuring the existing pulsed DC technology used by the 976 bar, Meech says the 971 has an improved design that is more resilient to the build-up of contamination which naturally occurs during use, and therefore allows for easier cleaning. Like previous designs, the emitters can be removed for offline cleaning or can be replaced individually, without the need to substitute the whole bar. Furthermore, Meech says the Hyperion 971 features an integrated and improved the compressed air-boost system, which permits better long-range performance in particularly difficult applications. Whilst providing very powerful ionisation performance, the 971 static bar is said to have shockless emitters, which make it safe for operators to handle. Available in a choice of lengths of up to 4m, the bar operates up to 15KV as standard and provide long-range ionisation typically from distances of 200 to 1000mm. Meech www.meech.com
Plastic recycler goes greener by swapping to AC drives Maintenance costs have been reduced significantly at a plastic recycling plant by replacing the DC drive on the critically important compounder with a variable speed AC system. The recycling plant, opened in 2004, converts discarded plastic into high density polyethylene (HDPE) pellets, which are used for manufacturing a range of heavy duty products such as civil engineering pipes, marine buoys, equipment for the agricultural and construction sectors and artificial grass. The motor driving the main compounder, like all DC motors, required regular maintenance for brush wear and refurbishment of the armature. This proved to be a major task that was also disruptive to production, so the site engineers decided to explore possibilities for switching to a brushless AC motor and asked Newton Tesla (Electric Drives) for some specialist support. This UK-based company specialises in supplying large drive packages, usually up to 1,000kW and based on an AC motor and inverter to give variable speed capability. Newton Tesla engineers developed a proposal that would provide the necessary low speed torque operating characteristic, while the robust reliability reduced the regular maintenance requirement. “We included a Mitsubishi inverter in the design, as this would contribute to a substantial reduction in power consumption and would further enhance the environmental credentials of the recycling plant,” recalls George Newton, Managing Director of the drives engineering company. “And of course there were significantly reduced energy bills as well as the maintenance savings.” George recalls that traditionally DC solutions were used for low speed applications, such as compounders and extruders, but as inverter technology has developed AC has moved more and more into favour. “The AC drive package we proposed would require no ongoing
maintenance work other than routine bearing lubrication.” George paired a 400kW 6 pole motor with an 866Amp inverter as the core of the drive system, the latter being a 740 series Mitsubishi Electric variable frequency unit. The 740 inverters are often referred to as ‘pump and fan drives’, as this is a major application area for them. However they are equally appropriate for other duties, where their ability to enhance the energy balance of the driven machine can generate energy savings of 60 percent or more according to Mitsubishi. “If there is a volumetric flow involved – of air, gas, liquid or molten plastic – energy savings are proportional to the cube of the difference between operating speed and maximum speed,” George explains. “A compounder or extruder runs way below its maximum speed the vast majority of the time, so to the energy savings are considerable.” Additional savings are made possible by Mitsubishi Electric's innovative OEC (Optimum Excitation Control) technology. This system ensures that the optimum magnetic flux is always applied to the motor, thus reducing losses. The result is maximum utilisation of motor capacity at maximum efficiency. “Energy prices have gone up and up in recent years and are expected to continue to do so. Any plant operator still using DC drives is well-advised to think about swapping to an inverter-fed AC solution,” advises George. “This will produce immediate saving in power bills, reduce maintenance and can be integrated with plant-wide energy management controls systems.” Mitsubishi Electric Web: automation.mitsubishielectric.co.uk
Chiller spreaders boost output for blown film plants Blown film processors can reportedly increase output by as much as 10% to 20% plus reap additional benefits with new PreNip Chiller Spreaders from Pearl Technologies, Inc. Offered to processors who experience blocking or have low ceiling heights, prenip chiller spreaders from Pearl are custom designed to mount at the top of the tent frame. They require only 8” of vertical space on the collapsing frame – in many cases, all that is needed is to remove the top two slats or rollers for installation. Benefits of the pre-nip chiller spreaders include: • Custom designed to fit any line • Improves film quality • Increases output by 10% - 20%, up to 50% for thick film producers • Eliminates film blocking, saves on anti-block additives • Can reduce film temperatures by as much as 50°F • Prevents sag at unwind • Eliminates wrinkles in the nip assembly Pearl engineers design and manufacture consumable parts for converting and extrusion capital equipment with custom made process enhancements. Extrusion 8 • WWW.EPPM.COM • APRIL 2013
Blown film processors can increase output by as much as 10% to 20% plus reap additional benefits with new Pre-Nip Chiller Spreaders from Pearl Technologies, Inc. products are primarily used in the blown film industry to improve film quality at higher outputs, reduce scrap at start-up and reduce maintenance. Pearl Technologies, Inc. Tel: +1 315 365 3742 Email: sales@pearltechinc.com Web: www.pearltechinc.com
MACHINERY ROUNDUP Temp control group adds ‘eco’ credentials to various lines Single Temperiertechnik of Germany has now added an ‘EcoPlus label’ to several products across its range of temperature control units. This development has been achieved using several hydraulic, electric or thermal components for temperature control systems and cooling systems. Plastics processors who are struggling with high energy costs and are interested in minimising the energy consumption of installed ancillary equipment will benefit from new technical improvements which are highlighted by the EcoPlus label, according to Single. Temperature control systems of the N1, NS and S lines are marked with the EcoPlus label due to the use of additional equipment such as Grundfos centrifugal pumps, which replace the standard peripheral impeller pumps. The power efficiency of these centrifugal pumps is increased threefold, the group claimed. As compact units, these pumps consume significantly less energy in standard systems but achieve a comparable flow rate. With their high power efficiency, all motor sizes for Grundfos centrifugal pumps belong to IE3, the highest motor efficiency class. By returning the temperature control media after cycle switch-over, the ATT (Alternating Temperature Technology) recovers the maximum energy content of liquid media. This approach is not possible with cartridge heaters, ceramic elements or induction heating used in combination with water cooling, stated Single. In contrast with ATT, other fluid alternating temperature control systems have either no container or no comparable intelligent media return. Comparative measurements during injection moulding processes have proven the superior energy efficiency of the ATT system time and again, which is now expressed by the EcoPlus label. In cyclical processes such as injection moulding, the EcoTemp passive alternating temperature control interrupts the cooling of the mould during the injection phase, so as to allow the cavity wall to heat up. This presents two major advantages over conventional
temperature control with a constant supply temperature: first, EcoTemp can shorten the cycle time, frequently achieving savings in the double digit percentage range. Many tests conducted by process engineers have proven that higher cavity temperatures during injection moulding followed by a more intense cooling phase saves cycle times. Second, EcoTemp can help reduce the supply temperature during cyclical processes. As these processes often operate with heat even during the cooling phase, a lower supply temperature reduces the amount of heating energy required and is therefore superior to conventional control systems. Evidence for both correlations was gathered and
documented during the injection moulding processes of a renowned supplier to the electronics industry. During these production runs, the energy saved over conventional temperature control systems amounted to 38 %. Therefore, all EcoTemp systems are marked with the EcoPlus label. All Single temperature control and cooling systems with pump speed control have also been awarded the EcoPlus label. Thanks to this feature, the system’s pump speed, i.e. the flow rate, can be limited to the capacity required for the process at hand. The reduction of the energy consumed by the optional pump is disproportionate to the pump speed reduction.
The EcoPlus label marks Single temperature control and cooling systems with highly energy-efficient equipment. Single Temperiertechnik GmbH Tel: +49 7153 3009 0 Email: info@single-temp.de Web: www.single-temp.de
Product launched for static elimination in gravimetric blenders Arrowquint, a UK-based company that specialises in static control solutions, has designed a new product that could help overcome the problems associated with static charge when using materials handling equipment. Gravimetric blenders and hopper loaders often have optical level switches that can become contaminated by dust or fines in the granulated material, which then sticks to the window through static charges. This blocks the window and prevents proper level control, which may result in either an intermittent or a continuous feed into the moulding machine. In order to overcome this, Arrowquint has designed a small flexible electrode which can be readily inserted into a blender or hopper loader to blow low pressure ionised air into the granulate around the level switch, eliminating the static charges and preventing the contamination. Arrowquint Web: www.arrowquint.co.uk APRIL 2013 • WWW.EPPM.COM • 9
MACHINERY ROUNDUP All-electric medical machine on show in Poland Polish representative MuehsamElektromech will be presenting Netstal’s all-electric ELION 1200 for medical applications at the Plastpol fair in Kiev, Poland. The machine is suitable for producing parts intended for cleanroom use in accordance with international guidelines. “The all-electric ELION is ideal for use in cleanrooms. It guarantees the highprecision manufacture of sterile parts in a very clean environment while achieving very short cycle times in compliance with all applicable legal regulations. The customer benefits from excellent mechanical engineering and a highly cost-effective solution thanks to our system and application expertise,” explained Dr. Patrick Blessing, Head of
Business Unit MED. At Plastpol, Netstal will be producing HDPE needle protectors on a ELION 1200-530 with a cycle time of 5.5 seconds. The HDPE material is being provided by Sabic Europe and the 48-cavity mould is coming courtesy of Swiss mouldmaker Kebo. Meanwhile, Italian group Piovan is taking care of raw material supply and cooling equipment. “The ELION features encapsulated and water-cooled electric motors so that virtually emission-free operation is guaranteed. Moreover, the processor benefits from the machine's low energy consumption.” Braking energy is fed back into the electrical circuit to supply additional consumers. Netstal claims that it is possible to save up to 70% of
energy consumption compared to conventional drive systems. “As a result of this saving, our customers can manufacture their products more costeffectively in the long term,” added Blessing.
Reknowned processor adds direct extrusion line for WPC decking
High-value extrusion coating line targets flexible packaging The new dsX flex-pack extrusion coating line from Davis-Standard provides converters and package printers with a high-value, competitively-priced system that will give them distinct advantages when seeking to expand sales in the price-sensitive global flexible packaging market, according to the group. This pre-engineered line can be delivered in as little as six months and provides customers with all the capabilities and flexibility needed to ramp up and compete effectively for a variety of rapidly emerging application opportunities including salted snack and noodle bags, toothpaste tubes, sachet packs, personal care products, condiment packs and stand-up pouches. Bob Florence, Executive Vice President Sales and Marketing of Davis-Standard said, “All of the components of the dsX flex-pack extrusion coating line are based on our proven, feature-rich designs and technology that minimise technical risks and lower cost of ownership. We have included everything our customers will need to achieve their flexible packaging manufacturing objectives, whether they are converters looking to upgrade for higher throughputs and quality; multinational suppliers in search of expansion opportunities; high-quality printers who want to enhance their lamination processes; or start-ups who could benefit from partnering with a company
CASE STUDY:
that can lead them through all the steps that assure extrusion coating success.” Florence continued: “In developing this system, DavisStandard focused on incorporating high-value features that would reduce variability for better end product quality; provide greater uptime and productivity; minimise waste along with operating and maintenance costs; and would be applicable to a wide range of end product applications.” Designed and engineered to provide superior value to comparably priced systems, the dsX flex-pack flexible packaging line includes: flexible packaging unwinder; corona treaters; extrusion laminator; gravure primer coater dryer; pull roll with nip; winder; electrically heated, air-cooled DavisStandard extruder with advanced feedscrew design; downstream, carriage, and controls (Seimens drives and controls used throughout). Lines are available in two versions to accommodate almost any plant: one is a longer line with the auxiliary unwinder placed close to the floor; the other raises the auxiliary unwinder to a position just above the winder to
shorten both the line length and the path of the auxiliary web to the laminator. Advanced computer technology that is standard on the dsX flex-pack includes DS APC (automatic profile control), which continually adjusts the product profile for best performance, and a DS5 computer, which allows for remote access to the line for troubleshooting and updating over a secure internet connection. Performance data is exportable to factory systems for SPC and other analytical management tools. The dsX flex-pack extrusion coating line represents the first of many new innovations expected to be introduced by Davis-Standard within the next year. Davis-Standard Email: dsx@davis-standard.com Web: www.davis-standard.com
Static control for the plastics industry
As static electricity is a problem that often goes undiagnosed and causes manufacturers costly headaches in terms of lost production and product rejects, Buckinghamshire-based SMC has developed a range of products designed to measure, control and remove it. SMC states products in its ‘Ionizer’ range deliver effective remedies to cure static electricity, leading to reduced production costs, improved performance, increased efficiency and improved safety. Such a solution from the Ionizer range was successfully implemented for an SMC customer that specialises in water bottle manufacturing. Plastics, along with rubber, have a tendency to produce static electricity as they act as insulators and can hold a charge rather than act as conductors of electricity. In this instance, plastic bottles were charged with static electricity 10 • WWW.EPPM.COM • APRIL 2013
during the fabrication process, causing costly problems for the manufacturer once they joined the transport line. The static charge being stored in the surface of the bottles caused them to repel each other and lose their vertical positioning, leading to the production line being shut down while the bottles were manually realigned. Although the customer did have a static removing device in place, it wasn’t capable of removing the static charge in the time set by the production process, which requires a high-speed transport system. SMC provided a solution with its bar-type ionizer, the IZS31, which the company says has a proven track record of removing static electricity extremely quickly. In this case, the IZS31 neutralised the static charge within the time set by the application. SMC states the result has transformed
Netstal Tel: +41 55 618 61 11 Email: marketing@netstal.com Web: www.netstal.com
SMC's IZS31 bar-type ionizer the water bottling plant’s production efficiency, removing disruption to the process and the need for human intervention. SMC Pneumatic www.smcpneumatics.co.uk
Oceplast, a well-known processor based in France, commissioned a complete WPC direct extrusion line from KraussMaffei Berstorff at the end of 2012. The company is one of the leading PVC processors in France and produces various WPC decking profiles using the direct extrusion process at its plant in Alzenay (northern France). “Oceplast, a long-standing customer of KraussMaffei Berstorff and founder of the OCEWOOD trademark that is renowned in France and Europe, chose our WPC concept since the twin-screw extruders have very high wear resistance”, said Michael Finkenzeller, Product Manager for WPC extrusion at KraussMaffei Berstorff. “The screws have tungsten carbide armor plating while the barrels are lined with a bi-metal bushing. Wear resistance is very important, especially in WPC processing, since this is the only way to attain the machine service lives demanded by processors and minimise standstill phases and maintenance costs”, continued Finkenzeller. The core component of the line is the KMD 75-32/WPC twinscrew extruder with a maximum output of up to 200kg per hour. Other line components, for example the calibration table, the haul-off/saw combination and the tilting table, were designed to meet the customer's requirements. The line is therefore extremely compact and is designed for processing extra wide profiles. The line features a single-step process which permits direct metering of the two components, i.e. wood and PVC. A two-component gravimetric system transports wood flour and PVC dryblend into a dynamic mixer which feeds the homogenised material mixture directly into the extruder. The complex compounding process using a heating-cooling mixer is therefore not required; the processor saves production space and energy as the wood flour is already pre-dried. KraussMaffei Berstorff Tel: +49 89 889 927 92 Email: annemarie.pabst@kraussmaffei.com Web: www.kraussmaffei.com
MACHINERY ROUNDUP New equipment removes contaminants in film blowing
More machines to hit the road this year
Blown film extrusion plants can now reportedly reduce airborne contaminants by as much as 80% with a new patented Saturn Evacuation System (SES) from Future Design Inc., and extend cleanings from every six weeks to quarterly, or longer. Future Design, now in its 35th year, specialises in air ring technology. The SES comprises a small air ring that fits any air ring or die that is constructed of aluminium and fits between the die and the primary cooling ring. Connected to the vacuum side of the blower, the system creates a positive vacuum that draws as much as 80% of the contamination from the low-pressure zone at the die exit. The polluted air is filtered and the discharged particulates directed to a suitable location. Contaminants from the blown film process are inevitable and cause safety, health and maintenance problems. Comprised of smoke, fumes, vapourous residues and other noxious polymers from the extrusion process of blown film, these contaminants cannot be captured by conventional exhaust systems and are too heavy to stay airborne. As a result, they settle on equipment frames, railings, electrical components or plant lighting throughout the plant. Many facilities shut down for one or more days as often as every six weeks to eliminate
The all-electric Engel e-mac injection moulding machine has begun a ‘European tour’ which started on 12th February and will extend into the summer. The group joins a host of major players who recently reported that they will support their participation at the K Show with international roadshows. The event got under way in the French town of Wissous on 12th and 13th February. It will move on to Hungary, the Czech Republic, Poland and Germany. Using two applications as examples, the full potential of the machine series will be demonstrated live at the regional subsidiary offices. Connector housings will be produced from fibreglass-filled PBT/ASA using an Engel e-mac 310/100 with integrated Engel viper 6 linear robot. All drives in the Engel e-mac are servoelectric. This, according to Engel, is to guarantee the best possible precision and process stability while maximising the effectiveness of the machine as a whole. The drives are operated by a modern axis system solution with stabilised intermediate circuit; braking energy is recovered and fed back into the grid. The series has four machine sizes with clamping forces of 50, 75, 100 and 180 tonnes. The e-mac has been designed
these contaminants. Initial plant installations of the new SES systems have enabled them to extend cleaning from weeks to months, a considerable cost savings, not to mention the health, safety and maintenance benefits. Airborne particulates as high as 60 million parts per million (ppm) have been reduced to as few as 400,000 ppm. A complete SES system is relatively inexpensive depending on the size of the die claims the group. Blown film extrusion plant operators can realise an ROI or payback in a very short time, and the saving and payback continues over the months and years when compared to the expenses for a plant shutdown every few weeks. Regular maintenance costs are also trimmed, not to mention the safety improvements in the work area. Future Design Inc. Tel: +1 905 361 9978 Email: sales@futuredesigninc.com Web: www.futuredesigninc.com
Spectroscopic plasma monitoring investigated at IKV Deposition of thin-layer barrier coating on plastics for barrier improvement is an innovative technology. To support online quality management of plasma processes, the Institute of Plastics Processing (IKV) at RWTH Aachen University is investigating the use of spectroscopic plasma monitoring. Plasma emissions are strongly associated to process parameters such as pressure, applied power and gas flow. However, scientists at the IKV say when looking at complex or rapid processes there is still a lack of viable and reliable industrial quality management systems. In these cases, establishing a temporal link between process variables and plasma properties is a crucial factor in order to obtain qualityrelated data in real-time. Based on the optical emission spectroscopy (OES) spectroscopic plasma monitoring can survey the plasma process in real-time and thus the treatment or coating processes. The advantage of this technique is its ability to monitor different process information, e.g., the condition of the processing chamber, like the degree of contamination the expected layer properties, such as barrier properties, scratch resistance or wettability or the reproducibility of batch processes. With this in mind, a plant control system based on programmable logic controller (PLC) has been developed at IKV. In close collaboration with Plasus Ingenieurbüro, the ‘Plasus Emicon’
for full modularity and automation technology integration. The compact design of the machine can save space whilst cutting operating costs. Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at
Plasma monitoring in action (Credit: IKV). system was integrated into the plant control system via Profibus DP. IKV states all available process data can therefore be collected and analysed simultaneously along with the measured plasma emissions, so that preventive action can be taken even in complex and rapid processes. Time and expensive sample checks are reduced to a minimum by continuous in-process performance monitoring. Further investigations on process monitoring, for example automatic acquisition of process homogeneity in large area coating processes, are in progress. IKV www.ikv-aachen.de APRIL 2013 • WWW.EPPM.COM • 11
MACHINERY ROUNDUP UK processor invests in five new thermoformers Kobusch UK Ltd., (part of the US and European group Sun Capital Partners Inc.), has purchased five FC 780 IM2 Speedmaster Plus thermoforming machines for delivery in the first half of 2013. These are being acquired from Swiss group WM Wrapping SA, and follows on from similar investments in 2011 and 2012. The W.M. FC 780 IM2 Speedmaster Plus, which has the possibility to form and cut in-mould, is the supplier’s latest evolution of electric thermoforming machines and has maximum tool dimensions of 780x570mm and a maximum forming height positive/negative of 130mm. Kobusch UK Sales Director, Tony Mitchell, said: “The previous six machines have been a success and the versatility they bring has helped us move into new areas of thermoforming and, therefore, has given us extra growth”. Machine movements are made with servo-motors which allows high rates of production up to 54 cycles per minute, depending on the material, and reduced energy consumption. The sheet heating section is equipped with both upper and lower heater banks, infra-red ceramic heating elements, and independently controlled zones which allows, according to the type of material being processed, the optimisation of the heating phase. Forming is by means of compressed air (up to 8 bar) and vacuum, which can be programmed in the required
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sequence with quick change between the upper and lower platens. The products are cut out using heated steel rule blades and then automatically counted and stacked. The forming unit, with a toggle closing movement, guided along four tie bars, develops a clamping force of 75 tonnes on four points of the platen. This provides a greater rigidity of mould clamping and a more homogeneous distribution of clamping force giving the machine the possibility to form and cut in place. Adjustment of the upper and lower platen heights is electric and there is also the option to fit an independent electrically driven plug movement. The cutting unit, with a toggle clamping movement, guided along four tie bars, has a power of 60 tonnes. This provides greater rigidity and a more even cutting force distribution. The machines are equipped with loadcells to measure the actual forming and cutting station clamping forces. All the adjustments and settings are made through the touch-screen colour LCD monitor, which is mounted on a control panel fitted to a sliding arm. All of the input data and recipes can be stored on a USB memory stick and a printer port can be used to reproduce paper copies of all of the video pages. The machines will be supplied with the latest software to provide automatic
setting of the machine parameters by applying the following product data: • Material type • Material thickness • Mould length & width • Product height • Number of cavities Once the parameters have been entered into the machine it is able to generate an optimised automatic cycle. The machine is compact thanks to the integration of the electric cabinet within the footprint of the unit. Tools are changed from the operator side to allow the best possible access to facilitate quick mould changes, which is aided
by the quick tool loading equipment. The FC 780 IM2 can also be supplied in a 4 station version with a hole punching press, model FC780E HP. FC 780 Speedmaster, available in E – IM– IM 2 – HP versions sits in the middle of WM’s steel rule cut range of machines, which also includes the following other models: • FC 600 E with forming tool dimensions 640x450mm • FC 1000 E – IM – IM 2 with forming tool dimensions 1060x700mm. WM Wrapping Machinery SA Web: www.wm-thermoforming.com
MACHINERY
SHOWCASE MOULDS & TOOLING ‘One-stop-shop’ for mould makers sees strong growth After extending its range of products, Meusburger, a 'one-stop-shop' for the mould and tools industry, was able to increase its turnover to €148m in 2012. The group reports this as an increase in turnover of 14.5% compared to the previous year. According to the management, this result is mainly due to the opening up of new markets in the tool and mould making sector. “We are the reliable partner for tool and mould making and offer our customers top service and the widest choice of products. Our customers are already enjoying the benefits of our large warehouse which ensures permanent
The specialist for tool and mould making is extending its product range.
availability of our products and very short lead times”, said Guntram Meusburger, Managing Director. The figure for the past business year was a record turnover for the group. In addition to consumables and cutting tools, the product range now also includes surface finishing tools. Meusburger adapts its product range for applications in tool and mould making and claims to offer high quality with short delivery times. The customer can save time and money, according to Meusburger, because there are fewer suppliers to approach for individual components. In 2013, Meusburger will extend its product range and invest large sums in the extension of its headquarters in Vorarlberg, Austria. The company says it plans to invest about €8m, not including machinery, in the largest extension building in its history. A new, three-storey factory building will be built in the north of the premises to consolidate Meusburger's central manufacturing and shipping plant. About 100 new jobs will be created. “This extension building is
called for by the ongoing expansion of sales markets and the resulting increase in turnover”, said Guntram Meusburger, Managing Director. The project is already being implemented, and completion of the new building is scheduled for the end of 2013.
Meusburger company grounds with projected extension building.
Meusburger Tel: +43 55 74 67 060 Web: www.meusburger.com
APRIL 2013 • WWW.EPPM.COM • 13
MACHINERY
SHOWCASE MOULDS & TOOLING ‘Tool-Mover’ offers safe and easy tooling transport The Tool–Mover from RUD Chains Ltd is a manipulation device for the safe turning and tilting of heavy and awkward plant items such as plastic injection moulding tools.
The Tool-Mover offers many safety features. It turns the load at the centre of gravity which means that the motion is smooth and the tool secure. It is equipped with a frequency controlled
drive which ensures an even and smooth drive from start to finish, and it can be stopped in any position securely even if power to the unit is cut.
Handling and turning of heavy injection moulding tools can be a dangerous job without the right equipment causing risk to the operators and damage to costly tools if they are not turned effectively. The Tool-Mover reportedly ensures that the handling and tilting of heavy and sensitive injection moulding tools are moved safely and securely therefore reducing costs due to damaged tools and improving the safety of the operator. The Tool-Mover is easy to use and position as it does not need to be bolted to the floor. It can be moved to locations in a facility by a crane or fork lift/pallet truck. It is able to turn injection moulding tools with a weight starting from 6.3t, through to 10t, 16t, 20t and the largest, 32t. Tools can easily be cleaned on the table due to its low platform height. The Tool-Mover is covered with polyurethane plates which help to preserve the tools. RUD Chains Ltd is a manufacturer of round steel chains and components for applications in mechanical engineering, hoisting, conveying and drive systems. RUD Chains Ltd Tel: +44 1227 276 611 Email: katie.crane@rud.co.uk Web: www.rud.co.uk
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MACHINERY
SHOWCASE MOULDS & TOOLING Two-stage ejector now with coated functional surfaces With an extensive range of two-stage ejectors, mould component specialist Hasco offers a variety of products for reliable motion control and demoulding during the injection moulding process. All two-stage ejectors are now available with DLCcoated (diamond-like carbon) functional surfaces. The Z169 two-stage ejector is a solution for activating a stripper plate. Automatic and precise holding and opening mechanisms allow the two plates to move interdependently. The movements “guarantee consistent part quality without compromise” according to Hasco. The Z1691 is an extension of the Z169. It offers the same motions plus improved locking. Another feature is simple assembly through the integrated flange attachment. Specially designed centering rings allow particularly smooth axial motion and a high service life. Available with a shaft diameter of 13-52mm, it can be used in small to large moulds. The Z1692 was developed for demoulding processes in which the first and second stroke have to function completely separately and independently of one another. The stroke can be subsequently modified or it can be preset to requirements directly. Z1695 is suitable for controlled plate movement during demoulding with an inclined sliding carriage. Precision movement of the first stage prevents stressing of the part. Subsequent opening of the rear stage allows ejection of the part at a predefined position. Designed for applications in which a central ejector cannot be used, Z1697 offers high forces when combining two or four units. The motion corresponds to that of Z169 and Z1691. A special feature is the additional guidance of the ejector system. The new Z1698 has been specially developed for off-centre mounting with double ejectors in the mould, where a central two-stage ejector cannot be used for constructional reasons or particularly large melts have to be moved that cannot be managed by a Z1695 standard two-stage ejector. Because of the lubricant-free functional
surfaces, the maintenance intervals are longer. Applications in medical and food technology are possible, as are parts that subsequently have to be painted or lacquered. The high layer hardness and low
friction values of the coated two-stage ejectors significantly improve the life of the mould and thus makes a major contribution to increasing productivity and lowering costs in the production process.
Hasco Tel: +49 2351 957 0 Email: info@hasco.com Web: www.hasco.com
APRIL 2013 • WWW.EPPM.COM • 15
MACHINERY SPOTLIGHT eppm
BLOW MOULDING
“GOLD STANDARD” PURGING ON OFFER FOR BLOW MOULDERS
Purging compound developer Aquapurge has reported a month of positive feedback and endorsement for its new Poly Clear HMEX product. Technical Director John Steadman said: “We knew when we launched last month that our Poly Clear HMEX is by far the most universal and most effective purging compound that Aquapurge has ever developed for difficult polyolefin changes. And now our customer base has confirmed it to us in spades; telling us that what we have is the fastest and easiest purge on the market. What we are also proving in these early days is the effective removal of loosened carbon without opening a Pandora’s Box on continuous and accumulator blow moulding machines.” Steadman continued: “All this feedback is part of an amazing reception for Poly Clear HMEX at over twelve blow moulding sites in the past few weeks. UK sales are now seeing a quantum shift, our Berlin-based German distributor is using all we can ship and we are already gearing a
boost in our Poly Clear HMEX production for the coming months.” Many blow moulders, according to the group, are sensitive about submitting their capital assets to new compounds and new processes. “We were very fortunate to have opened as many doors as we have over the past five weeks. In the past many blow moulders have had unfortunate experiences; everything has been tried to poor effect and there have been stories of damage being done to screws. The up side of this for us is that through March 2013, Poly Clear HMEX has confounded user expectations. Moulders have been amazed at the results, perhaps because they believed it might crash and burn. The exact opposite is the case.” Poly Clear HMEX works best at maximum throughput. For continuous extrusion processes, typical use is 1/10 in weight when compared to HDPE – and the same ratio for accumulator-based moulding. Aquapurge reports it is ‘delighted’ with what the product has achieved in a short space of time. Steadman added: “We developed the new compound from Poly Clear 100 to Poly Clear HMEX and we are now 50% faster.” Aquapurge continues to stress that a
regular practice of blow moulding machine purging is important for business. “Purging gives blow moulding producers an opportunity to really flex with the market demand,” said Steadman. “Why make your customers wait in line for business? It simply gives them an opportunity to move on and shop elsewhere.” Poly Clear HMEX is targeted at delivering benefits to producers of plastic blow-moulded container applications, typically from 0.25l upwards; saving downtime; material cost and colour contamination. Aquapurge believes that many blow moulders are currently tying up valuable time and money, simply by: • Not purging their equipment at all; • Simply running colour through to clear for the next job; • Producing customer orders to an ‘ideal’ colour schedule; • Scheduling tool changes simply to match the colour running at that time. Steadman said: “These are common practices, and can actually devalue the whole production process; decrease machine utilisation and also the value of polymers used.” Poly Clear HMEX is therefore intended to offer a more profitable solution; and to insure and protect against any production disruptions that can harm the profitability of each order.
VISION-BASED INSPECTION SYSTEM LAUNCHED FOR PET BLOW MOULDING
Agr International has unveiled its Pilot Vision system, a vision-based inspection and quality management system for PET containers. The Pilot Vision system is the third component to Agr’s Process Pilot Family of products, geared towards providing manufacturers with a total blow moulding management approach. Having previously introduced components that provide in-machine material distribution measurement as well as automated blow moulder control, Agr has developed the Pilot Vision system as the final component to complete this comprehensive package. The Pilot Vision system is designed to work in conjunction with today’s high speed reheat stretch blow moulding equipment to provide detection of random occurring defects during the production of PET bottles. According to Robert Cowden, Agr’s Chief Operating Officer: “The increased use of non-virgin materials has contributed to growing incidences of contaminants, black specs and unmelted material that can randomly appear during the blowing process, compromising quality and usability. Since these occur on a random basis, 100% inspection is required. Our new Pilot Vision system was designed with this issue in mind, it gives bottle makers
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The blue purge here shows Aquapurge Poly Clear HMEX being used to purge and colour change a continuous extrusion blow moulding machine. This particular machine is enabled to run in either continuous or accumulator mode, producing blow mouldings up to a maximum shot weight of 3 kg. Using Poly Clear HMEX the colour change took 20 kg of purging compound and a total of 45 minutes downtime, from blue to white. Normally, under the previous process regime the procedure would have taken at lest 3.5 hours and involved at least 320 kg of purging compound.
Aquapurge Tel: +44 20 8813 7990 Email: enquiries@aquapurge.com Web: www.aquapurge.com
the assurance that bottles with these types of defects will not enter the production stream.” The Pilot Vision system is a modular vision-based inspection system that mounts inside the blow moulder. The compact design of cameras and lighting components make it compatible with a wide variety of blow moulder models and brands. Its operating speed of up to 100,000 bottles/hour is compatible with even the highest speed blow moulding systems available today. The open architecture of this system allows for simultaneous management of up to six cameras in multiple locations. These are typically configured in four separate inspection stations; preform inspection in the oven area, bottle seal surface, bottle base and bottle sidewall inspection that permits complete sidewall inspection of bottles up to 16 inches tall. Featuring the latest vision and inspection technology, the Pilot Vision system utilises high-resolution Gig-e cameras and variable multi-spectrum LED illumination for maximum flexibility, reliable operation and, most importantly, clear and precise imaging. In addition, to accommodate the harsh environment inside the blow moulder, camera and imaging components are sealed to prevent damage from fluids and moisture. Active cooling is also available for high temperature operation. Agr International, Inc. Tel: +1 724 482 2163 Email: ddineff@agrintl.com Web: www.agrintl.com
MATERIALS
EU 10/2011 compliant stock shapes launched for food industry Quadrant Engineering Plastic Products (EPP) has updated its range of Food Grade Plastics in line with the new European Union Regulation (EU) 10/2011. The portfolio of certified materials, covering PE through to PEEK, gives food producers the assurance of fulfilling the highest safety and quality levels for their food and beverage production systems. New Regulation (EU) 10/2011 is a further development of Directive 2002/72/EC for plastics materials in contact with food,
and specifies much stricter test conditions for migration. Within the EU, compliance is required for all food contact materials. All Quadrant EPP Food Grade semifinished stock shapes and customised finished parts are processed and handled according to the new regulation and to the consistent quality control guidelines of Good Manufacturing Practice (GMP). Quadrant EPP accompanies each delivery with complete documentation, from choice of raw material to finished parts. This allows full traceability and also supports customers in reducing their own inhouse product testing time and costs. Customers receive a Declaration of compliance with the
Expanded range for water-injection technology (WIT)
BASF is expanding its range of polyamide grades optimised for the use of water-injection technology (WIT) in injection moulding. The new WIT grades are Ultramid A3HG6 WIT Balance and Ultramid A3WG7 WIT. Thanks to water-injection technology, hollow plastic parts, for example, for medium-carrying lines that require a very good inner surface, can be produced by injection moulding. These two materials are now available in commercial quantities. Owing to its improved hydrolysis resistance, the polyamide (PA) Ultramid A3HG6 WIT Balance is particularly wellsuited for components that carry coolant or that come into contact with water. At the same time, the content of PA 6.10 in this material also translates into high stress-cracking resistance to calcium chloride, thus taking into account the more stringent requirements made in
terms of resistance to road salt. Particularly in Asia, calcium chloride is often spread on icy roads. In contrast, BASF recommends its new Ultramid A3WG7 WIT, which is reinforced with 35% glass fibres, especially for tubes that convey oil such as those employed for dipsticks, or else for other components that have to meet high demands in terms of oil resistance, stiffness and dimensional stability. Both materials lend themselves very well for WIT processing. In the meantime, the hydrolysis-resistant basic product of the WIT series, namely, Ultramid A3HG6 WIT, has become the material of choice for many WIT applications such as cooling water pipes. BASF Tel: +49 621 60 78780 Email: ultraplaste.infopoint@basf.com Web: www.ultramid.de
order (DCO) according to EN 10204-2.1 that ensures the uninterrupted traceability of the plastic product from the stock shape back to the raw material used by batch. Each production step is tested and documented by Quadrant EPP. Quadrant is also introducing a Declaration of Compliance (DoC) for every delivery – a documentation requirement valid as of 2016 – that includes the complete test conditions together with the migration values of the materials. Tests to determine the migration values of Quadrant EPP’s food contact polymer materials were conducted on the thermoplastic stock shapes by independent external laboratory Intertek. These tests were performed according to regulation (EU) 10/2011. The portfolio of over 30 products was tested per Overall Migration Limit (OML) and Specific Migration Limit (SML) to measure the material inertness and provide a toxicological evaluation of individual substances. By including the pre-tested results with the DoC, customers can more easily calculate migration values for their individual applications – a further step in
supporting their overall cost-efficiency. As part of its complete Food Grade Program, customers can benefit from Quadrant’s international partner network to select the right material for their application. The material selection and application advice considers the food type in contact with the plastic parts, and temperature and food contact time. “Quadrant is constantly developing innovative production and application solutions to help customers improve their production performance,” commented Ulf Barth, Market Segment Manager Food Processing Industry, Quadrant EPP Europe. “The Quadrant Food Grade Program offers the food market the widest selection of engineering plastic stock shapes and design possibilities. Materials certified to the highest safety level, migration calculation support, and application selection recommendations, assist our customers in reaching the best possible cost-performance ratio for their individual system.” Quadrant EPP Tel: +41 62 885 84 43 Email: sigrid.dopfer@qplas.com Web: www.qplas.com
Anti-counterfeiting with additive masterbatch The GabrielChemie Group has launched a new additive masterbatch that it says will combat the losses faced by the plastics industry through product counterfeiting, which it estimates is “billions of Euros”. Maxithen ProTec4 is said to represent a unique security system that can prove the origin of products exactly and cannot be copied. The special masterbatch is said to provide plastic products with an unmistakable code that demonstrates a clear proof of its origin. The masterbatch is manufactured to an individual code for each product, which the company states are as unmistakable as a genetic fingerprint. This makes it impossible to exactly replicate an employed pigment in order to copy the product protection. The individual security pigments can reportedly be verified using a specially programmed
The new special masterbatch will be added to the Gabriel-Chemie Group’s portfolio detector. Gabriel-Chemie states the use of different codes means that even different product batches can be identified. Maxithen ProTec4 can be also used to monitor the production process. By directly communicating with the machine during processing, an overdose or underdose of additives or colour pigments can be ruled out. Gabriel-Chemie Group www.gabriel-chemie.com APRIL 2013 • WWW.EPPM.COM • 17
MATERIALS ROUNDUP Wire and cable TPEs offer high-level flame retardance Advances in formulation and compounding technology have enabled Teknor Apex Company to develop a family of thermoplastic elastomers (TPEs) for wire and cable that are RoHSand REACH-compliant while meeting stringent criteria for flame retardance, the company claims. Elexar EL-1934 Series compounds have UL-94 flammability ratings of V0 at 0.060 in. (1.52 mm), meet UL 1581 WV-1 and 1061 flammability tests without dripping, and have limiting oxygen indices in the 28-32% range (compared with 22-26% for conventional flame-retardant TPEs used in wire and cable). All of the compounds are UL 2556-registered for long term aging at 105˚C, are UL-1581registered for sunlight resistance, and have brittle points of -55˚C or lower. Shore A hardness ranges from 58 to 82. Teknor Apex recommends Elexar EL1934 Series compounds for use in insulation, jacketing, and moulded parts for flexible cords, coil cords, and cables in power tools, appliances, industrial robots, welding equipment, and entertainment audio and lighting systems. “Elexar EL-1934 Series compounds are high-performance elastomers that exhibit superior flame properties in comparison with conventional TPEs for wire and cable while meeting requirements for a wide range of end-use conditions,� said Ross Van Royen, market manager for the Thermoplastic Elastomer Division of Teknor Apex. “These versatile materials
UK distribution for Turkish PA 6 and 6.6
Epsan has two compounding plants in Turkey.
exhibit good resistance to oil and UV, stay flexible upon exposure to cold weather, exhibit good retention of tensile properties upon aging, and provide excellent electrical properties for data, communications, and other low- to medium-voltage applications.�
Properties of three grades in the Elexar EL-1934 Series are detailed in the table. Teknor Apex Europe Tel: +44 121 665 2100 Email: eutpe@teknorapex.com Web: www.teknorapex.com
UK polymer distributor, Longfield Chemicals, has signed an exclusive distribution agreement to market the polyamide 6 and 6.6 compounds produced by Turkish compounder, Epsan Plastic. The agreement, which applies to the UK, currently covers distribution of the full range of polyamide compounds including the Eplamid, Eplon and Epimix brands, along with a comprehensive range of industrial quality grades. “Longfield Chemicals will supply the complete range of Epsan Plastic’s high performance compounds for companies in the UK. As our brand and product range expand, so does our need for outstanding distribution partners,� said Global Sales Manager, Arda Efe. Epsan specialises in the production of high performance polyamide compounds and currently has two plants located in Turkey as well as distributors throughout Europe. Longfield Chemicals www.longchem.co.uk
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MATERIALS ROUNDUP Antimicrobial additives feature in new partnership Albis Plastic GmbH, one of Europe’s specialists for the distribution and compounding of technical thermoplastics with headquarters in Hamburg, has announced a cooperation agreement with additives manufacturer Addmaster (UK) Ltd., Great Britain, involving antimicrobial additives. Based on this, Albis Plastic will in the future offer products formulated with Addmaster’s (UK) silver based Biomaster technology which considerably reduces the growth of microorganisms. These Albis products involve both masterbatches (Albis Additive-Batch Hygienic Material) as well as compounds (ALCOM Hygienic Material). Both Albis solutions will carry the “Biomaster Protected” label and are registered in accordance with the German Ordinance on Notification of Biocidal Products (ChemBiozidMeldeV) at the registration office for biocides of the BAUA (Federal Institute for Occupational Safety and Health). The goal of the application is to equip plastics, without having to coat them, for hygiene-critical areas of use with antimicrobial properties for the secure prevention of the growth of germs and bacteria. “We are very pleased about our collaboration with Albis, which offers Biomaster’s customers another option of using pre-compounded materials and masterbatches with certified quality. Aligning the market leading Biomaster antimicrobial technology with the reputation of Albis Plastic is part of our strategic plan,” explained Paul Morris, Managing Director of Addmaster (UK) Ltd. “We want to make it as easy as possible for our customers to include Biomaster in their polymer products. This is now also being supported by the extensive technology and marketing expertise of both companies. “This agreement perfectly suits our orientation to speciality solutions,” commented Marcel Wiesner, Product Specialist Masterbatches at Albis Plastic. “Hygienic solutions, particularly those for antimicrobial protection, are experiencing more and more attention in Europe. By combining Biomaster’s brand and know-how with the expertise in compounding technology and the Europe-wide sales network of Albis Plastic we are now able to offer our customers a wide range of antimicrobial polymers such as PE, PP, ABS, PC, PA and many more.” The new agreement covers Europe and includes the possibility of a co-branding of the Paul Morris, Managing Biomaster Director of Addmaster brand and (UK) Ltd. logo.
Supplier publishes engineering plastics manual Engineering and high-temperature plastics provide an impressive and varied array of properties and great scope for application. However, the use of these modern materials calls for an ever wider fund of expertise. With its latest engineering plastics manual, plastics supplier Ensinger has now published a reference work collating specialist knowledge from every aspect of plastics processing. At 100 pages, the new manual contains considerably more information than its predecessor and looks at the latest new developments. The manual starts with an overview and direct comparison of materials based
on their most important properties, modifications and fields of application. A colour-coded index links this introduction to more detailed information. In the chapters on material selection and further processing, users are provided with the facts they will need for the construction of components or for machining semi-finished materials. This information has been formulated in clearly arranged graphs and diagrams and is backed up by a wide selection of application examples. “Engineering Plastics – The Manual” is available immediately in printed and digital form in German and English. The PDF is available as a download on the
Ensinger website: www.ensingeronline.com/en/downloads/brochures/ Ensinger Tel: +49 7032 8190 Web: www.ensinger-online.com
Addmaster (UK) Limited Tel: +44 1785 225656 Email: info@addmaster.co.uk Web: www.addmaster.co.uk Albis Plastic GmbH www.albis.com APRIL 2013 • WWW.EPPM.COM • 19
MATERIALS ROUNDUP TPE group offers solutions for automotive mats The HEXPOL TPE group have developed several grades of thermoplastic elastomers (TPEs) specifically engineered to address the requirements for automotive mats. The range, known as Dryflex AM, combines the performance of rubbers with the processability of plastics and includes grades based on SBS and SEBS which are available in hardnesses from 50 to 75 Shore A. High flow grades are available which have been designed for complex mouldings with a large surface area such as trunk liners. Other applications for Dryflex AM materials include floor mats, coin mats, fascia mats and trim. For automotive floor mats the material needs to have high scratch and abrasion resistance. It is also critical that the
material is non-slip, even when wet. The material structure of Dryflex AM compounds produces the high coefficient of friction, helping to create a non-slip surface. Dryflex AM materials are low odour and fogging. They require no vulcanisation and are 100% recyclable during production. This means less energy is used and production is faster and more cost-efficient. Sven-M. Druwen, European Sales Coordinator for HEXPOL TPE commented, “Our teams work hand-inhand with our automotive customers to develop solutions that address new and emerging demands. With governments’ worldwide enacting fuel efficiency and carbon emissions laws, one of the ways car manufacturers are looking to
address these regulations is vehicle lightweighting. By reducing the weight of each component they can look to reduce the weight of the whole vehicle. That is one of the reasons we have developed our TPEs for automotive mats, they have a lower specific gravity compared to several alternative materials, you can therefore not only create lighter-weight parts, but you can also produce more parts per kilogram of material.” HEXPOL TPE brings together ELASTO UK, ELASTO Sweden, Müller Kunststoffe in Germany and Hexpol Compounding (Foshan) in China. HEXPOL TPE is part of polymer group HEXPOL.
Hexpol TPE Tel: +46 532 607500 Email: info@elasto.se Web: www.hexpoltpe.com
Polyurethanes group extends contract with European distributor Huntsman Polyurethanes is extending the scope of its distribution arrangements with Azelis – a PanEuropean distributor of speciality chemicals. From April 1, 2013, Azelis will supply key products from Huntsman Polyurethanes’ adhesives, coatings and elastomers (ACE) range throughout Germany and Austria. The deal will build on a prior arrangement between the two companies, which covers France and Benelux. Previously Huntsman Polyurethanes had supplied customers in Germany and Austria direct. However, with demand for its ACE chemistries
growing in these markets, the team decided it was the right time to hand distribution to a trusted partner. Huntsman and Azelis will be able to approach, service and support a wider range of customers, each offering a quality package more closely aligned with their specific customer and market requirements. Products covered by the new agreement include some of Huntsman Polyurethanes’ core chemistries – SUPRASEC MDI, IROSTIC TPU and IRODUR crosslinking technology for industrial adhesive applications. Michel Dumusois, International Business
Director Azelis Coatings, said: “At Azelis, we are extremely well placed to take over supply of Huntsman Polyurethanes’ ACE products in these new agreed markets. We have strong local relationships, working closely with our customers, and importantly, we know we also cooperate well with Huntsman. As we continue to promote Huntsman Polyurethanes’ key ACE brands across our network we are primed to build awareness, and increase use across Germany and Austria as well.” Nicolaas Weyns, Key Account Manager at Huntsman Polyurethanes said: “The
time is right to grow our ACE business in Germany and Austria, and working with an experienced distributor is the best way to achieve this. We know that many of our customers value the extra flexibility that comes from sourcing products via a third party. One of the main advantages is access to a range of complementary products. We’ve worked with Azelis since 1993 and know this will continue to be a fruitful partnership with benefits for all concerned.” Huntsman Polyurethanes Email: ace@huntsman.com Web: www.huntsman.com/pu/ace
Additive grades protect against counterfeits Addmaster, a UK-based supplier of additives for plastics, states that its product verification system for polymers is being used daily behind some of the world’s most famous brands as counterfeit products are estimated to cost the global economy over “£250 billion pounds per year”. Easy to incorporate and invisible to the naked eye, the company states Verimaster can be added to any polymer with no loss to physical or optical properties and tested with Addmaster's detection tools to prove its authenticity. Grades are now said to be available that allow detection to be carried out at source with the sensors (pictured) or via laboratory-based tests that can detect multiple signatures. Addmaster states Verimaster is particularly effective in protecting manufactured plastic products from counterfeiting, as it’s easy and cost effective to add as a masterbatch, compound or within the polymer feedstock. “When up to 20 percent of prescription drugs and over 550,000 aircraft parts 20 • WWW.EPPM.COM • APRIL 2013
Addmaster’s system is used for detection are thought to be counterfeited each year, it shows that nothing is off limits to copycat producers,” said an Addmaster spokesperson. Addmaster www.addmaster.co.uk
MATERIALS ROUNDUP European masterbatch group starts production in Russia The Gabriel-Chemie Group is planning to expand its production capacities by building a new production plant in Russia. By the end of this year, investments will be made in the building of the new production plant in the “Special economic industrial zone Alabuga”. A production hall, a laboratory and a warehouse will be built on an area of five hectares in various construction phases. In the first phase, the production capacity will be 4,000 tons of
masterbatches per year; this will rise to 14,000 tons in the final phase. Colour masterbatches (including black and white) and additives will be produced. The economic and industrial zone Alabuga, positioned in one of the largest industrial areas, offers the GabrielChemie Group an optimal on-site infrastructure and therefore also the possibility of reacting to customer inquiries more flexibly and faster. “With the planned expansion of capacities, we are able to meet the
growing requirements of the Russian plastics industry and are at the same time able to strengthen our position as a manufacturer of masterbatches in the Russian market”, said Mr. DI Rodolfo Santa Olalla, CEO of the Gabriel-Chemie Group. The planned investments also mean that new jobs will be created if business continues to develop well. But investments will also be made in personnel development. Training courses, for example, take place at the
various production plants of the group in order to meet the high customer requirements in future, too. The rapid production, the laboratories, the warehouse and the sale office OOO Gabriel-Chemie RUS2 will remain in the Moscow area.
Sealing quality may also be optimised with DPET’s highly planer surface topography. Additionally, DPET cuts easier than traditional PET sheets, meaning more uniform cutting, and knives that last longer between sharpening and replacement. DPET
also delivers a smooth and glossy surface for detailed printing designs and process printing or label application.
Gabriel-Chemie GmbH Tel: +43 2252 636 300 Email: info@gabriel-chemie.com Web: www.gabriel-chemie.com
PET sheet optimised for Form-Fill-Seal jobs Form-fill-seal (FSS) is a fairly simple and highly efficient process. The packaging material is formed into a package, then filled with the food product, then sealed. There are typically two types of FFS process: vertical and horizontal. Vertical is typically used for flexible plastic packaging. During this production process a plastic film is fed vertically through a machine. The horizontal process, as its name suggests, involves having rigid sheet fed into a machine horizontally to form a rigid plastic package. “Manufacturers deploying FSS for the packaging of yoghurt have been able to maintain the necessary high production rates, reduce their processing steps, and decrease their need for manual labour,” stated William J. Barenberg, Jr., COO of Octal, a
manufacturer of PET sheet. “The FSS process also minimises the risk of food contamination due to reduced contact with equipment and plant personnel. All of these benefits combined have aided manufacturers to yield an overall cost saving compared to other yoghurt packaging options.” Yoghurt packaging systems are some of the most demanding in the world. Consistency and machinability for uptime and productivity is a key performance indicator. Octal’s DPET direct-to-sheet manufacturing system is designed to provide the kind of consistency it takes to realise the absolute maximum from Form, Fill, and Seal (FFS) lines. With a typical gauge variation of +/- 2 to 3 microns (in a claim made by Octal) DPET enables FFS operations to run at highly consistent rates day after day.
Octal Web: www.octal.com
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MATERIALS ROUNDUP Medical grade polyurethane resistant to Environmental Stress Cracking Parker Hannifin Corporation, a global specialist in motion and control technologies, has created a medical grade polyurethane that not only displays characteristic polycarbonate resistance to oxidation and alcohol swelling, but also demonstrates expanded resistance to environmental stress cracking. Developed by the Engineered Polymer Systems (EPS) Division of Parker, the product, called Parker Medical Grade ALC Polyurethane, is an aliphatic polycarbonate-based thermoplastic polyurethane designed for use in medical and life science applications. ALC polyurethanes are non-yellowing, colour-matchable, thermoplastic polyurethanes available in clear or radiopaque grades. Characteristics and advantages include: USP Class VI certified; biocompatible and biostable – passes cytotoxicity and indirect hemolysis tests; expanded resistance to chemical attack for better in-body integrity; softens in the body; enhanced reliability for increased yields; mechanical properties; able to be compounded with custom colorant and radiopaque fillers; manufactured in an ISO-certified clean room environment. Medical applications for Parker ALC polyurethanes include: vascular access devices; cardiovascular treatment devices; disposable surgical supplies; tracheotomy devices; urological devices; dialysis devices; and feeding tubes.
“Parker’s new ALC polyurethanes offer a proven advantage over competitive products,” commented Arlo McGinn, PhD, Parker EPS Senior Chemist. “Many medical grade urethanes, including ALC polyurethane, are now made with aliphatic polyurethane instead of the old standard, aromatic polyurethane, because of yellowing and carcinogenic concerns. The aliphatic polyurethanes have lower mechanical properties than aromatic but degrade to potentially safer end products, do not discolor upon exposure to light, and also show enhanced resistance to hydrolytic decomposition. However, along with the decreased mechanical properties, aliphatic polyurethanes are more prone to a physical degradation process – termed environmental stress cracking – than their aromatic counterparts. “Parker has successfully addressed this issue through its proprietary formulation and advanced manufacturing processes,” said McGinn. “We analysed the performance of several aliphatic polycarbonate urethanes, including our ALC polyurethanes and two competitors. Upon exposure to alkaline conditions, differences in tube performance within the ALC class were compelling: the competitive ALC urethane tubes quickly degraded and failed due to the effects of environmental stress cracking. During the same time period, however, Parker’s ALC formulation showed no significant change after initial softening over the course of the testing, and demonstrated
enhanced resistance to environmental stress cracking.” Parker ALC polyurethanes may be extruded as well as injection moulded. Extrusion configurations can be single lumen or multi lumen, as well as tapered (bump) or coextruded. Polyurethane materials are specified for medical device components due to their ability to meet the stringent performance, biocompatibility, and sterilization requirements of the applications in which the devices are used. Parker offers single-source engineering, production, validation, and
complete project management to effectively deliver USP Class VI certified medical grade thermoplastic polyurethane tubing and other products for medical devices that demand precision and consistency. Expanded capabilities include ISO Class 7 and Class 8 clean room manufacturing. Registrations include ISO 13485 and ISO 9001. Parker Hannifin Corporation Tel: +1 801 972 3000 Email: eps-ccare@parker.com Web: www.parker.com/eps
Engineering compounds gain distribution in Nordic and Benelux countries Teknor Apex UK Ltd. has named Distrupol Ltd. to distribute its engineering thermoplastic (ETP) compounds in Denmark, Finland, Norway, Sweden, Belgium, and the Netherlands. The ETP compounds to be available through Distrupol include polyamide products under the Beetle and Chemlon brands, plus PBT and PET polyesters. Distrupol already represents ETP
compounds from Teknor Apex in the United Kingdom and Ireland. J L Goor Materials, Ltd. also represents these products in Ireland, and Telko continues to distribute ETPs from Teknor Apex in Denmark and Sweden. Distrupol’s European corporate headquarters are in Chertsey, Surrey, UK. Distrupol Web: www.distrupol.com
Advanced antimicrobial additives given new properties for end-use At Techtextil 2013, which will be held from 11-13 June in Frankfurt, Sanitized AG, a producer of antimicrobial hygiene function and material protection for textiles and plastics will be launching two new advanced additives designed for the protection of plasticised PVC. In addition to long-lasting antimicrobial action, the two products are said to offer a range of application-specific benefits including longer life-cycles, improved weather ability and thermal stability, as well as higher resistance to UV and yellowing. The first of the new products, Sanitized PL 12-32, is a formulation with water resistance and UV stability which make it suited to outdoor applications such as awnings and tents. The second new product, Sanitized PL 12-33 is characterised by high thermal stability, 22 • WWW.EPPM.COM • APRIL 2013
regardless of elevated temperatures that may be necessary during processing, with the ability to retain product transparency. Its properties make it suited to indoor applications such as flooring and furnishings. Plastisols, coatings or foams employed in many flexible PVC products are very sensitive to attacks from microbes. In outdoor applications, the extra-cellular enzymes in such microbes can break down plasticizers – and other additives that are susceptible to them. By applying these new Sanitized additives product stability can be increased, claims the group. Sanitized AG Tel: +41 34 427 16 24 Email: sibylle.haenni@sanitized.com Web: www.sanitized.com
MATERIALS
SHOWCASE BIOPOLYMERS Bio-based heat shrink film gains new distribution in Europe Metabolix, Inc., a bioscience company focused on delivering sustainable solutions for plastics, chemicals and energy, has announced that it has entered into a distribution agreement with Tianjin GreenBio Materials Co., Ltd., a biomaterials company based in Tianjin, China. Under the terms of the agreement, Metabolix will distribute GreenBio's SoGreen heat shrink film in Europe and will be the exclusive distributor in the Americas. In addition to a distribution relationship, Metabolix and GreenBio have also signed a supply agreement for PHA biopolymers. Under the arrangement, GreenBio will supply PHA resins to Metabolix, which will extend the range and availability of the Company's PHA products. “Tianjin GreenBio has developed a heat shrink film based on PHA biopolymers. This product complements our product slate aimed at film and bag applications and we expect will be of interest to customers in the U.S. and Europe seeking biobased materials and biodegradable performance,” said Bob Engle, Vice President, Business and Commercial Development, Biopolymers, at Metabolix. “With products and technology that are complementary, the distribution and PHA supply agreements mark a first step toward potentially working with Tianjin to develop additional PHA biopolymer products.” Tianjin GreenBio offers two grades of heat shrink film that are used to bind together items for packaging, shipping, and storage. One SoGreen product is designed to replace noncompostable PVC film often used to package boxed goods, software and other non-edible products. The other is designed to replace softer polyethylene films, also not compostable and often used for wrapping multiple items, often bulky and irregular in shape, such as packs of bottled water. The SoGreen heat shrink film resins (2001 and 3001) are certified by DIN CERTCO to meet the EN 13432 standard for compostable plastics. “We are excited to work with Metabolix to gain greater exposure for our products in the Americas and Europe,” said Dr. Lu Weichuan, Chairman and President of Tianjin GreenBio. “Metabolix has extensive experience in biopolymers, and we look forward to working together to build the market for PHA-based biopolymer products.”
New film product emerges from polyamide research Royal DSM, a global Life Sciences and Materials Sciences company, has announced that its development partner, MF Folien GmbH in Kempten, Southern Germany, has introduced a new polyamide film, which is based on DSM’s bio-based EcoPaXX polyamide 410. MF Folien is a specialist in the production of polyamide film, and has been DSM’s development partner for EcoPaXX film from the start of the project. In 2011, the company was the first to create samples of 30 micron cast film from EcoPaXX. This film has the same high quality level for which MF Folien is very well known in the market. Samples of film based on EcoPaXX are available in various thicknesses: 30, 40 and 50 microns. Potential application areas are in flexible food packaging, building & construction, medical, aviation and shipping. Speaking on behalf of MF Folien, Mr. Rainer Leising, general sales manager, said: “We are delighted to be working with DSM on the development of this innovative and sustainable material solution. Since we first introduced EcoPaXX film, with its distinctive shiny, silvery ‘high-tech’ appearance, the material has been featured in our product brochure.” EcoPaXX polyamide 410 films are strong and transparent with a high puncture resistance. They have a reduced moisture transmission rate versus polyamide 6 film, and a comparable oxygen barrier. When fully wet, the oxygen barrier of polyamide 410 is even higher.
Recently, three grades of EcoPaXX were given the “Certified Biobased Product” label, awarded by the United States Department of Agriculture (USDA). These labels certify a proven bio-based content of around 70%. The bio based content of EcoPaXX polyamide 410 stems from one of its building blocks, derived from castor oil obtained from plants that grow in tropical regions and which are not used for food products. The carbon dioxide, which is generated during the production process of the polymer, is fully compensated by the amount of carbon dioxide absorbed in the growth phase of the castor beans. DSM introduced EcoPaXX in order to meet increasing market demand for high performance durable bio-based engineering plastics. Kees Tintel, Business Manager EcoPaXX at DSM, said: “We recognise the market’s
desire for more sustainable solutions that have a lower footprint and are bio-based. By applying DSM’s Bright Science, we were able to develop this material, which in addition to its green performance, delivers the same or even better properties compared to its traditional alternatives.” Mr. Tintel added: “EcoPaXX reflects DSM’s focus on innovative and sustainable materials. In addition to EcoPaXX, DSM offers a range of other bio-based high performance materials, including Arnitel Eco, a bio-based thermoplastic copolyester, and Palapreg ECO, a bio-based duroplast.” DSM Engineering Plastics Tel: +31 46 477 3051 Email: mirelle.kreeft-vander@dsm.com Web: www.dsm.com
Metabolix Web: www.metabolix.com
APRIL 2013 • WWW.EPPM.COM • 23
MATERIALS
SHOWCASE BIOPOLYMERS Dog waste bag makes use of ‘Biohybrid’ technology Custom Bioplastics LLC has launched a “Bio-buddy dog waste bag” developed using Cardia’s new ‘Biohybrid’ technology. The bag is now being manufactured and marketed by Custom Bioplastics, an established manufacturer of blown and cast film plastic packaging. The groups claim that the development was made in response to Governments and pet owners calling for a sustainable and renewable alternative to the conventional dog waste bag. Cardia’s Biohybrid technology requires less oil than normal plastic, so has a lower carbon footprint. Custom Bioplastics also use recycled plastics in the manufacturing process. Custom Bioplastics Managing Director, Mr Dick Mathes, said: “The new Biohybrid Bio-buddy dog waste bag is made with a combination of recycled resin and Cardia’s Biohybrid technology. Bio-buddy’s Biohybrid dog waste bags allow for plant starch
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“
The “Bio-buddy dog waste bag” is a positive example of an application that now meets these requirements and is a great achievement by both companies.
”
to be combined with recycled resin. The plant starch lessens the total carbon footprint of the bag along with creating a bag that is soft and silky to the touch. Mr Mathes continued: “We are excited
to work with Cardia Bioplastics. Our packaging products made from their Biohybrid resins will form an integral part of our responsible plastic bag and film offering,” he said. Cardia’s Chairman Mr Pat Volpe said:
“The product has been developed with Custom Bioplastics to meet the growing demands for a sustainable pet waste bag with a lower carbon footprint, driven by consumer, brand owners, government and municipals.” “The Bio-buddy dog waste bag demonstrates the latest in sustainable technology and again confirms the diverse application of Cardia’s Biohybrid™ proprietary technology. Cardia’s main advantage besides the soft touch is that we deliver a product with a lower carbon footprint using renewable and sustainable resources - in line with the recent growing global trend.” “The “Bio-buddy dog waste bag” is a positive example of an application that now meets these requirements and is a great achievement by both companies.” Mr Volpe also said. Cardia Bioplastics Europe Tel: +49 4162 908 5695 Email: info@cardiabioplastics.com Web: www.cardiabioplastics.com
MATERIALS
SHOWCASE BIOPOLYMERS Research looks at new organic chemicals for bioplastics New research to investigate a new source of organic chemicals for the manufacture of bioplastics could signficantly reduce costs and increase performance, according to reports. The UK’s innovation agency, the Technology Strategy Board, has awarded a grant to a consortium led by Biome Technologies, to investigate a bio-based alternative for the oil dervied organic chemicals used in the manufacturer of bioplastics. The research will be undertaken by the group’s bioplastic division Biome Bioplstics, one of the UK’s leading developers of natural plastics, in conjunction with the University of Warwick’s Centre for Biotechnology and Biorefining. The £150,000 grant is part of the Technology Strategy Board’s ‘Sustainable high value chemical manufacture through industrial biotechnology’ technical feasability competition, which funds projects that apply sustainable bio-based feedstocks and biocatalytic processes in the production of chemicals. “Biome leads the market in high performance applications, with products that outperform our competitors. In the longer term, however, it is our intention to produce bioplastics that can challenge the dominance of oil-based plastics, and ultimately replace them completely’, explains Biome Bioplastics CEO Paul Mines.
Biome plastic extrusion. “In order to achieve this, we need to undertake research and development activities that tackle the intrinsic synthesis of bioplastics that currently keeps costs high and limit performance”. Biome has partnered with the University of Warwick’s Centre for Biotechnology and Biorefining that is pioneering academic research into lignin degrading bacteria. Biome is working with the Warwick team to develop methods to control the lignin breakdown process to determine whether these chemicals can be extracted in significant quantities. The TSB grant will support an initial
feasibility project to isolate a chemical from lignin to replace the oil-derived equivalent currently used in a polyester that conveys strength and flexibility in some of Biome’s products. The production of such a bio-based polyester would reduce the cost and further enhance the sustainability of these products. “The environmental and social concerns surrounding the use of fossil fuels and food crops make lignin a compelling target as a source of chemicals”, explains Professor Tim Bugg, Director of the Centre. “Often considered a waste product, it may provide a sustainable source of building blocks for aromatic chemicals that can be used in bioplastics”. If the initial feasibility assessment is successful, building on this work, Biome will explore the possibilities for deriving a wide selection of bio-based aromatic chemicals from lignin, further reducing cost and expanding bioplastic functionality. “The bioplastics market remains small compared to that of fossil-based polymers”, comments Paul Mines. “Growth is restricted by the price of bioplastic resins being 2-4 times that of their petrochemical counterparts. We anticipate that the availability of a high performance polymer, manufactured economically from renewable sources would considerably increase the market”. Industrial biotechnology is firmly supported by the UK government as a means of developing less carbon instensive products and processes. It poses a significant opportunity for the UK’s chemical sector to maintain and increase its competitiveness through the development of efficient and sustainable ways of satisfying our chemical and material needs. Bioplastics are key to this sector and are leading the way for other manufacturers to move into this space.
Bioplastics get the cold treatment
A famous Italian ice-cream maker is to completely replace its disposable plastic items with Mater-Bi, the biodegradable and compostable bioplastic from Novamont. Grom, which has 57 sales outlets across Europe, Japan and the Americas, has taken the decision to use Mater-Bi to make all of the disposable items at its sales outlets, including spoons, cups, refuse sacks and carrier bags. Grom is also using specially made Mater-Bi mulching film for growing strawberries and melons at its farm. Novamont states Mater-Bi is
becoming one of the reference materials for food packaging and catering due to its biodegradability and compostability, which represent added value for products contaminated with food scraps which would otherwise be difficult or uneconomical to recycle. Last year, fast food giant McDonalds chose Mater-Bi to provide its customers at London 2012 with cutlery, straws, cups and lids made of biodegradable plastics. Novamont Web: www.novamont.com
Biome Bioplastics Tel: +44 2380 867100 Email: info@biomebioplastics.co.uk Web: www.biomebioplastics.com
APRIL 2013 • WWW.EPPM.COM • 25
APPLICATION FOCUS PACKAGING
“Click n” Dip’ concept from packaging group Two new dips in the TexMex range from Santa Maria, the biggest Nordic supplier of spices and tastes of the world, now come in a handy packaging solution – a 215ml SuperLock container with click-on screw lid from RPC Superfos. The products, TexMex Onion & Garlic and TexMex Chunky Salsa provide a great add-on to any Mexican style meal. Packaging Development Technologist Åsa Yhlen from Santa Maria said of the new pot: “I believe that plastic as a packaging material will keep gaining ground. Glass is great but takes up a lot of space on the pallet. The stacking facility of the SuperLock pot makes it easy to handle in connection with the filling process,” says Åsa Yhlen. “Another good thing is that we can skip a working procedure thanks to inmould labelling, which means that the
label is fused directly onto the surface of the plastic moulding. So the need for subsequent labelling is eliminated and this makes the filling process more efficient.” In-mould labelling has an additional advantage: the labels are in clear and sparkling colours and not susceptible to peeling. Design options are vast and include a see-through area. And to find a suitable look for the dip packaging, Santa Maria worked with a design agency. As part of the pot is transparent, the colour of the dip has an impact on the overall impression: Garlic & Onion is white, Chunky Salsa is red and obviously each label design had to integrate the colour of the dip. Santa Maria is a well-known brand in the Nordics for spices Thailand, India and Mexico. It belongs to the Finnish Paulig Group and constantly works with product development.
The SuperLock packaging is a multiaward winner designed to meet barrier demands. Convenience products can stay on shelf twice as long - or even three times longer - in SuperLock than in reference packaging thanks to the combination of membrane sealing and
barrier protection which is possible on all surfaces according to RPC.
Packaging group wins contract for bespoke PE mailing bags
Polystyrene brand celebrates 75 years in packaging
UK-based polythene packaging manufacturer, Duo Plastics UK, has won a contract with PhotoBox, the European market leader for online photo printing, to supply bespoke branded mailing bags. The contract win will see Duo provide all of the printing brand’s European outbound mail order packaging, which features a vibrant green mono-layer polythene mailing bag with a silver design printed on both sides. Lawrence Merritt, Managing Director of PhotoBox, commented: “We made a business decision early this year to move to branded polythene mailing bags to distribute our products, as it offers lightweight, weather-proof protection and ensures our products arrive perfectly with our customers whilst keeping postage costs to a minimum. Due to the nature of the products it is imperative that no water gets into the package, so polythene offers the best properties – we are delivering people’s memories, so for us to remain market leaders, our products need to arrive in picture-perfect condition.” David Brimelow, Managing Director of Duo, said: “Our extensive experience enabled us to accommodate PhotoBox’s specialist print requirements, which like all our products are wholly manufactured within the UK.” Duo Plastics UK Tel: +44 161 203 5767 Email: enquiries@duo-uk.co.uk Web: www.duo-uk.co.uk 26 • WWW.EPPM.COM • APRIL 2013
RPC Superfos a/s Tel: +45 5911 1110 Email: superfos@superfos.com Web: www.superfos.com
Styron, a supplier of polystyrene, recently celebrated 75 years of the commercialisation of Styron Polystyrene. As one of the group’s oldest commercial brands, Styron Polystyrene can be found in many packaging applications. Since its introduction into the packaging market, Styron Polystyrene (PS) has been used in particular in packaging applications. The Styron Technical Service & Development team works closely with PS customers to optimise their packaging solutions. Drivers going forward are costefficiency, product differentiation through packaging solutions, the inclusion and demonstration of sustainability and the desire for weight reduction, reported the group. Samer Al Jabi, Global Product Manager explained: “PS has gained a strong position especially in the dairy packaging market because it has helped brand owners seize several opportunities such as high production speed capability and oxygen permeability. However, whilst we celebrate 75 years of Styron Polystyrene, innovations in PS resins continue. CO RE, our patented foaming technology, for instance, is aimed at helping the dairy packaging and food service industries to increase cost competitiveness whilst reducing packaging weight. Customer projects have illustrated significant density reductions of 13% to 20%, depending on the polystyrene packaging application.” Styron Web: www.styron.com
INDUSTRY NEWS & EVENTS
Growth in the Southeast Asian markets: A K 2013 report Messe Düsseldorf, the organiser of K 2013, will publish a series of market reports in the months preceding the event. The following is extracted from the first in the series, on the subject of growth for the plastic sector in the Southeast Asian markets. When the global economy dipped in 2008 and again in 2010, opportunities for growth in Southeast Asia remained unperturbed. The convergence of ASEAN into a single market, the ASEAN Economic Community (AEC), by 2015, presents further opportunities for companies in the plastics and rubber sectors that are seeking a larger market share. The Association of Southeast Asian Nations (ASEAN)’s 600 million consumer base is treading towards an optimistic growth trend. Although anchored to the US and Europe for their export revenues, the shift to regional consumption has since increased and has buffered the group against the global crisis. The region’s plastics industry has shown an average annual growth of 9%, against declining demand, volatile prices, capacity constraints and labour shortages. Firming up trade initiatives, such as the ASEAN Free Trade Agreement (AFTA) in 2010, which has cut importation tariffs from zero to 5%, as well as the ASEANKorea Free Trade Area (AKFTA); the trade pact with China (ACFTA), and the Expanded Economic Engagement (3E) initiative are expected to bolster investment opportunities for the ASEAN. This should be furthered with the consolidation of the ASEAN Economic Community (AEC) by 2015, which aims for a single market and production base, with duty waived amongst the member countries. Improved economic conditions and favourable manufacturing environments in Singapore, Malaysia, Indonesia, Thailand and Philippines have drawn
significant investments to the engineering plastics market in Southeast Asia. According to Frost & Sullivan, it was valued at EUR 6 billion in 2011 and is expected to reach EUR 3.2 billion by 2018, and will grow more than 1015% over the eight years, due to the robust sales in electrical appliances and vehicles in the region. Moreover, demand for more fuel efficient vehicles that are CO2 emissions regulation-compliant; smaller, turbocharged engines and lightweight parts have made inroads in the region, thus driving the market for engineering plastics. In Singapore, printed or organic electronics as well as green electronics, bioelectronics and security devices are emerging growth areas for the country’s plastics sector. According to the Economic Development Board (EDB), printed electronics is already contributing to 10% of the country’s total electronics output and by 2020 will grow by 30%, against the global market that is expected to grow to more than EUR 9.4 billion in 2016, says BCC Research. The biorenewable materials market, which according to Frost & Sullivan is expected to grow at a rate of over 19% until 2018 (Strategic Analysis of the AsiaPacific Biorenewable Materials Market), is the target of Thailand’s governmentinitiated strategy to turn the country into a bioplastics hub by 2021. It also hinges on the Thailand’s biobased polylactic acid (PLA) capacity, which will increase to 721,000 tonnes in 2020, according to the National Innovation Agency (NIA) of Thailand and Nova Institute of Germany. This is against the Asian capacity for
PLA, which is expected to reach more than 350,000 tonnes. But most of the capacity will be exported as domestic demand still remains weak. A forerunner in the packaging sector is Indonesia, which has a sizable domestic demand from its food, beverage and pharmaceutical industries; with the sector’s revenue climbing 11% to EUR 3.27 billion in 2012. Indonesia’s plastic consumption went up to 3 million tonnes in 2012 and almost 70% of the total plastics use was accounted for by the food and beverage packaging sectors. Meanwhile, the medical device sector in Malaysia is forecast to reach EUR 1.27 billion in 2015. Comprised of 190 medical device firms producing gloves, catheters, cannula needles, lenses, orthopedic products and other high value devices, the country’s industry has been meted as a priority sector under the National Key Economic Area (NKEA). It is geared to serve the flourishing regional demand, fuelled by an ageing population, increased access to healthcare, lifestyle modifications and shifting trend to-wards medical tourism, according to the Malaysian Investment Development Authority (MIDA). While Vietnam’s plastics sector grew by 15-20% in 2011 and is anticipated to grow to 17.5% by 2020, it may not be competitive because the country still relies heavily on imported raw materials and machinery for the sector. Meanwhile, the mélange of performances of some ASEAN members in the automotive segment show that
demand and other variables, including government support, upgraded facilities and location, factor in the growth. For example, the Philippines’s low domestic demand for vehicles could prompt some of the existing car manufacturing plants based to shut down. Likewise, the comparably small industry could hit the consumption of engineering plastics and rubber, although PVC will benefit from the 6% growth in the construction sector. Nonetheless, location-strategic Thailand still remains as Asia’s Detroit, with its automotive sector growing at around 8.1% of GDP, with local capacity forecast to reach 2.3 million units by 2014. The various free trade agreements it is involved in, as well as the government support bolsters Thailand’s competitiveness. Overall, a healthy automotive industry in the ASEAN will foster higher demand and help to pull up rubber prices, especially for the top Asian rubber producers, Thailand, Indonesia and Malaysia, which account for 67% of global output of rubber. K 2013 Web: www.k-online.de
Food contact conference back for 2013 he leading global conference for Food Contact has returned to Europe for 2013. As the only global food contact forum, the programme will once again feature presentations from national regulators from across the globe, to provide delegates with all of the most relevant food contact developments. The full conference programme for Global Food Contact 2013 includes high level discussions of all the hot topics facing the global food contact industry. Programme highlights include: an update on Chinese Food Contact Material Regulation and
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proposed future developments from Lei Zhu of the China National Center for Food Safety Risk Assessment; a regulatory perspective from the Japanese National Institute of Health Sciences; a panorama of MERCOSUR legislative developments from Alejandro Ariosti of INTI, Argentina and a new discussion for 2013 from Nestle and EHEDG on Food Contact Materials for Machinery: ensuring Food Safety through the advised selection of materials. “This is the only global food contact conference of its kind and I am really looking forward to bringing it back to
Europe this year. There is a lot to take in on this year’s agenda, and it is particularly important now more than ever to be aware of how regulations in new markets are taking shape and the global diversity of this conference and its attendees reflects that,” said Hayley Marsden, Conference Director. The conference also provides attendees the opportunity to network with food contact professionals from across the globe and throughout the whole supply chain, and allows them to get involved with the in-depth pre-conference workshops available on US-FDA and national European regulations.
Global Food Contact 2013 Web: www.food-contact.com
INDUSTRY NEWS & EVENTS ROUNDUP Tube trade show dedicates hall to plastic tubing ube, the International Tube Trade Fair, is held at the Düsseldorf Exhibition Centre every two years. Here world market leaders, innovators and other industry experts meet to gather information on current technologies and future trends in the fields of machinery and equipment for tube making and processing industries, tube accessories and the tube trade over five trade fair days. Making its debut at Tube next year will be the PTF Plastic Tube Forum in Hall 7.1, a special show where everything revolves around plastic
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tubes and their versatile applications. The plastic tubing market, in particular, faces major challenges in energy and environmental technology. Plastic tubes are found in gas or drinking water supply, in heating and sanitation systems, in the chemical or pharmaceutical industries, geo-chemistry and the automotive industry. New trends in tubing technology will be presented in all of its facets at Tube 2014 in Düsseldorf. The Plastic Tube Forum, in Hall 7.1 aims to become an established, exclusive meeting point for raw
materials producers, tube manufacturers, tube dealers, raw materials dealers and users. Complete packages including numerous special service features can be booked in two categories with the project department of Tube 2014.
Images copyright Messe Düsseldorf. Tube 2014 Web: www.tube.de
New lightweighting education and research forum starts work The Aachen Center for Integrative Lightweight Production (AZL) of RWTH Aachen University has named its founding partners in a kick-off meeting. Representatives of the 33 founding companies came together to start the cooperation in Aachen. In the framework of the Excellence Initiative by the German Government, new clusters will be established on the campus of the University of RWTH in Aachen in the next 10 years: 19 new institutions will be set up on 800,000m2. As one of the first institutions on the new Campus, the Aachen Center for Integrative Lightweight Production (AZL) will be set up. The AZL, founded by Prof. Dr. Christian Brecher and Prof. Dr. Christian Hopmann, is part of the faculty of mechanical engineering, with 62 professorships and more than 10.000 students. The aim of AZL is to develop the automated production of load- and costoptimised lightweight components, suitable for mass production and versatile process chains in composite and multi-material design. This network in lightweight production at one single location features the necessary expertise along the entire value chain within walking distance on the campus assembled around the AZL, where over 700 scientists are working on production technologies, lightweight materials and applications. The expertise covers the production from carbon- and glass fibres, textile preforming, high-volume plastics processing, automation, machining and testing to applications ranging from oil, water, gas, infrastructure, buildings and automotive engineering. Dr. Michael Emonts, CEO of AZL, explained the research environment: “AZL is set up within the new cluster “Integrative Production Technology”, which additionally offers approximately 25,000 m2 laboratory space for 800 scientists, at the Campus Melaten in Aachen. Within the Campus, companies have the possibility to open own branches or complete development laboratories. The advantage of the direct contact to the staff and the equipment of the excellent research institutes – and especially the close contact to highly qualified students as potential staff after graduation – is already used by major companies from different industrial sectors.” One of the first projects with the
founding partners of AZL is a strategic market and technology study over 12 months (started in March 2013), focussing essentially on the evaluation of the technical feasibility for mass production of new applications for lightweight materials to establish the institute’s activities. This study identifies applications, components, distribution channels, number of pieces, economic potential, requirements for materials and process chains in five major market segments. Dr. Kai Fischer, Divisional Director Composite Production Technology of AZL, explained: “The unique aspect of this study is that new markets for composites are being identified which are not yet accessible for these materials. The study therefore provides an ideal basis for the development of new strategic business areas for the participating companies all along the value chain.” “We are delighted to announce at the JEC Show in Paris 33 founding partners for the launch of the AZL, covering the whole value chain. Most of them are revealed below, some of them will stay anonymous”, said Dr. Kai Fischer. “From materials suppliers over moulder, manufacturing suppliers, tier 1 and tier 2 to OEMs, we are proud and happy to have with us AFPT, Ashland, DSM, DuPont, EMS Chemie GmbH, EMSysteme, FA Kümpers, Future Fibres, Gurit, Henkel AG & Co. KgaA, Johnson Controls GmbH, Kegelmann Technik, Lamilux, LANXESS, Laserline GmbH, Lürssen Werft, Mahr Metering, Opel, Röchling, SABIC, Siemens, Tencate, ThyssenKrupp AG, Ticona, Toyota Motor Europe.” Dr. Fischer continued: “The cooperation of this fantastic network is the foundation of the AZL and its future projects.” In summer 2014, the AZL will open its doors with the result of the study. Since 2012, AZL has been working in industrial projects and public research. Additionally the targeted projects
resulting from the market and technology study will be developed and implemented. Michael Effing, CEO of AMAC, who supports the AZL, commented: “Many of the current mainly thermoset-driven applications still have significant labour costs and we see them step by step moving to Middle East and Asia. The Composite technology is of imminent importance for Western Europe and North America, like for lightweight Automotive applications or others. We need to ensure that this technology can stay in Europe and that is why we build on the promising value of the integrated manufacturing of composite systems at the AZL. This is how we want to support the future of Composites in the Western World.” Together with the opening of the AZL, the unique Composite Academy will be launched. Dr. Michael Emonts explained: “The AZL’s Composite Academy will offer various disciplines for extra-occupational training, education, seminars or in-depth qualification of experts on all levels, like technicians, lab workers, engineers, and managers. Participants will be able to
Planned buildings for the Integrative Production Technology Cluster at RWTH Aachen University Campus. pass specific education in the field of composite technologies and extraoccupational education.” Dr. Emonts continues: “With the background of the current shortage of experts and the need for restructuring industrial companies in the future with the introduction of new materials, this Composite Academy will provide essential services, which complete the unique One-stop-shop offer of the AZL. We expect the Composite Academy to take off in 2015”. Aachen Center for Integrative Lightweight Production (AZL) Web: www.azl.rwth-aachen.de APRIL 2013 • WWW.EPPM.COM • 29
INDUSTRY NEWS & EVENTS ROUNDUP Household brand names to speak at Masterbatch 2013 Coca-Cola, Danone, Nokia and Johnson & Johnson make the lineup The programme has been announced for the AMI’s Masterbatch 2013 conference, which will take place from 3rd-5th June 2013. The event has become well established as a regular international forum for the global masterbatch industry attracting over 200 attendees every year. The conference is being held at the Marriott Hotel in Frankfurt, Germany with headline sponsorship being provided by BASF. Other sponsors include Automatik Plastics Machinery GmbH, Clariant, 3M, Plasmec S.r.l. and Columbian Chemicals Europa GmbH. AMI’s Masterbatch conference will allow interaction with speakers from Coca-Cola, Danone, Nokia and Johnson & Johnson. A series of presentations will look at
the latest trends in colourants, special effect pigments and functional additives to give fresh insight into how to add value to products. The pigments session will include papers from Clariant, BASF Schweiz AG and Dupont de Nemours, while the materials session will look at developments in resins and functional additives with papers from BASF Schweiz AG, 3M and Great Lakes Solutions, a Chemtura Business. This session will also include a keynote presentation from Danone about additives as enhancers. The conference will include updates on machinery with papers from Farrel Pomini Mixing Group, Automatik Plastics Machinery GmbH and Fraunhofer Institute for Structural Durability and System Reliability.
The event will close with a business forum looking at design, colour trends in consumer products, enhancing brands with colour and what that will mean for the use of masterbatch. Speakers from Nokia, Johnson & Johnson, Polymer Asia and A. Schulman Europe will consider these issues. The conference will also provide a detailed analysis of the current European masterbatch market and AMI's Research Director, Andrew Reynolds, will be presenting the role and future of the masterbatch industry. AMI Plastics Tel: +44 117 924 9442 Email: info@amiplastics.com Web: www.amiconferences.com
Colour contentrates for compounders to be made in Poland Clariant, a worldwide supplier of specialty chemicals, was joined by guests for the groundbreaking of its new plant in Konstantynów Łódzki, Poland. The ceremony held on site was attended by the Swiss ambassador, and representatives of local authorities and the Łód Special Economic Zone as honorary guests. The new, modern plant will commence production of colour concentrates for producers of plastic materials one year from now. The investment, worth CHF 11.3 million, will allow Clariant to increase production capacity and strengthen its position in Polish and European markets.
Under the guidance of the Łód Special Economic Zone, Clariant, will construct a new production site, laboratory, warehouse, and offices at the location. Covering an area of approximately 6,800 square meters, the facility will enable Clariant to double the production capacity for masterbatches in Poland and also to create new job opportunities for qualified employees. “You cannot underestimate the meaning of this investment for the entire company. The market for masterbatches, though demanding, develops dynamically and a modern facility such as this in Konstantynów Łódzki, will allow us to develop new solutions tailored to the specific needs of customers effectively,” commented Hans Bohnen, Head of Clariant Business Unit Masterbatches. The symbolic groundbreaking in Konstantynów is the culmination of the company’s 22 yearlong presence in Poland. Over the years Clariant’s
subsidiary has been a model which has been implemented in other countries of Central and Eastern Europe. This commitment was recognised by Clariant’s senior management and was one of the key factors in the decision to locate the investment in the Łód region. “Clariant Polska’s success is built on ambitious and highly qualified employees. As a team we have shown how we can positively influence the development of the entire company. Our further growth is also a result of an exemplary cooperation with the local communities and representatives of Łód Special Economic Zone,” added Ralph Rutte, President of Clariant Polska. The decision to place the new production facility in the Łód region is an important step in the development of Clariant’s strategy in Europe. It also acknowledges the region’s role in the company’s long-term investment policy. This comes largely as a result of excellent cooperation with the
The planned building. representatives of Łód Special Economic Zone as well as the government, which have both supported the investment at all its stages – from consultancy and planning to building. “Central Europe is a very promising market and Poland, as a large and dynamically growing country in the region is the natural place for further investments. We are deeply convinced that our engagement in building a new facility in Konstantynów will prove to be beneficial for both Clariant and the Łód region,” – concluded Patrick Jany, CFO Clariant International AG. Clariant International Ltd Tel: +41 61 469 6363 Email: kai.rolker@clariant.com Web: www.clariant.com
175 years of mechanical engineering from Munich This year, the KraussMaffei Group celebrates its 175th anniversary as a business. Domiciled in Munich since 1838, the company has a strong tradition in international mechanical engineering. Since 1999/2000, the KraussMaffei Group has exclusively manufactured machines and systems for the production and processing of plastics and rubber. Today, the group is a global leader in the plastics and rubber industry. “The KraussMaffei Group with its 4,000 employees can proudly look back on the 175 years of its existence. That is because the company has over this long period succeeded in maintaining a leading international position as an 30 • WWW.EPPM.COM • APRIL 2013
innovative mechanical engineering firm in its various fields of activity. Today, we still enjoy a position of leadership in the global market as a manufacturer in the plastics and rubber industry. I would like to thank all employees who have played a great part in the company's development”, said Jan Siebert, Chief Executive Officer (CEO) of KraussMaffei Group GmbH. “We are also renowned for our high level of expertise in technology, processes and applications. That makes us the most valued partner worldwide at the side of our customers. Add to this the high level of motivation and the passionate commitment of our employees, as well as our sheer drive and determination to always find the
best possible solutions for our customers. All of these goals are encapsulated in our motto: ‘Great Passion. Proven Value. Unique Excellence!’”, Siebert continued. The KraussMaffei aims to step up its presence in growth markets, and particularly in BRIC countries. Speaking about the upcoming K show in Germany, Siebert continued: “As a technology leader, we will use the K 2013 to showcase our premium quality products and high end processes for global market trends. We will also use this occasion to mark the 175th anniversary of our company. The KraussMaffei Group, with its high quality products and services portfolio as well
as its innovation and solution skills, is strongly positioned to meet the challenges that lie ahead to the benefit and advantage of our customers.” KraussMaffei Group Web: www.kraussmaffeigroup.com
INDUSTRY NEWS & EVENTS ROUNDUP New Managing Director for blown film equipment group Rüdiger Wander has been appointed to the position of Managing Director of Octagon Process Technology GmbH by Prof. Dr. Karl, the President, owner and founder of the company. Mr. Wander will manage the company in close cooperation with the Technical Director Jürgen Geiger and together with Prof. Dr. Karl who will remain to be an active part of the company. Born in 1966, Rüdiger Wander completed his studies in European Economy and began his career as Commercial Manager in the office communications sector. In 2007, Wander started to be active for Octagon as an independent consultant only to join the company on a permanent basis 18
months later taking charge of the commercial sector as Commercial Director. For 26 years Octagon has been in the business of developing and manufacturing high precision systems for quality control designed for smooth integration into blown film lines as well as their offline use for the purpose of helping to maintain the film thickness both in web direction and the circumference of the film. These include systems for the automatic control of film gauge (SmartLip), online gauge measurement (PMS), offline gauge measurement (GPA) and gravimetric extruder control and dosing by the loss-
of-weight process (GDS). These products are sold world-wide, either directly or via representatives for installation on new and for retrofitting on existing extrusion lines, or they are available as integral components of OEM systems. Wander sees his future tasks with emphasis on the continuation of the company policy as manufacturer of measure and control technology for the blown film industry with a world-wide service orientated care of customers.” Octagon Process Technology GmbH Tel: +49 9 31 27 96 70 Email: contact@octagon-gmbh.de Web: www.octagon-gmbh.de
Rüdiger Wander, Managing Director of Octagon Process Technology GmbH
Specialty chemicals group posts strong 2012 results German specialty chemicals company Lanxess has announced strong figures for the past fiscal year, with improvements in key reported numbers. “2012 was the best year in our growth story so far. Our business model proved itself once again,” said Lanxess’ Chairman of the Board of Management, Axel C. Heitmann, at the Annual Press Conference in Dusseldorf. Lanxess confirmed the preliminary results for 2012 that it published on March 7, 2013. Group sales grew by 4% in fiscal 2012 to €9,094 million. Business development was driven notably by the focus on emerging markets, solid demand for agrochemicals, strong contributions from acquisitions and the price-before-volume strategy. Performance Polymers showed a solid performance and remained the largest segment in business terms, raising sales by more than 2% from the strong level of the prior year to some €5.2 billion. The Butyl Rubber, Performance Butadiene Rubbers and Technical Rubber Products business units, which all serve the automotive and tyre industries, experienced a drop in volumes. However, sales were buoyed by the positive portfolio effects from the Keltan EPDM business acquired in 2011. EBITDA pre exceptionals of the segment climbed by 6.4% to €817 million. Sales of the Advanced Intermediates segment grew by more than 8% in 2012, to roughly €1.7 billion. The increase was mainly attributable to continuing high demand for agrochemicals. Both the Advanced Industrial Intermediates and the Saltigo business units benefited from this demand, Saltigo having aligned its activities even more toward agrochemicals. EBITDA pre exceptionals climbed by nearly 16% year-on-year to €305 million. Sales of the Performance Chemicals segment improved by more than 3% in 2012 to approximately €2.2 billion. Volumes fell in the Rubber Chemicals and Rhein Chemie business units, where customers in the automotive-related industries account for a substantial proportion of sales. Positive effects came from the acquisitions made by the Material Protection Products, Functional Chemicals and Rhein Chemie business units. EBITDA pre exceptionals of the segment was down by nearly 3% to €281 million, primarily due to higher energy and manufacturing costs. Lanxess Web: www.lanxess.com APRIL 2013 • WWW.EPPM.COM • 31
INDUSTRY NEWS & EVENTS ROUNDUP Collaborative moulder earns ‘Energy Efficiency Award’ AMK from Germany was presented with this year’s Arburg Energy Efficiency Award on 12 March 2013. AMK uses energy-optimised Allrounders in its own injection moulding plant, as well as also using them to produce components for servo motors. These then go towards making a significant contribution to the energy efficiency of Arburg’s electric and hybrid machines. Moreover, AMK and Arburg are jointly involved in a development partnership in the field of specific electric drives. The Arburg Energy Efficiency Award was brought into being in 2008 and since then has been presented each year to companies which take an innovative, integrated and global approach to energy efficiency. “Prize-winners attract particular attention by virtue of their corporate philosophy and activities in the area of energy-efficiency,” said Michael Hehl, Managing Partner and Spokesperson for the Arburg Management in his address. The list of previous award-winners ranges from Wago and Tyco Electronics, through Wild & Küpfer, to the Lego Group and Continental.
AMK Managing Directors Eberhard Müller (second from left) and Dr. Günther Vogt (second from right), along with the Arburg Managing Partners Michael Hehl (left) and Eugen Hehl (center) accompanied by Herbert Kraibühler, Managing Director Technology & Engineering (right). The Arburg Energy Efficiency Award 2013 was presented during a gala evening for some 50 guests, held at the Arburg headquarters. A seven-strong delegation from AMK travelled to Lossburg to receive the award. During the presentation speech, Herbert Kraibühler, Arburg’s Managing Director Technology and Engineering, stated that the 2013 winner had earned this award on two counts: “We are united with AMK in a very close partnership. Our collaboration encompasses both the consistent development and implementation of energy-efficient electric drives on our machines, as well as the use and optimised application of Allrounders.” Joint development activities in the drive sector began almost 20 years ago. The philosophy of advancing new
European recycled products group invests in UK
technologies in terms of energy and production efficiency, as well as quality enhancement, unites the two companies and has been the starting point for their collaborative innovations, such as water-cooled converters. AMK has been involved in the development
Hahn Plastics, a European manufacturer of recycled products made from mixed plastic waste, has announced significant investment plans in the UK. Hahn’s recycled plastic products are widely used in the construction, industrial and agricultural markets across Europe for their stronger performance and environmental benefits over traditional materials such as wood and concrete. The German-based parent company, Hahn Kunststoffe GmbH, has invested in a 45,000 square foot production and warehousing facility at Salford, Manchester. The UK operation will engage in stocking, distributing and manufacturing an extensive range of Hahn’s patented recycled plastic products for agriculture, industry and construction. Hahn states this commitment will enable UK customers to enjoy better access to the extensive range of 1,500 product lines in more colourways with better stock availability, quicker delivery and great after sales service from a local work force. In addition to the existing ‘Hanit’ family, the UK operation will offer an added high-spec formulation, ‘Hanplex’, which is appropriate where
applications require a more robust material. Hahn’s UK Sales and Marketing Director, Paul Harris, commented: “As the demands towards sustainable materials in construction go from strength to strength, the local investment in stock, production facilities, and jobs here mean that we are best placed to serve today’s market demands and continue innovating the next generation of construction materials. The huge range of standard products available from stock means that there is a real alternative to the use of traditional materials in many applications.” Managing Director, Stephan Seibel, added: “Hahn Kunstoffe GmbH is delighted to be investing in the UK, following export sales success to date. We have experienced great demand in the UK market in recent years, from all sectors of industry and agriculture. We hope to underpin our commitment in the market by providing a greater level of service by local stock holding and manufacture.”
Arburg Tel: +49 7446 333259 Email: contact@arburg.com Web: www.arburg.com
TPE supplier undergoes complete re-structure API, a European specialist in thermoplastic elastomers reports that it has “embarked upon a radical process of organisational change” in order to respond to the challenges arising from changes in the economy, finance and international markets. The decision has been made, like many groups in recent years, to concentrate on the market application rather than on the product. This has led to the creation of three business units focused on different market sectors:
Parent company Hahn Kunststoffe GmbH is investing in the UK market
of the electric Allrounders from the outset.
• BU Footwear and Sporting Goods • BU Automotive and Technical Articles • BU Packaging e Medical The focus on the applications combined with an increased decision-making and operating autonomy has meant all the members of the Business Units will now be taking greater charge of their activities. A new marketing position has also been created. The individual filling this role will take over a strategic and cross-
organisational position within the new structure. Mr Sandro Gusi, Managing Director of API, explained the reasons behind the re-organisation: “The truly innovative character of the change lies in having decided to apply this to a moderately structured yet medium/small sized company like API. A real and never ending process of cultural growth that presupposes a continual drive towards improvement both in our efficiency and our quality. The very best reaction came from our own people who have proven to be highly motivated and proudly prepared to operate in this new organisational context, to profitably grow anew.” The new organisational structure was inaugurated in early 2013 to all distributors and agents representing API worldwide, during an event entitled, “Change on Air”. API S.p.A. Tel: +39 0424 579711 Email: api@apiplastic.com Web: www.apiplastic.com
Hahn Kunststoffe GmbH www.hahnkunststoffe.de APRIL 2013 • WWW.EPPM.COM • 33
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www.EquipNet.com/EPPM Sales@EquipNet.com • Tel: +44.118.901.6161
Maschinenhandel Borowski Used plastic processing machines Injection moulding, blow moulding and accessories Tel. 0049-2173-8950790 Fax 8950799 www.mhborowski.de info@mhborowski.de
Over 35 Years of Service
1350mm Wide Welex Union ABS,HIPS, PMMA Capped ABS Sheet Extrusion Line Comprising 100mm Extruder, Coextruder, 1350mm X 450mm Stack, Guillotine.
1300mm Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders. 1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.
Tel: +44 (0) 1793 827666
4 component Ferlin gravimetric blender model FGB5-4 For up to 500kg/hr. Piovan hopper loaders.
Email: sales@transxl.co.uk
1800mm wide Reifenhauser sheet extrusion line, 120mm 33D extruder, melt pump, die, 1800mm x 410mm 3 roll stack, haul off, guillotine, stacker 1995.
SHEET LINES
Web: www.transxl.co.uk
45mm Kuhne single screw extruder model K45E 30D plugged vented. 20-204 rpm. 24kw dc motor.
863mm wide EDI Ultraflex H75 flex lip sheet die. 0-1.9mm die gap. 240 V heating.
GRANULATORS 500mm Zerma model GSH-500/600 660 x 350mm Cumberland model 6/84.
2400mm Cincinnati PVC Sheet line 2300mm Omipa Pmma Extrusion Line 1800mm Virginio Mai 3 layer coex line 1700mm Bandera/virgin Mai ABS Line.
EXTRUDERS
1500mm Bandera 3 roll stack 1350mm Welex/Union line 1350mm Welex 3 roll stack 890mm Welex Coextrusion Welex World Standard sheet Line. 90mm Extruder. Circa 50mm Co-extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1998.
1300mm Battenfeld coextrusion sheet line. 1040mm Welex Coex sheet line. 1040mm Welex 3 roll stack
1850mm Battenfeld Gloenco PP PE Cast Film Line: 120mm+60mm extruders, feedblock. 1650mm Cloeren auto die, 1850mm Chill roll, haul off, winder.1993.
890mm Welex World Standard sheet Line. 90mm Extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1997.
1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line 890mm Welex Pet sheet line
115mm Hartig Extruder, 30d 100mm Union extruder. 90mm Welex single screw extruder 80mm Cincinnati Titan twin screw 90mm John Brown Egan single screw extruder 70mm Battenfeld-kuhne Extruder 60mm Cincinnati coextruder 50mm Welex co extruder. 25:1 l/d ratio. 50mm Betol extruder 25:1d 45mm Kuhne model K45E 30D
1000mm Omv Coextrusion Sheet Line. 120mm Omv Extruder, 60mm Coextruder, Melt Pump, 1000mm X 500mm Roll Stack, Haul Off, Winder.
THERMOFORMING DIES
700mm Illig RDM 63/15B cup forming line 700mm Illig Rv74 Vacuum Former
6 colour Van Dam 560AA PT printer
70mm Battenfeld-kuhne Extruder, Electrically Heated Air Cooled 5 Zone, Plug Vented Barrel. Screen Changer.
4.5” Welex single screw extruder. 30D vented., static mixer, gear pump. 2003.
980mm EDI model Ultraflex HR75 915mm EDI flex lip sheet die 900mm Kuhne model BDF 90F 863mm EDI Ultraflex H75 flex lip sheet die 500mm Masterflex flex lip cast film die 1987
500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.
1700mm Bandera Virginio Mai PMMA ABS sheet extrusion line. 80mm extruder, 1600mm Simplas die, 2-7mm thickness. Complete line 1987.
100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent. 110kw dc motor and drive. Temperature panel 1987.
2 Component Maguire model WSB 420 gravimetric weight scale blender. 2 hopper loaders.
605mm Kiefel KL2 SH Thermoformer, 540mm Kiefel KL2EH vacuum former 700 X 500mm Illig Rv74 Vacuum Former. Unwind. Top And Bottom Heaters. Forming Station. Punch. Stacker And Waste Wind Up. 2004 100hours only!!!
1040mm Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.
500mm Illig RDM 50/3 Lid Thermoformer
92mm Amut twin screw profile extrusion line with BA92 twin screw extruder, 8m calibration table, 2 belt haul off, travelling cross cut saw. 2001.
60mm Betol/Corelco pipe corrugation lines model EC255LLV complete with die head and corrugation dieset, cooling bath, hauloff & fly cutter, 500hours only!!!
TRANSXL INTERNATIONAL THORNHILL SOUTH MARSTON SWINDON WILTSHIRE SN3 4TA ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk
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